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‖ | Engineering Design Calculations
Strongbacks

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Thrust Calculations
Total thrust per bore

C1/D1 C2/D2 C3/D3

Thrust component from area subject to injection pressure, Pi = 1450 psi

AUEB.sb1 = 0 in 2 AUEB.sb2 = 0 in 2 AUEB.sb3 = 0 in 2

External diameter of pipe

Dh1 = 4.5 in Dh2 = 0 in Dh3 = 0 in

Thrust component from area subject to design pressure, Pd = 450 psi

ASep.sb1 = 15.9 in 2 ASep.sb2 = 0 in 2 ASep.sb3 = 0 in 2

Thrust calculated from pressure areas or direct input

TC1.D1 ≡ if TC1.D1.m ＝ 0 lbf | TC2.D2 ≡ if TC2.D2.m ＝ 0 lbf | TC3.D3 ≡ if TC3.D3.m ＝ 0 lbf |

‖A | ‖A | ‖A |
‖ UEB.sb1 ⋅ P i + A Sep.sb1 ⋅ P d | ‖ UEB.sb2 ⋅ P i + A Sep.sb2 ⋅ P d | ‖ UEB.sb3 ⋅ P i + A Sep.sb3 ⋅ P d |
else | else | else |
‖T | ‖T | ‖T |
‖ C1.D1.m || ‖ C2.D2.m || ‖ C3.D3.m ||

TC1.D1 = 7157 lbf TC2.D2 = 0 lbf TC3.D3 = 0 lbf

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Tiebar Analysis
Tiebar Data
C1/D1 C2/D2 C3/D3

Tiebar size Sb.tb1 = 0.625 in Sb.tb2 = 0 in Sb.tb3 = 0 in

2
Tiebar tensile area Ab1.t.tb = 0.226 in Ab2.t.tb = 0 in 2 Ab3.t.tb = 0 in 2
Number of tiebars Nb.tb1 = 2 Nb.tb2 = 0 Nb.tb3 = 0
Thrust restrained by tiebars TC1.D1 = 7157 lbf TC2.D2 = 0 lbf TC3.D3 = 0 lbf
Tiebar Stress
Stress in tiebars due to thrust σtb1.ps.req ≡ if Nb.tb1 ≠ 0 | σtb2.ps.req ≡ if Nb.tb2 ≠ 0 | σtb3.ps.req ≡ if Nb.tb3 ≠ 0 |
‖ | ‖ | ‖ |
TC1.D1 | TC2.D2 | TC3.D3 |
‖ ―――― ‖ ―――― ‖ ――――
‖ Nb.tb1 ⋅ Ab1.t.tb | ‖ Nb.tb2 ⋅ Ab2.t.tb | ‖ Nb.tb3 ⋅ Ab3.t.tb |
‖ | ‖ | ‖ |
else | else | else |
‖ 0 ⋅ psi | ‖ 0 ⋅ psi | ‖ 0 ⋅ psi |
‖ | ‖ | ‖ |
σtb1.ps.req = 15833.9 psi σtb2.ps.req = 0 psi σtb3.ps.req = 0 psi
Allowable stress in tiebars σb1.tb.a.d = 25000 psi σb2.tb.a.d = 0 psi σb3.tb.a.d = 0 psi

Results Resulttb1 = “Pass” Resulttb2 = “Not applicable” Resulttb3 = “Not applicable”

Tiebar Torque
Nut factor Ktq1.tb = 0.17 Ktq2.tb = 0 Ktq3.tb = 0
Stud nominal diameter Dtq1.tb ≡ Sb.tb1 Dtq2.tb ≡ Sb.tb2 Dtq3.tb ≡ Sb.tb3
Dtq1.tb = 0.625 in Dtq2.tb = 0 in Dtq3.tb = 0 in
Target bolt preload Fpr.tb1 ≡ σtb1.ps.req ⋅ Ab1.t.tb Fpr.tb2 ≡ σtb2.ps.req ⋅ Ab2.t.tb Fpr.tb3 ≡ σtb3.ps.req ⋅ Ab3.t.tb
Fpr.tb1 = 3578 lbf Fpr.tb2 = 0 lbf Fpr.tb3 = 0 lbf

Torque Tqtb1 ≡ Ktq1.tb ⋅ Dtq1.tb ⋅ Fpr.tb1 Tqtb2 ≡ Ktq2.tb ⋅ Dtq2.tb ⋅ Fpr.tb2 Tqtb3 ≡ Ktq3.tb ⋅ Dtq3.tb ⋅ Fpr.tb3
Tqtb1 = 32 ft ⋅ lbf Tqtb2 = 0 ft ⋅ lbf Tqtb3 = 0 ft ⋅ lbf

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Registration # F-003143 Crunch Ring Strongback Analysis Page 2 of 9
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Crunch Ring Strongback Analysis

Crunch Ring Strongback Data
Purpose: This analysis will calculate the frictional force caused by the Crunch Ring Strongback and the internal
stresses of the Crunch Ring Strongback due to the bolting.
References: ASME Boiler and Pressure Vessel Code, Section II, Part D, (Table for Maximum Allowable Stresses, 2019Edition)
Mechanics of Materials by Beer and Johnston, 1981
Machinery's Handbook, 23rd Edition, pages 1278-1279 and 1498-1520
Roark's Formulas for Stress & Strain, Warren C. Young, Fifth Edition, Table 30, case 17, page 464.
An Introduction To The Design And Behavior Of The Bolted Joint by Bickford, Second Edition, Page 133.

Blue dimensions are the dimensions for Crunch Ring Bending in Ear

Data for up to three crunch ring strongbacks are shown below. Data will only be provided if used.

Crunch ring strongback data

Strongback 1 Strongback 2 Strongback 3

Largest diameter in strongback block Dsb1 = 6.5 in Dsb2 = 0 in Dsb3 = 0 in

Strongback bore diameter dsb1.bo = 4.48 in dsb2.bo = 0 in dsb3.bo = 0 in
Gap at Splitline Lgap.sb1 = 0.125 in Lgap.sb2 = 0 in Lgap.sb3 = 0 in
Bolt circle diameter (half joint studs) dsb1.bc = 6 in dsb2.bc = 0 in dsb3.bc = 0 in
Width of Clamp (in contact with header) Wsb1 = 1.5 in Wsb2 = 0 in Wsb3 = 0 in
Tie Bar Hole Diameter ( only when dh.sb1 = 0 in dh.sb2 = 0 in dh.sb3 = 0 in
tiebars are not on splitline)

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Crunch Ring Strongback half-joint studs

Half joint stud material StudMaterialb1 = “SA-193 Grade B7”

Crunch Ring Stud Size Sb.sb1 = 0.75 in Sb.sb2 = 0 in Sb.sb3 = 0 in

Total number of Studs Nb.sb1 = 2 Nb.sb2 = 0 Nb.sb3 = 0
Prestress as a percentage of yield percy.b1 = 37% percy.b2 = 50% percy.b3 = 50%
Length of moment arm inducing tipping Ltb1.tip = 0 in Ltb2.tip = 0 in Ltb3.tip = 0 in

Number of Nuts on half-joint studs Nb.sb1 = 2 Nb.sb2 = 0 Nb.sb3 = 0

The analysis below may apply to up to three different sets of variables, the function is defined in general terms
and each data set is then run through the function and outputs the final calculated stress.

CrunchRingStresses ⎛⎝Fb , Nb.sb , tcr , Wsb , dh.tb , dbc.sb , dsb.bo , Dh⎞⎠ ≡ try |
‖ |
‖ Pcr ← Fb ÷ ⎛⎝Dh ⋅ Wsb⎞⎠ |
Summation of forces in X-direction R2
‖ R2 ← Fb ÷ 2 |
R2 - Fx = 0 R2 = Fx = Fy ‖ Area ← ⎛t - d ⎞ ⋅ W |
Cross sectional area Area ‖ ⎝ cr h.tb⎠ sb |
‖ R2 |
Tensile Stress of Crunch Ring Strongback σ1 ‖ σ1 ← ―― |
‖ Area |
‖ A ← ⎛⎝dbc.sb - dsb.bo⎞⎠ ÷ 2 |
Distance from bolt centerline to bore A |
‖ Fb ⎛ tcr ⎞
‖M←― ⋅ ⎜ ― - A ⎟ |
Summation of moment about R2 M ‖ 2 ⎝2 ⎠ |
M - Fx ( t/2 + R - R*sin45 ) - Fy ( R*sin45 ) + BL ( R + A ) = 0 ‖ tcr |
‖c←― |
Neutral fiber c ‖ 2 |
‖ 1 |
‖ I ← ―⋅ Wsb ⋅ ⎛⎝tcr - dh.tb ⎞⎠
3 3
|
Moment of inertia I ‖ 12 |
‖ |M⋅c| |
‖ σ2 ← |―― | |
Bending Stress of Crunch Ring Strongback σ2 ‖ | I | |
‖ σc ← ||σ1|| + ||σ2|| |
‖ return ⎡ σ σ σ P ⎤ |
Combined Stresses of Crunch Ring Strongback σc ‖ ⎣ 1 2 c cr ⎦ |
on error |
‖ |
⎡ ⎤
‖ return ⎣ 0 psi 0 psi 0 psi 0 psi ⎦ |

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Crunch Ring Strongback Results
Bolting force applied CR Strongback 1 CR Strongback 2 CR Strongback 3
| |
Stud prestress σb.sb1.ps ≡ percy.b1 ⋅ σb1.sb.y.o σb.sb2.ps ≡ percy.b2 ⋅ σb2.sb.y.o σb.sb3.ps ≡ percy.b3 ⋅ σb3.sb.y.o
| |
σb.sb1.ps = 30532 psi | σb.sb2.ps = 0 psi | σb.sb3.ps = 0 psi
| |
| |
Stud preload Fpr.b1 ≡ σb.sb1.ps ⋅ Ab1.t.sb | Fpr.b2 ≡ σb.sb2.ps ⋅ Ab2.t.sb | Fpr.b3 ≡ σb.sb3.ps ⋅ Ab3.t.sb
| |
Fpr.b1 = 10210 lbf Fpr.b2 = 0 lbf Fpr.b3 = 0 lbf
| |
| |
Bolt force applied on pipe Fsb1 ≡ Fpr.b1 ⋅ Nb.sb1 | Fsb2 ≡ Fpr.b2 ⋅ Nb.sb2 | Fsb3 ≡ Fpr.b3 ⋅ Nb.sb3
| |
Fsb1 = 20420 lbf | Fsb2 = 0 lbf | Fsb3 = 0 lbf
| |
Holding force of ring Ff.sb1 ≡ 2 ⋅ μcr ⋅ Fsb1 | Ff.sb2 ≡ 2 ⋅ μcr ⋅ Fsb2 | Ff.sb3 ≡ 2 ⋅ μcr ⋅ Fsb3
| |
Ff.sb1 = 12252 lbf | Ff.sb2 = 0 lbf | Ff.sb3 = 0 lbf

ResultF.f1 = “Pass” ResultF.f2 = “Not applicable” ResultF.f3 = “Not applicable”

Note: calculated friction force must be 1.5x greater than the required restraint load to "pass"

Maximum internal crunch ring stresses due to half-joint bolting

⎡⎣ σcr1.1 σcr1.2 σcr1.c Pcr1 ⎤⎦ ≡ CrunchRingStresses ⎛⎝Fsb1 , Nb.sb1 , tcr1 , Wsb1 , dh.sb1 , dsb1.bc , dsb1.bo , Dh1⎞⎠

⎡⎣ σcr2.1 σcr2.2 σcr2.c Pcr2 ⎤⎦ ≡ CrunchRingStresses ⎛⎝Fsb2 , Nb.sb2 , tcr2 , Wsb2 , dh.sb2 , dsb2.bc , dsb2.bo , Dh2⎞⎠

⎡⎣ σcr3.1 σcr3.2 σcr3.c Pcr3 ⎤⎦ ≡ CrunchRingStresses ⎛⎝Fsb3 , Nb.sb3 , tcr3 , Wsb3 , dh.sb3 , dsb3.bc , dsb3.bo , Dh3⎞⎠

Maximum allowable plate stress

1.5x allowable in tension for combined stress σpl.sb.comb.a ≡ 1.5 ⋅ σpl.sb.a.d σpl.sb.comb.a = 27150 psi

CR Strongback 1 CR Strongback 2 CR Strongback 3

Tensile Stress of Crunch Ring Strongback σ1 σcr1.1 = 6739 psi σcr2.1 = 0 psi σcr3.1 = 0 psi
Bending Stress of Crunch Ring Strongback σ2 σcr1.2 = 10209 psi σcr2.2 = 0 psi σcr3.2 = 0 psi
Combined Stresses of Crunch Ring Strongback σc σcr1.c = 16948 psi σcr2.c = 0 psi σcr3.c = 0 psi

Resultcr1.d = “Pass” Resultcr2.d = “Not applicable” Resultcr3.d = “Not applicable”

0.17 ⋅ 0.625 in ⋅ 4271 lbf = 37.8161 ft ⋅ lbf

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Crunch Ring Half-Joint Stud Torque

CR Strongback 1 CR Strongback 2 CR Strongback 3
| |
Stud size Sb.sb1 = 0.75 in Sb.sb2 = 0 in Sb.sb3 = 0 in
| |
Stud tensile area Ab1.t.sb = 0.3 in 2 | Ab2.t.sb = 0.0 in 2 | Ab3.t.sb = 0.0 in 2
| |
Stud prestress σb.sb1.ps = 30532 psi | σb.sb2.ps = 0 psi | σb.sb3.ps = 0 psi
| |
Nut factor Ktq1 = 0.17 | Ktq2 = 0 | Ktq3 = 0
| |
Stud nominal diameter Dtq1 = 0.75 in | Dtq2 = 0 in | Dtq3 = 0 in
| |
Target bolt preload Fpr.b1 = 10210 lbf Fpr.b2 = 0 lbf Fpr.b3 = 0 lbf
| |
Torque Torquepl1 ≡ Ktq1 ⋅ Dtq1 ⋅ Fpr.b1 | Torquepl2 ≡ Ktq2 ⋅ Dtq2 ⋅ Fpr.b2 | Torquepl3 ≡ Ktq3 ⋅ Dtq3 ⋅ Fpr.b3
| |
Result Torquepl1 = 108 ft ⋅ lbf | Torquepl2 = 0 ft ⋅ lbf | Torquepl3 = 0 ft ⋅ lbf
| |
| |

Tipping effect of Crunch Ring due to Tiebars

CR Strongback 1 | CR Strongback 2 | CR Strongback 3
| |
Moment arm of tipping effect Ltb1.tip = 0 in | Ltb2.tip = 0 in | Ltb3.tip = 0 in
| |
Force inducing tipping F1.tip ≡ TC1.D1 ÷ 2 F2.tip ≡ TC2.D2 ÷ 2 F3.tip ≡ TC3.D3 ÷ 2
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F1.tip = 3578 lbf | F2.tip = 0 lbf | F3.tip = 0 lbf
| |
Tipping moment M1.tip ≡ F1.tip ⋅ Ltb1.tip | M2.tip ≡ F2.tip ⋅ Ltb2.tip | M3.tip ≡ F3.tip ⋅ Ltb3.tip
| |
M1.tip = 0 ft ⋅ lbf | M2.tip = 0 ft ⋅ lbf | M3.tip = 0 ft ⋅ lbf
| |
Required stress in half-joint σtip1.req ≡ if Wsb1 ≠ 0 | | σtip2.req ≡ if Wsb2 ≠ 0 | | σtip3.req ≡ if Wsb3 ≠ 0 |
studs to resist tip (to prestress) ‖ | | ‖ | | ‖ |
‖ ――――|M 1.tip ‖ ――――|M 2.tip ‖ ――――|M 3.tip
| |
‖ Wsb1 ⋅ Ab1.t.sb | | ‖ Wsb2 ⋅ Ab2.t.sb | | ‖ Wsb3 ⋅ Ab3.t.sb |
‖ | ‖ | ‖ |
else | | else | | else |
‖ | ‖ | ‖ |
‖ 0 ⋅ psi | ‖ 0 ⋅ psi | ‖ 0 ⋅ psi |
σtip1.req = 0 psi σtip2.req = 0 psi σtip3.req = 0 psi

Allowable stress in half-joint σb.sb1.ps = 30532 psi σb.sb2.ps = 0 psi σb.sb3.ps = 0 psi
studs to resist tip
Result
Resultcr1.tip.i = “Not applicable” Resultcr2.tip.i = “Not applicable” Resultcr3.tip.i = “Not applicable”

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Registration # F-003143 Buckling of Pipe due to Crunch Ring Page 6 of 9
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Buckling of Pipe due to Crunch Ring

Reference: Roark's Formulas for Stress & Strain, Warren C. Young, Fifth Edition, Table 30, case 17, page 464.
Header Input Data
Modulus of Elasticity Eh = 25900 ksi Injection Pressure Pi = 1450 psi Pi = 1450 psi
Pipe yield stress σpe.h.y.o = 25740 psi Operating Pressure Po = 450 psi
Poisson's Ratio ν = 0.3
Analysis
σbuckling ⎛⎝Dh , th , Wsb , Pcr⎞⎠ ≡ ‖ if Dh ＝ 0 in ∨ th ＝ 0 ∨ Wsb ＝ 0| |
‖ | |
‖ ‖ ‖ return 0 psi | |
‖ |
External Radius of pipe Rh ‖ R h ← Dh ÷ 2 |
Pressure acting to buckle pipe qh ‖ qh ← Pcr - Po |
‖ |
‖ a ← ―― Wsb |
Factor a
‖ 2 |
‖ 1 |
‖ ―
4 |
‖ ⎛ 3 ⋅ ⎛⎝1 - ν 2 ⎞⎠ ⎞ |
Factor λ ‖ λ ← ⎜―――― ⎟ |
2 2
‖ ⎜⎝ Rh ⋅ th ⎟⎠ |
‖ 3 |
Factor D ‖ D ← ―――― Eh ⋅ th |
‖ ⎛
12 ⋅ ⎝1 - ν ⎠ 2⎞ |
‖ |
Maximum Moment per unit length ‖ M ← qh ⋅ e -λ ⋅ a ⋅ sin ⎛λ ⋅ a⎞ |
‖ max ―― 2
⎝ ⎠
|
Mmax ‖ 2⋅λ
|
‖ qh
Maximum deflection ymax ‖ ymax ← -―――
⎛
⋅ ⎝1 - e -λ ⋅ a
⋅ cos ⎛⎝λ ⋅ a⎞⎠⎠ |
⎞
4 |
‖ 4⋅D⋅λ |
‖ σ ← ‖ σ ← 0 psi | |
Circumferential membrane stress σpe.h.2 pe.h.2 ‖ 1 |
‖ | ymax ⋅ Eh | |
‖ ‖ | | | |
‖ 2σ ← |――― | + | ν ⋅ σ 1| |
‖ | R | |
‖ ‖ h | |
‖ -6 ⋅ Mmax |
Meridional bending stress σpe.h.1b ‖ σpe.h.1b ← ――― 2 |
‖ th |
Circumferential bending stress σpe.h.2b ‖ σpe.h.2b ← ν ⋅ σpe.h.1b |
‖ ⎛ ⎞ |
Maximum calculated stress σpe.h.max ‖ σpe.h.max ← max ⎝σpe.h.2 , σpe.h.1b , σpe.h.2b⎠ |
‖ return σpe.h.max ||
‖

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Header Data
C1/D1 C2/D2 C3/D3
External diameter of pipe Dh1 = 4.5 in Dh2 = 0 in Dh3 = 0 in
Minimum wall thickness th1 = 0.237 in th2 = 0 in th3 = 0 in
Length of header under injection Wsb1 = 1.5 in Wsb2 = 0 in Wsb3 = 0 in
External pressure due to crunch ring Pcr1 = 3025.195 psi Pcr2 = 0 psi Pcr3 = 0 psi
Maximum allowable calculated stress σpe.h.allow ≡ 90% ⋅ σpe.h.y.o σpe.h.allow = 23166 psi
Definitions C1/D1 C2/D2 C3/D3
σC1.D1 ≡ σbuckling ⎛⎝Dh1 , th1 , Wsb1 , Pcr1⎞⎠ σC2.D2 ≡ σbuckling ⎛⎝Dh2 , th2 , Wsb2 , Pcr2⎞⎠ σC3.D3 ≡ σbuckling ⎛⎝Dh3 , th3 , Wsb3 , Pcr3⎞⎠
Results
σC1.D1 = 22829 psi σC2.D2 = 0 psi σC3.D3 = 0 psi
Results

Buckling C1/D1 Buckling C2/D2 Buckling C3/D3

Resultσ.C1.D1.i = “Pass” Resultσ.C2.D2.i = “Not applicable” Resultσ.C3.D3.i = “Not applicable”

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Confidential and Proprietary Information Weight and Void Strongbacks Calculations

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Weight and Void
PERIMETER Void Calculations:
Number of Perimeter Seal Injection Valves NIV ≔ 16 Sealant Selection ssealant ≔ 2X
Volume in Injection Valves, Perimeter Groove, Bores, Stud Holes

VIV ≔ NIV ⋅ 0.12 ⋅ in 3 VIV = 1.92 in 3

3 3
Vperim ≔ ― ⋅ in ⋅ ― ⋅ in ⋅ ⎛⎝18.45 ⋅ in - 1.0 ⋅ in ⋅ 3 - 1.125 ⋅ in ⋅ 2⎞⎠ Vperim = 1.8563 in 3
8 8
⎛3 3 ⎞ ⎛3 3 ⎞
VBores ≔ ⎜― ⋅ in ⋅ ―⋅ in⎟ ⋅ ⎛⎝8.42 ⋅ in ⋅ π⎞⎠ ⋅ 2 + ⎜― ⋅ in ⋅ ―⋅ in⎟ ⋅ ⎛⎝4.62 ⋅ in ⋅ π⎞⎠ ⋅ 1 VBores = 4.7404 in 3
⎝8 16 ⎠ ⎝8 16 ⎠
⎛ 2 2⎞
π ⎛ 2 2⎞
π
Vstudholes ≔ ⎝⎛⎝1.0 ⋅ in⎞⎠ - ⎛⎝0.7946 ⋅ in⎞⎠ ⎠ ⋅ ―⋅ ⎛⎝3 ⋅ in⎞⎠ ⋅ 3 + ⎝⎛⎝1.125 ⋅ in⎞⎠ - ⎛⎝0.91 ⋅ in⎞⎠ ⎠ ⋅ ―⋅ ⎛⎝8 ⋅ in⎞⎠
4 4

Vstudholes = 5.3546 in 3
VBC ≔ VIV + Vperim + VBores + Vstudholes
VBC = 13.9 in 3
lb
Sealant = “2X” rcomp = 1.5 δsealant = 0.051 ――
in 3
VAC ≔ VBC ⋅ rcomp VAC = 20.8 in 3

Weight of Stud/Allthreads/Nuts, Injection Valves, Sealant

Stud Size (in) Ss1 ≔ 0.875 Ss2 ≔ 1.0 Ss3 ≔ 0.75 Ss4 ≔ 0.625
Number of Studs Ns1 ≔ 3 Ns2 ≔ 2 Ns3 ≔ 2 Ns4 ≔ 2
Stud Length (in) Ls1 ≔ 6 Ls2 ≔ 8 Ls3 ≔ 8 Ls4 ≔ 5.0
Number of nuts Nn1 ≔ 6 Nn2 ≔ 2 Nn3 ≔ 4 Nn4 ≔ 4
Weight (Clamp Weight from SolidWorks Model)

WClamp ≔ 118.55 ⋅ lb WClamp = 118.6 lb WIV ≔ NIV ⋅ 0.27 ⋅ lb WIV = 4.3 lb

WStrongback1 ≔ 10.40 ⋅ lb WStrongback1 = 10.4 lb WIV.VF ≔ NIV.VF ⋅ 0.27 ⋅ lb WIV.VF = 0 lb
WStrongback2 ≔ 0 ⋅ lb WStrongback2 = 0 lb Wsealant ≔ VAC ⋅ δsealant Wsealant = 1.1 lb
Wmisc ≔ 0 ⋅ lb Wmisc = 0 lb Wsealant.VF ≔ VAC.VF ⋅ δsealant.VF Wsealant.VF = 0 lb
Wstudsnuts = 13.4 lb

WTotal ≔ WClamp + WStrongback1 + WStrongback2 + Wmisc + Wstudsnuts + WIV + Wsealant + WIV.VF + Wsealant.VF

WTotal = 148 lb

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Registration # F-003143 Page 9 of 9