Importance of Flange facing in Modern world
Importance of Flange facing in Modern world
What Is Flange?
When it comes to connecting pipes, vessels, or valves, flanges are pretty helpful. Likewise, flanges and gaskets or other means are beneficial to connect bolting.
Types of Flanges
Based on Connection Types
The most often used flange types in the petrochemical and chemical industries are:
Neck Flange for Welding
Slips on Flange
Flange with a Socket Weld
Flange for a Lap Joint
Threaded Flange
Flange with Blind Flange
Flange Facing Types
Many technicians use a full-faced flange to connect the gasket. To avoid joint leakage, flanges with multiple faces require different gaskets that should never join together. There are six different types of flange faces to choose from.
Flange with a flat face (FF)
Flange with a raised face (RF)
Flange for a ring junction (RTJ)
Flange for a lap junction
5 flanges (male and female) (M&F)
Tongue-and-groove flanges, large and tiny (T&G)
Based on their pressure-temperature rating, the following are the major flange divisions.
The designation for pressure-temperature ratings is followed by a dimensionless number: 150, 300, 400, 600, 900, 1500, and 2500.
A variety of names refers to pressure Classes. For example, 150 lb, 300 lb, 400 lb, 600 lb, 900 lb, 1500 lb and 2500 lb.
Following are the most prevalent flange surfaces.
Smooth
Serrated
Standard Finish
The most typical flange finishing surface is stock finish. Serrated surfaces are typical on raised face flanges. Finally, flat face flanges are utilized for lower pressure applications and feature a smooth surface finish.
Material for Flanges
Stainless steel, cast iron, aluminum, brass, bronze, and plastic are all used to make pipe flanges. Still, the most commonly used material is forged carbon steel with the machined component.
A flange's material usually goes with the pipe selection; in most situations, a flange and the pipe share the same material.
Reason of Flange Damage (Scratches, Leakages, Gouges)
According to studies, the overall number of failures due to defective parts is as follows:
Flange misalignment (12% )
Loose bolts (15% )
A faulty gasket (22% )
Damage to the flange (25% )
Malfunctioning installation (26%)
Some of the other common causes of flange leaking
Uneven Bolt Stress
It is a common cause of flange leakage. Some bolts may be loose, while others may be over-tightened, crushing the gasket due to an erroneous bolt-up method or confined working conditions at the flange. It can result in leaks in the field, mainly due to high-temperature stressed bolts loosen.
Improper Flange Alignment
Mainly flange face alignment results in unequal seal compression, local crushing, and leakage.
Inadequate Gasket Centring
If a gasket is put off-center concerning the flange faces, leakage occurs because the gasket gets squeezed.
Damaged or Dirt Flange Faces
Dirt, scale, scratches, protrusions, weld spatter on gasket seating surfaces, and warped seating surfaces provide leakage channels or produce uneven gasket pressure, resulting in flange leakage.
Excessive Piping System Loads at Flange Locations
Excess stresses and flexure can cause flanges to lose or distort, resulting in leaks.
How to reduce these occurrences
· Do not use a chisel, screwdriver, scraper, or grinder to scrape gasket debris from the flange surface. Use a soft wire brush made of a more delicate substance than the flange itself, such as copper.
· Based on the flange characteristics, optimal gasket layer, rigidity, and material compressibility is selected.
After removing the gasket, visually inspect both the gasket and the flange to see if the gasket selected is doing its job. The media may seep between the gasket and the flange if the material or installation procedure is poor.
Choose a gasket with excellent anti-stick qualities.
· Based on the flange characteristics, optimal gasket layer, rigidity, and material compressibility is selected.
After removing the gasket, visually inspect both the gasket and the flange to see if the gasket selected is doing its job. The media may seep between the gasket and the flange if the material or installation procedure is poor.
Choose a gasket with excellent anti-stick qualities.
Advantages of Machine and Service Providers
Improved sealing qualities,
More accurate positioning and compaction of sealing material,
More appropriate sealing and specialized
Sealing materials.
Importance of Flange Facing in Different Industries
Pipelines, power, petrochemicals, oil & gas, and other essential sectors all rely on flanges. Flange facing services and controlled bolting service are two examples of flange maintenance activities that can help prevent leaks and losses. Therefore, a facility should have necessary flange maintenance tools to ensure the lowest flange downtime and production losses.
Flange Facing Tools
Flange facing is the most critical flange maintenance operation. Repair broken flanges, heat exchangers, refacing valve flanges, resurfacing big pump base housings, boiler feed pump flanges, and more with the tool purchased to face flanges. Gases and liquids travel through a long spiral path rather than across a flat flange face, which decreases the possibility of leaks.
Torque Wrenches
As crucial as flange-facing tools, torque wrenches are essential. Bolts loosen owing to frequent vibrations in the flange. It needs good tightening precisely to avoid bolt loosening. By providing consistent bolt stress, these tools ensure controllable bolting in flanges and reduce the risk of leaks.
Flange spreaders
They are used to open flanges swiftly. These tools are lightweight, portable, and simple to set up and use. ATEX-certified spreaders are frequent in industries prone to explosions, such as oil and gas, power, and petrochemicals.
Flange Pullers
These tools make pulling, and closing flanges a breeze. To service all horizontal and vertical flanges, flange pullers are the best. They are ideal for usage after face flanges and other flange maintenance chores.
Flange Aligners
Flange alignment tools are the best way to prevent leaks from correcting flange misalignments within joints, such as lateral or rotational misalignments. In addition, flange aligners are safer and faster than traditional procedures.
Content Sources :- ABSGroup
Neck Flange for Welding
Slips on Flange
Flange with a Socket Weld
Flange for a Lap Joint
Threaded Flange
Flange with Blind Flange
Flange Facing Types
Many technicians use a full-faced flange to connect the gasket. To avoid joint leakage, flanges with multiple faces require different gaskets that should never join together. There are six different types of flange faces to choose from.
Flange with a flat face (FF)
Flange with a raised face (RF)
Flange for a ring junction (RTJ)
Flange for a lap junction
5 flanges (male and female) (M&F)
Tongue-and-groove flanges, large and tiny (T&G)
Based on their pressure-temperature rating, the following are the major flange divisions.
The designation for pressure-temperature ratings is followed by a dimensionless number: 150, 300, 400, 600, 900, 1500, and 2500.
A variety of names refers to pressure Classes. For example, 150 lb, 300 lb, 400 lb, 600 lb, 900 lb, 1500 lb and 2500 lb.
Following are the most prevalent flange surfaces.
Smooth
Serrated
Standard Finish
The most typical flange finishing surface is stock finish. Serrated surfaces are typical on raised face flanges. Finally, flat face flanges are utilized for lower pressure applications and feature a smooth surface finish.
Material for Flanges
Stainless steel, cast iron, aluminum, brass, bronze, and plastic are all used to make pipe flanges. Still, the most commonly used material is forged carbon steel with the machined component.
A flange's material usually goes with the pipe selection; in most situations, a flange and the pipe share the same material.
Reason of Flange Damage (Scratches, Leakages, Gouges)
According to studies, the overall number of failures due to defective parts is as follows:
Flange misalignment (12% )
Loose bolts (15% )
A faulty gasket (22% )
Damage to the flange (25% )
Malfunctioning installation (26%)
Some of the other common causes of flange leaking
Uneven Bolt Stress
It is a common cause of flange leakage. Some bolts may be loose, while others may be over-tightened, crushing the gasket due to an erroneous bolt-up method or confined working conditions at the flange. It can result in leaks in the field, mainly due to high-temperature stressed bolts loosen.
Improper Flange Alignment
Mainly flange face alignment results in unequal seal compression, local crushing, and leakage.
Inadequate Gasket Centring
If a gasket is put off-center concerning the flange faces, leakage occurs because the gasket gets squeezed.
Damaged or Dirt Flange Faces
Dirt, scale, scratches, protrusions, weld spatter on gasket seating surfaces, and warped seating surfaces provide leakage channels or produce uneven gasket pressure, resulting in flange leakage.
Excessive Piping System Loads at Flange Locations
Excess stresses and flexure can cause flanges to lose or distort, resulting in leaks.
How to reduce these occurrences
· Do not use a chisel, screwdriver, scraper, or grinder to scrape gasket debris from the flange surface. Use a soft wire brush made of a more delicate substance than the flange itself, such as copper.
· Based on the flange characteristics, optimal gasket layer, rigidity, and material compressibility is selected.
After removing the gasket, visually inspect both the gasket and the flange to see if the gasket selected is doing its job. The media may seep between the gasket and the flange if the material or installation procedure is poor.
Choose a gasket with excellent anti-stick qualities.
· Based on the flange characteristics, optimal gasket layer, rigidity, and material compressibility is selected.
After removing the gasket, visually inspect both the gasket and the flange to see if the gasket selected is doing its job. The media may seep between the gasket and the flange if the material or installation procedure is poor.
Choose a gasket with excellent anti-stick qualities.
Advantages of Machine and Service Providers
Improved sealing qualities,
More accurate positioning and compaction of sealing material,
More appropriate sealing and specialized
Sealing materials.
Importance of Flange Facing in Different Industries
Pipelines, power, petrochemicals, oil & gas, and other essential sectors all rely on flanges. Flange facing services and controlled bolting service are two examples of flange maintenance activities that can help prevent leaks and losses. Therefore, a facility should have necessary flange maintenance tools to ensure the lowest flange downtime and production losses.
Flange Facing Tools
Flange facing is the most critical flange maintenance operation. Repair broken flanges, heat exchangers, refacing valve flanges, resurfacing big pump base housings, boiler feed pump flanges, and more with the tool purchased to face flanges. Gases and liquids travel through a long spiral path rather than across a flat flange face, which decreases the possibility of leaks.
Torque Wrenches
As crucial as flange-facing tools, torque wrenches are essential. Bolts loosen owing to frequent vibrations in the flange. It needs good tightening precisely to avoid bolt loosening. By providing consistent bolt stress, these tools ensure controllable bolting in flanges and reduce the risk of leaks.
Flange spreaders
They are used to open flanges swiftly. These tools are lightweight, portable, and simple to set up and use. ATEX-certified spreaders are frequent in industries prone to explosions, such as oil and gas, power, and petrochemicals.
Flange Pullers
These tools make pulling, and closing flanges a breeze. To service all horizontal and vertical flanges, flange pullers are the best. They are ideal for usage after face flanges and other flange maintenance chores.
Flange Aligners
Flange alignment tools are the best way to prevent leaks from correcting flange misalignments within joints, such as lateral or rotational misalignments. In addition, flange aligners are safer and faster than traditional procedures.
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