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Repair and Maintenance of Industrial Flanges

At the most basic level, flanges are helpful to add connecting joints, structures, or mechanical parts within an assembly. However, if we talk about pipe fittings, flanges are needed to support, connect, close, and cover systems ranging from basic plumbing to industrial networks.

There are a few useful introductions about the flange cover, high-temperature flange sealing, and flange packing system.

Flange joint (Flange cover)

The use of flange covers is mainly for anticorrosion and flange connection in all industries. The flange head of the product is to produce the flange surface (ring joint or raised surface). It is gaskets and double-ends studs free from corrosion, and the product is suitable for 316 non-metallic (plastic) and stainless steel. Its manufacturing dimensions are ½-144 inch ANSI, AWWA, and API flange connection diameter. A flange sealing system combined with the flange packing is useful in a harsh environment for protection.

Structure of flange sealing cover:

. 316 SS worm gear fixture;
. 316 stainless steel castings;
. 316 stainless steel belt or non-metallic belt;
. ECH rubber pad (temperature: from – 34.4°C to 149°C) safety relief valve can    release 5 psi;
. The chlorinated rubber layer of the sealing groove (temperature: –           34.4°C to 82°C).

The high-quality flange sealing cover is that it is easy to connect, detect and install. In addition, the durability and stability of the UV non-metallic materials make them a good option for reuse.

Packing systems of industrial flanges

It is suitable for the temperature of 80°C. Flange packing is unique and solves corrosion for a long time.

Flange packing is a type of composite polymer polarity based on coating. Paste form makes it reusable without pretreatment. In addition, the viscoelastic formulation allows the materials to lower into the gap and space, resulting in the excellent seal used against corrosion.

Because of its easy use and money and time-saving capacity, the packing system provides long-term protection.

When we talk about the properties of flange packing, keep this in mind that it can be an excellent bonding to steel and iron, FB (melting epoxy powder) polyurethane. Polyethylene high resistance is the temperature and weathering of anti-salt ranging from 51°C to 80°C filling the voids.

The flange surface can be reused/removed without preprocessing using a gas or manual gun with a flexible gun that you can inject gently. It can also ensure that the ring slot is filled with the CZ winding tape before sealing it.

Different packing systems for flanges

Below are a few different systems that are used for packing the flanges:

. E-2400/E2000 is useful to protect the steel flange, structure, pipe, and bold from corrosion by a non-electrolytic method.. E-2400/E2000 is a high-temperature antiseptic flange packing that helps protect the flange connection from corrosion at the temperature of 149°C.
. E-2400/E2000 high-temperature flange packing suits the 149°C well.
. ASTM-B1117 salt spray test was used on the nut bolt assembly for 2000 hours of testing. The area protected by the E2000/2400 may rotate with the hand. Proper use of E2000/2400 may help protect the flange connection from corrosion.

Sealing of high-temperature flanges

High-temperature flange parts usually need to be flat and high-temperature sealed. If there is no additional sealing with good sealant in the separate pressure region, flange part, or if it is affected by the pressure, it may lead to manufacturing deformation or inaccuracy. It is to say that, in separate pressure areas, the leakage phenomenon under pressure needs to plan repaired. High temperature and high-quality sealing may make it in the standard applications of the gas engine, steam engine, or high-temperature flange. It helps keep the inert so that it is easy to bear the heat with lubricant, light fuel oil, water, steam, or air.

Conclusion

The high temperature in flanges is suitable for the condition as it has high requirements for the temperature and pressure of flat and smooth flat sealing surfaces. Sealing products will not cure, and their consistency may change to maintain elasticity and flexibility, so there are no time requirements. It may be immediately put into operation after the construction. If the users need to repair the damage to the high-temperature sealing surface, it must coordinate with the repair products.

Visit Texas Flange today for more information on the repair and maintenance of industrial flanges!

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Factors to Consider When Choosing Flanges for Your Industrial Piping System

Flanges play a vital role in the gas and oil piping system, connecting valves with other equipment. Pipe flanges are the second-most commonly used joining mechanism after welding.

It also provides added flexibility that allows easier disassembly and assembly of pipe systems. They provide easy access during the inspection, repairs, and cleaning of natural gas and oil pipelines.

Here are a few factors to keep in mind during the flange selection process:

Flange types

Flanges come in different types for industrial use. You may need to choose carefully an ideal flange design that fits well with your piping system. The most common type of flanges used in the petrochemical industry are:

1. Slip-on flange

2. Welding neck flange (buttweld)

3. Socket weld flange (counterbore)

4. Blind flange

5. Lap joint flange (rotating flange)

6. Threaded (companion) flange

pipe flanges

Other special flanges commonly used in the gas and oil industry include:

Nipoflange

Reducing flange

Expander flange

Orifice flange

Long weld neck flanges

The flange face types and design may have a significant impact on the piping system’s final performance.

Material

Forged carbon steel pipes are one of the common types present in the market. Additionally, you can find flanges manufactured from bronze, cast iron, aluminum, and stainless steel. You may also find flanges with specialty metals like Monel, Inconel, and chrome-moly.

The type of material used depends on the piping systems and industrial application. It is to ensure that they are strong and durable enough in the long run. However, in most instances, the flanges and pipes are made of the same material.

Size

If you want a flange in a proper fit, you need to look into the flange dimensions and size. You need to be keen on how the flange interfaces with the pipes and gaskets to ensure an ideal size. Below are a few standard dimension considerations:

1. Pipe size

2. Thickness

3. Bolt circle diameter

4. Inner diameter

5. Nominal bore size

6. Outside diameter

Classifications

All flanges fall under different categories specified by ASTM or ASME standards. Characteristics of a specific flange type impact its performance across a range of industrial environments. Steel pipes are available in a variety of pressure classes and styles. The classification of metal flanges is from 150 to 2500# rating. Some standard classifications used in petrochemical industries include:

2500# (and higher for API)

1500#

900#

600#

300#

150#

The different categories vary depending on the temperature and pressure tolerances, flange size, design, or material used. The pressure ratings may decrease with the rise in temperature.

Thickness

Depending on how thick the flange is, it is easy to determine the high pressure it can handle, in any application thicker flange can resist higher pressures.

Bolt holes

Bolt holes make it easy to measure the size of the pressure class and flange. The number of bolt holes, pitch circle diameter, and the actual bolt hole size on the flanges are 3 factors that need to be addressed.

Pressure class

Pressure class helps to understand the marginal pressure level under which the flange can function safely and sustain. Each standard has several levels of pressure available, from high-pressure to low-pressure tolerance. The pressure level of the products to which the flange will be connected must be the same as the valves and pipes in the process.

Statistics on Industrial Pipeline

The Pipeline and Hazardous Materials Safety Administration under the US Department of Transportation have made an estimate which shows approximately 1,585,672 miles of natural gas pipeline and 160,521 miles of liquid petroleum pipeline across the nation. Over 28.3 trillion cubic feet of natural gas was delivered to consumers in 2019 via the gas-integrated transportation network.

Conclusion

There’s an endless list of factors to consider when you choose flanges for the Industrial Pipeline system. However, the given above are a few specific or crucial ones you must not skip out.

We hope that with the help of this guide, you will be able to identify the key things before purchasing flanges. To learn more about flange basics, visit https://www.texasflange.com/flange-basics/

 

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Mistakes You Don’t Want To Make With Flange Fittings

Flanges are amongst the fastest and most secure methods to connect and protect pipe systems. The use of flanges adds flexibility to the piping system by allowing easier assembly and disassembly and greater access to the system components. Though flange fittings are quite a reliable option for your piping systems, there are few items you need to review before installing flange fittings. Many factors need to be considered carefully while manufacturing and selecting flange fittings. For example, sizing, flange specifications, flange designs, pricing, and durability are all important. Here are some mistakes you should avoid while making flange fittings:

Not Interchangeable:  One must ensure that the major flange fitting specifications and codes do not get interchanged in assembly due to pressure changes and bolt patterns. Often, the dimensional places of the hole can seem close, but not identical. Be very careful about the sockets and joints used for the flange fittings and pipe connections.

Overtightening Joints and Connections: Many people falsely believe that overtightening the connections would prevent the leaking of pipes and other joints. In the event you overtighten the joints and connections, there are increased chances that the pipes will rupture and break. Therefore, you should ensure that the fittings are snug and not excessively tight, according to the corresponding torque values.

Using a cracked flange: Using a broken flange is amongst the biggest and preventable mistakes you can make. Unfortunately, cracked or chipped flanges can lead to leaking in your assembly, thus posing several problems to your crew. It is better if you repair the flanges beforehand or buy new ones for the project. You need to follow a well-known specification for the use of flanges and their installation.

Undone Bolts: Usually, while doing maintenance and repairs, it is essential to loosen the bolts of the flange guards. You must be highly cautious of the loosened bolts since they can lead to significant accidents and leakage problems. You might also experience accidental spray out, occasional leakage, and pipe damage when dealing with flange bolting.

Flange Fittings

Not Wearing Gloves: While working over flange fittings and valve components, it is essential to take several precautions that pertain to safety standards. One of the most common mistakes committed while making flange fittings is not wearing proper safety gear and equipment while working on flange fittings. You come across various handling acids and alkalis while working upon fittings, connections, and pipes. Therefore, it is vital to wear protective hand gloves that are heat resistant and acid protective.

Not Turning Off Water: Many DIY installers believe they can change valves quickly, even when the fluids are running through the pipes. In case you try to assemble the flanges and fittings when the water valve is on, there is a lot of pressure with water flooding across the floor and increasing the overall workload of individuals. Therefore, it further increases the damage caused due to water spillage and exaggerates overall financial damage and project downtime.

Not following proper guidelines: Before you try and install pipe fittings and connections, you must follow appropriate guidelines. DIY installations are significantly easier for home projects but require following proper procedures guidelines to make proper connections in industrial applications. One tends to ignore all the safety precautions and guidelines while making DIY installations at home. You must pay attention to all the steps during installation, wear proper safety gear and follow essential instructions per the appropriate specifications.

Poor Flange and ring condition: Another critical aspect to consider while making flange fittings is the condition of flange rings and gaskets. You should ensure that the flange fittings and spare parts used are in proper condition: free from damage and cracks. Also, the parts and pipes should be absolutely dry when connecting them, and they should also be free from any corrosion. You should also change or replace the old rings with new ones regularly to reduce damage and leakage.

Negligent Dimensional Analysis: Sometimes, individuals focus on changing the flange fittings but do not consider the technical aspects of flange installations. You should be well aware of the various flange dimensions of bolts and nuts used in the overall installation process. Ensure you have the spare parts or bolts of accurate dimensions so that you don’t face any problems during their assembly.

Flange fittings can seem rather easy to install or use but require precision and practical skills to some extent. You cannot just make a fitting as you deem appropriate. It is essential to be cautious while following proper safety precautions and guidelines for a successful installation. Most importantly, you should be quite attentive when making connections for flange fittings as you need to be certain about the correct bolt and flange dimensions, assembly, and installation. As for the mistakes discussed above, they are preventable and are required if you wish to make your flange fittings leakproof, damage-resistant, and practical to install.

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Importance of ASTM Standards For You

The use of flanges has grown significantly over time, prominently due to the development of new infrastructures and their need to export gases and liquids. Usually, flanges and piping are crucial for developing these export pathways, and refineries come with high volume requirements for industrial flanges.

Something often regarded as one of the essential steps during the process is finding a reliable and trustworthy contractor. Some contractors and subcontractors try to cut corners when it comes to making more money, leading to unnecessary replacements and costly repairs at the end of your project launch.

It has become essential to interview suppliers and contractors and find out if they follow the standards set by ASTM or not. Make sure they follow the protocols and standards properly and work accordingly with relevant products per the ASTM guidelines. If this happens, there is little to worry about your project work because you will be putting your capital and equipment in capable hands.

At TEXAS FLANGE, we provide high-quality ANSI, API, and AWWA pipe flanges in carbon steel as per ASTM standards. These pipe flanges are available in carbon and various alloy steels with sizes available from 1/2″ to 166″.

Meaning of ASTM Standards

The American Society for Testing and Materials is known as ASTM and is one of the leading forces in the certification and development of products. ASTM, being a reputable American organization, has international recognition and includes best practices to determine whether a material grade and product is worthy of investment and use in common applications.

ASTM has garnered its recognition as a global leader for the delivery and development of voluntary consensus standards. More than 12000 standards given out by ASTM are used worldwide to improve product quality, strengthen the market trade and access, enhance safety and health, and let the customers know they can count on products. This organization is also serving many industries like construction, metal forming, consumer products, petroleum, etc. The development of standards has been done per the guiding principles of the World Trade Organization. These standards are helpful for companies, individuals, and institutions around the world. Most all government regulators also cite standards in codes, regulations, and laws.

The ASTM standards help improve:

1. Quality of the products which contain referenced material grades

2. Worker safety and health standards

3. Strengthening the market around all trades

4. Sustainability of materials developed

5. Recognition of existing and updated international cross-references between standards

Importance of ASTM Standards

The ASTM standards are also helpful in making these products much safer to use, so there are no related dangers. The standards allow the suppliers to understand that their products are top-notch, and they offer the best quality to their customers.

The suppliers following the ASTM standards can easily guarantee that they offer the best quality products to their customers. For getting approval for ASTM certification, products need to go under rigorous testing to make sure they are reliable under high pressure and stress calculation-tested situations.

These kinds of situations give customers the satisfaction to know that their products comply well with the industry’s standard evaluations.

ASTM at Texas Flange

At Texas Flange, we use only those products which follow the standards set by ASTM. All our products are certified, deemed efficient, and durable. Slip-on, Blind, Threaded, Socket Weld, Lap joint, and Weld Neck flanges are all available at Texas Flange. All of these flanges are designed with specific pressure ranges to provide excellent connectivity, from low stress and volatility applications such as simple structural assemblies to high pressure and temperature services on critical jobs which require extreme safety.

At TEXAS FLANGE, we are here to help you with your needs related to flanges, fittings, and custom steel components. We have been in the business of quality flange manufacturing since 1986, and we are confident in helping you find a solution more quickly, affordably, and with more expertise than the competition. We are committed wholeheartedly to provide our customers with the finest quality flanges and flange fittings in a timely manner.

We are pretty excited to hear from our customers and their new projects each and every day. You can visit our website for more related information and view our gallery for a comprehensive list of our products. We’d love to hear about your project too, so get in touch with us today!