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Top 3 Advantages of Choosing Custom Pipe Fittings

There are multiple pipelines spread across the US that are used to deliver trillions of cubic feet of natural gas and tons of liquid petroleum all year round. While most of these pipes are joined conventionally, there are instances where there may be a need to use custom pipe fittings to support and join pipes. Usually, custom pipe fittings are created when the required couplets or fittings need to match a custom or unique design.

Custom Pipe Flange Fittings

Meaning of custom flanges

Custom flanges or non-standard flanges mean the flanges do not meet the international standards of flanges; custom flanges are instead designed for a special application.

A flange has many dimensions to design in the flange standards and the dimensions are indicated clearly. When a company designs and produces custom flanges, they do not follow any references or have any standards, but they need to confirm the dimensions. As a company, when you approach a business-like Texas Flange, it is best to show all the requirements and details you require.

The creation of custom pipe fittings is possible with software, allowing the designer to tweak part properties like system definition, shape, and size.

Advantages of custom pipe flanges

There are multiple advantages to using custom couplets or pipe fittings, which will be discussed below in three sections.

Build for the job

In a few instances, when people fail to find a fitting to match the pipe system in place, they usually use wooden props and blocks as alternatives. While it may seem innovative, it provides a quick solution but will not stand the test of time.

It is advisable to use a professional pipe support system when working with pipe systems. Investing in the best products available due to the large quantities in an order will be better suited for the business.

Flexible design

Custom pipe flanges are designed to suit many different applications and for specific purposes, but you will not need to worry about them not fitting in the pipes correctly. Custom pipe fittings allow you to work with any type of piping material but are a test as they hold weights of more than 8,000 pounds.

Despite the situation you are dealing with, they are designed to handle strain to an extent.

Professional advice at your disposal

When you think about using custom pipe flanges and make a plan, you won’t just acquire a perfect product but will obtain a network of experienced professionals who can stand by the quality of the product. Designers who work on custom pipe flanges can address all the concerns and questions you may have when it comes to your project.

The above are three main advantages of using custom pipe flanges which are made to suit the exact piping you are working with but also offer the perfect solutions to all your piping concerns.

If you need help for your next business project and wish to get the best custom pipe flanges, contact Texas Flange. Our knowledgeable team members will be happy to assist you and help you point in the direction.

 

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How To Prevent Corrosion On Flanges

Shutdowns in the industries cost millions… even when planned properly. Shutdowns are significantly impacted by the operating costs due to damaged parts, including flange face imperfections, gasket failure, or general corrosion. A leak may occur when corrosive media meets the sealing surfaces of facing flanges. It is why flange maintenance is a crucial step that helps to prevent leakage.

corrosion flange

Types of corrosion

Flanges may go through two types of corrosion in their lifetime. These include aperture and pitting.

Pitting corrosion

Pitting occurs on the flange face and often appears in groups or clusters. The type of corrosion may result in small cavities or pits that form at the material’s surface. Proper alloy selection is one of the best-recommended ways to prevent pitting corrosion.

Crevice corrosion

Crevice creep occurs when there is a buildup in the concentrated substance between the two adjoining flanges. It is the type of corrosion that can be very damaging because it is not easy to inspect the area of its occurrence.

Currently, monitoring the flange damage is to disassemble the joint and visually inspect the surfaces. It is not ideal due to the down cost and time. There has been some development using some non-destructive techniques to examine the amount of corrosion to the flanges.

Prevention methods

Maintenance of paints is one of the most common methods that help to prevent corrosion. Maintenance paints are commonly urethane or epoxy-based coatings. Most maintenance paints bond directly to the substrate as a hard coating. With the use of maintenance paints, a perfect amount must be applied. If the paint is too thin, the area will be ineffective; however, if the paint is too thick, it will lead to seizing the fastenings.

There have been a lot of different flange shapes and angles, and you may not be able to coat the whole area. After the flange inspection, another layer of coating needs to be applied. A benefit of using maintenance paints is that they do not require specialist equipment or hot work.

Mechanical solutions are usually clamp encapsulated or rigid, covering the flange or the void between the flanges. These clamps or covers are made from plastic or stainless steel and incorporate a rubber seal.

The next solution is the usage of tapes, be it semi-solid or full. Tapes can be composed of viscoelastic polymers, wax, petrolatum embedded into the fabric for wrapping. These are useful specifically for their water-repellent nature of semi-solid polymers, although they may be less common in high-pressure applications.

All the preventative methods have some pros and cons—no solution can help prevent the corrosion from happening entirely. However, regular inspections and maintenance can help to prevent rapid corrosion and general upkeep is encouraged.

Ways to repair corroded flanges

There are three main ways you can use to repair the corroded flanges:

. Adding a polymer composite to rebuild the flange face.
. Add material to ring grove or sealing face and then machine within flange tolerance.
. Remove the damaged flange and weld a new one (safest choice).

Factors that influence flange corrosion resistance during the operating conditions

Three prominent factors influence flange corrosion resistance during the operation conditions. These are:

. The temperature of the corrosive agent
. Purity of corrosive agent
. Corrosive agent concentration

Conclusion

Few flange materials are subject to stress corrosion cracking given the general volume of applications that do not operate under heavy media stress. However, it is a fact that needs consideration while selecting the material and gasket type. When you choose a proper gasket, it can help prevent corrosion from aggressive chemicals.

There are also different flange faces, and gaskets must adhere to the proper type of flange face. When dealing with chemical oxidizers/HF acid, it is crucial to select a robust gasket that can help to prevent corrosion.

If you want to learn more about flange corrosion, visit our website today!

 

 

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Gasket Kit for Flange Isolation Joint

A flange isolation gasket kit helps protect the pipeline flanges from corrosion that happens due to galvanic corrosion. The purpose of the flange isolation kits is to prevent the (electrolytic) corrosion of flanged joints and flanges that static currents present on a piping system may induce.

The gasket isolation kit consists of a unique gasket, isolation sleeves for the nuts, stud bolts, and special washers. These components are manufactures in special materials with proper chemical stability, dielectric, and low water absorption properties.

Types of Flange Gasket Kit

Here are some types of flange gasket kits:

Flange Kit Type “F” (Ring Face Gasket)

The Type F isolation gaskets (ring type) fit raised face flanges (RF). The external diameter of F type gasket is smaller than the flange face surface.

You can add special band protectors to the flanged joint that will help to strengthen the cathodic isolation created by the flange isolation kit.

Type F gaskets are manufactured from 1/8” thick fabric-based phenolic sheets either with or without coating or with a nitrile rubber coating on the two faces. The Type F gaskets are also available in non-asbestos fibers with high isolation capacity.

Type “E” Flange Insulation Kit (Full face)

Type “E” gaskets (full-face type) come with an outside diameter that matches the diameter of the flange, i.e., they cover the whole flange surface area.

The design also helps to keep the foreign material outside the flanges joints and enhances the isolation properties of the kit. Type E flange insulation kits come in high-temperature, neoprene-faced phenolic and phenolic materials.

Type “D” Flange Insulation Kit (API Ring Joint Gasket)

Type “D” isolation gaskets fit flanges with ring joint face, as they suit the ring joint groove of RTJ flanges (style R, RX, and BX). Type D gaskets are available in a phenolic grade which is called “API ring joint”.

Type “O” Flange Insulation Kit

Type O Gaskets feature an extra sealing element on both sides of the device, usually, Viton Rubber, Nitrile, or PTFE, and are available in both full and ring face design. Type O Gaskets are manufactures with G-10 and phenolic materials.

The materials for insulation sleeves are, by default phenolic or polyethylene.

Installation of gasket kit

Installation of gasket kit is easier if you know how to do it the right way. Here are few tips to keep in mind before you go for installation

Check and clean

It is best to remove all the debris and impurities from washers, fasteners, and gaskets. Check all the fasteners (nuts, studs, bolts) and washers to ensure defects like cracks and burns. Always check the flange surfaces, make sure about defects.

Align flanges

Make sure the flanges and bolts’ holes coaxial coincide. The minimum flange gap is 10 mm. Insert the gasket carefully and parallel. Do not use jointing compounds, lubricants, or grease with gasket and flange surface. The compounds can affect the friction between the gasket and the flange can lead to premature joint failure.

Install flange kits

Apply bolt lubricant to the nut and bolt threads and the face of the nut and tighten it. Assemble the steel washer, insulation washer, and insulation sleeve to the bolts by turn (ensure the steel washer is always close to the nut). Insert the bolts holes. Avoid the use of the hammer, as it will damage the sleeves.

Check the alignment of the flange surface and size of the sleeve if you find installation difficult. Put insulator washer, steel washer, and nut into bolts on another side of the flange. Tighten all the bolts until the flange meets the gasket.

Do not forget to use the calibrated torque wrench or another tool that has control functions. You can install it following the recommended torque. Tighten the nut always in the symmetrical cross drawing.

Below are 5 steps you need to follow:

Initial tighten all the nuts by hand as you can use a small wrench for big nuts.

Tighten each nut by 30% of recommended torque.

Tighten each nut by 60% of recommended torque.

Tighten each nut by 100% of recommended torque.

Tighten all nuts in a clockwise direction to make sure all the nuts reach the required torque.

Materials for flange isolation gasket kit

  Gasket Material Dielectric Strength Maximum Temperature Water Absorption
  Neoprene faced Phenolic 500 175 F 0.45%
  Plain Phenolic 500 225 F 1.10%
  Garlock 3400 630 700 F
  Klinger C4401 300 750 F
  G10 (NEMA) UL94 VO FR 0.01%
  Insul-Seal 500 175 F 0.50%
  JM 940 Red Devil 2400 700 F
  Phenolic RTJ Type D 500 225 F 1.00%
  Teflon 600 600 450 F

Conclusion

From the above classification, it is clear that flange isolation gasket kits are designed to provide complete electrical isolation of a flanged joint. The kits can be made of many different electrical isolation materials from resins, minerals, and rubber because of their isolation properties.

Many brands supply gasket kits for flange isolation joints. If you need assistance to know more about it, contact Texas Flange today and we will get you in touch with the correct suppliers.