PIPE FLANGES:

Pipe flanges are used to mechanically connect pipe sections to other pipe sections, inline
components, and equipment. Flanges also allow pipe to be assembled and disassembled
without cutting or welding, eliminating the need to issue a burn card for cutting and welding
when dismantling is required. In providing a breakable joint, flanges unfortunately provide a
potential leak path for the service fluid contained in the pipe. Because of this, as in all other
joints, they need to be minimized where possible.
The most prevalent flange standards to be used in industry are based on requirements of the
American Society of Mechanical Engineers (ASME) Standards. These include:
B16.1 – Cast Iron Pipe Flanges and Flanged Fittings,
B16.5 - Pipe Flanges and Flanged Fittings (NPS 1/2 through NPS 24),
B16.24 – Cast Copper Alloy Pipe Flanges and Flanged Fittings,
B16.36 – Orifice Flanges,
B16.42 – Ductile Iron Pipe Flanges and Flanged Fittings, Large Diameter Steel Flanges (NPS
26 through NPS 60)
B16.47 – Large Diameter steel flanges (NPS 26 through NPS 60)
NPS, indicated above, is an acronym for Nominal Pipe Size.

FLANGE CLASSIFICATION:

On the Basis of Connection With Pipes

Flanges are available with various contact facings (the flange-to-flange contact surface) and
methods of connecting to the pipe itself. The flanges under B16.5 are available in a variety of
styles and pressure classifications. The different styles, or types, are denoted by the way each
connects to the pipe itself and/or the type of face. The type of pipe-to-flange connections
consist of Threaded, Socket Welding (or Socket Weld), Slip-On Welding (or Slip-On),
Lapped (or Lap Joint), Welding Neck (or Weld Neck), and Blind.

Threaded Flange

In this type of flange the bore is threaded, thus enabling assembly without welding. This
obviously limits its application to relatively low pressure piping systems. The flange may be
welded around the joint after assembly, but this is not considered a satisfactory method of
increasing its pressure applications.
The primary benefit of threaded flanges is in eliminating the need for welding. In this regard
Threaded flanges are sometimes used in high-pressure service in which the operating
temperature is ambient. They are not suitable where high temperatures, cyclic conditions or
bending stresses can be potential problems.

Socketweld Flange

The Socket weld flange is made so that the pipe is inserted into the socket of the flange until
it hits the shoulder of the socket. The Pipe is then backed away from the shoulder
approximately 1/16” before being welded to the flange hub. If the pipe were resting against
the shoulder (This is the flat shelf area depicted in Fig. as the difference between diameters B
and B2) of the socket joint during welding, heat from the weld would expand the pipe
longitudinally into the shoulder of the socket forcing the pipe-to-flange weld area to move.
This could cause the weld to crack. The Socket weld flange was initially developed for use
on small size, high-pressure piping in which both a back-side hub weld and an internal
shoulder weld was made. This provided a static strength equal to the Slip-On flange with a
fatigue strength 1.5 times that of the Slip-On flange. Because the two-welds were labour
intensive it became the practice to weld only at the hub of the flange. In doing this it
relegated the socket weld flange to be more frequently used for small pipe sizes (NPS 2” and
below) in non-high-pressure, utility type service piping. The Socket weld flange is not
approved above Class 1500.

Slip-On Flange

Unlike the Socketweld flange, the Slip-On flange allows the pipe to be inserted completely
through its hub opening. Two welds are made to secure the flange to the pipe. One fillet
(pronounced “fill-it”) weld is made at the hub of the flange and a second weld is made at the
inside diameter of the flange near the flange face. The end of the pipe is offset from the face
of the flange by a distance equal to the lesser of the pipe wall thickness or 1/4” plus
approximately 1/16”. This is to allow for enough room to make the internal fillet weld
without damaging the flange face.
The Slip-On flange is a preferred flange for many applications because of its initial lower
cost, the reduced need for cut length accuracy and the reduction in end prep time. However,
the final installed cost is probably not much less than that of a Weld Neck flange. The
strength of a Slip-On flange under internal pressure is about 40% less than that of a Weld
Neck flange. The fatigue rate is about 66% less than that of a Weld Neck flange. The Slip-On
flange is not approved above Class 1500.

Lap Joint Flange

The Lap Joint flange requires a companion lap joint, or Type A stub-end to complete the
joint. The installer is then able to rotate the flange. This allows for quick bolthole alignment
of the mating flange during installation without taking the extra precautions required during
prefabrication of a welded flange.
Their pressure holding ability is about the same as a Slip-On flange. The fatigue life of a Lap
Joint/stub-end combination is about 10% that of a Weld Neck flange, with an initial cost that
is a little higher than that of a Weld Neck flange.
The real cost benefit in using a Lap Joint flange assembly is realized when installing a
stainless steel or other costly alloy piping system. In many cases the designer can elect to use
a stub-end specified with the same material as the pipe, but use a less costly, e.g. carbon steel,
Lap Joint Flange. This prevents the need of having to weld a more costly compatible alloy
flange to the end of the pipe.

Weld Neck Flange

The reinforcement area of the Weld Neck flange distinguishes it from other flanges. This
reinforcement area is formed by the added metal thickness, which tapers from the hub of the
flange to the weld end. The bore of the flange needs to be specified in order to obtain the
same wall thickness at the weld end as the pipe it will be welded to. This will give it the same
ID bore as the pipe. The Weld Neck flange is actually the most versatile flange in the ASME
stable of flanges. Much of its use is for fitting-to-fitting fabrication in which the flange can be
welded directly to a fitting, such as an elbow, without the need for a short piece of pipe, as
would be required with a Slip-On flange. It can be used in low-pressure, non-hazardous fluid
services as well as high-pressure, high-cyclic and hazardous fluid services.
While the initial cost of the Weld Neck flange may be higher than that of a Slip-On flange the
installed cost reduces that differential. And for conditions of possible high thermal loading,
either cryogenic or elevated temperatures, the Weld Neck flange would be essential.

Blind Flange

While the Blind flange is used to cap off the end of a pipeline or a future branch connection it
is also used for other purposes. It can be drilled and tapped for a threaded reducing flange or
machined out for a Slip-On reducing flange. The reduced opening can be either on-center or
eccentric.

ON THE BASIS OF FLANGE FACING

Raised Face Flange

Raised Face flanges are the most common type used in industrial applications due to their
versatility in gasket compatibility, robust construction that prevents flange rotation under load
and the unitized design.
Flat Face Flange
Mating faces of both flanges are flat across the entire face both inside and outside the bolts.
These unconfined gaskets require a mechanical stop to control compression height, such as a
spiral wound gasket, should be designed with this consideration.

Tongue and Groove Flange

Compressibility characteristics of the confined design need to be taken into consideration

when applying gaskets to this flange style to ensure flange surfaces do not meet and prevent
over-compression on the gasket. The groove width is typically not wider than 1/16” (1.5 mm)
over the tongue width to control gasket compression and creep relaxation due to gasket
migration. The gasket dimensions will typically match the tongue dimensions.

Ring type joint:

This is a method of ensuring leak proof connection at high pressures. A metal ring is
compressed into ahexagonal groove on the face of flange to make the seal. This jointing
method can be employed on weld neck, slip on and blind flanges.

Flange Specification and

Identification

Specification
A flange is specified by the following information:

a) Type and Facing: i.e. whether the flange is for example “Weld Neck, RTJ” or “Socket
Weld, RF”.

b) Nominal Pipe Size: required for all flanges, usually in inches.

c) Flange Pressure Class: required for all flanges, e.g. Class 150, 300, 900, 1500, 2500 etc.

d) Standard: i.e. ANSI B16.5, BS 1560, API 6A, API 605 or ASME B16.47.

e) Material: a material specification must be stated and will be as quoted in the piping
specification.

Identification

Normally, the flange specification will be hard stamped on the flange. In the case of existing
plant, the information may not be legible and it is then necessary to identify the flange by
visual observation and physical measurement.

a) Visual Observation: required to identify the type of flange and type of gasket used.

b) Physical Measurement: required to identify the nominal bore and the class of the flange.
Check the number of studbolts, studbolt diameter, studbolt Pitch Circle Diameter (PCD) and
the flange thickness. Compare these figures with standard flange data as found.

The Gasket
A gasket is a compressible material, or a combination of materials, which when clamped
between two stationary members prevents the passage of the media across those members.
The gasket material selected must be capable of sealing mating surfaces, resistant to the
medium being sealed, and able to withstand the application temperatures and pressures.
A seal is effected by the action of force upon the gasket surface. This force which compresses
the gasket, causes it to flow into the flange macro and micro imperfections. The combination
of contact stress, generated by the applied force between the gasket and the flange, and the
densification of the gasket material, prevents the escape of the confined fluid from the
assembly. On seating, the gasket must be capable of overcoming the macro and micro
imperfections. Macro defects are imperfections such as flange distortions, non-parallelism,
scoring, troughs, while superficial imperfections such as minor scratches and minor scores
are considered micro imperfections. In order to ensure the maintenance of the seal
throughout the life expectancy of the assembly, sufficient stress must remain on the gasket
surface to prevent leakage. The residual bolt load on the gasket should at all times be greater
than the hydrostatic end force acting against it. The hydrostatic end force is the force
produced by the internal pressure which acts to separate the flanges

Gasket Selection:
Gaskets can be classified into three categories: soft cut, semi-metallic and metallic types. The
physical properties and performance of a gasket will vary extensively, depending on the type
of gasket selected and the materials from which it is manufactured.
Physical properties are important factors when considering gasket design and the primary
selection of a gasket type is based on the following:
• Temperature of the media to be contained
• Pressure of the media to be contained
• Corrosive nature of the application
• Criticality of the application

CLASSIFICATION OF GASKETS

Non-metallic gasket
Sheet materials are used in low to medium pressure services. With careful selection these
gaskets are not only suitable for general service but also for extreme chemical services and
temperatures.
Types: Compressed Fiber Sheets, PTFE, Biaxially Orientated Reinforced PTFE, Graphite,
elastomer, Insulating Gaskets.

Semi metallic gasket

These are composite gaskets consisting of both metallic and non-metallic materials. The
metal provides the strength and the resilience of the gasket and the non-metallic component
provides the conformable sealing material. These gaskets are suitable for low and high
pressure and temperature applications. A wide range of materials is available.
Types: Spiral Wound Gaskets, covered serrated metal core, Metal Jacketed Gaskets, MRG’s
(metal reinforced gaskets).

Metallic gasket
These gaskets can be fabricated in a variety of shapes and sizes recommended for use in high
pressure/temperature applications. Except for weld ring gaskets, high loads are required to
seat metallic gaskets, as they rely on the deformation or coining of the material into the
flange surfaces.
Types: Ring Type Joints, Lens Rings, Weld Rings, Solid Metal Gaskets.

Non-metallic gaskets should always be of the minimum thickness consistent with the
style of the flanges to be sealed, and compatible with the medium.

GASKETS GENERALLY USED AT TCL BABRALA

Compressed Asbestos Fibre Gasket (CAF)
CAF gaskets are used for low pressure applications and were typically found on Class 150
and Class 300 flanges, and will probably still be in many flange applications. CAF gaskets
were normally used on Raised Face flanges (self centering flat ring type gasket), but may also
have been used on Flat Face flanges (full face type gaskets are required). Though of
apparently simple design, the CAF gasket should be treated with equal respect as with all
gaskets to ensure effective sealing. CAF gaskets are manufactured from asbestos fibres
bonded in a nitrile rubber compound. Sealing is by a similar mechanism to the spiral wound
gaskets where the gasket material is soft enough to flow into the phonographic groove on the
flange face when com-pressed. Correct gasket thickness is therefore important. The surface
finish on RF flanges used with CAF gaskets will be relatively coarse compared to that for SW
gaskets. The required surface finish will be as stated in the relevant section on Class 150
flanges. The gasket may or may not be coated with graphite. The graphite has non-stick
properties and enables the easy removal of the gasket when a flange is split. Graphite coated
CAF gaskets SHOULDNOT be used in the following instances:

a) Austenitic stainless steel flanges on water duties.

b) Aggressive water duty (e.g.cement lined pipework).
c) Duties where temperatures exceed 450degrees C.
Asbestos is a carcinogenic material to TCL is gradually changing from CAF to other
gasket options.

Spiral Wound Gaskets

These gaskets are fitted with an internal guide ring which:

• Provides an additional compression stop.
• Restricts the lateral flow of the gaskets toward the bore.
• Acts as a heat and corrosion barrier protecting the gasket and flange.
By filling the annular space between the gasket and flange, it reduces turbulent flow of the
fluid or the possibility of the accumu-lation of solids,and possible corrosion.
Spiral wound gaskets are typically used on intermediate pressure systems and will be found
on Class 300 flanges, Class 600 and Class 900 flanges. SW gaskets are used on RF flanges
with a smooth surface finish, as quoted in “Surface Finish Values for Flange Facings for
Class 150 to 2500 Flanges”. Where SW gaskets are used with standard Class 150 flanges and
smaller sizes of standard Class 300 flanges,the higher seating load requirements and low
bolting availability necessitates use of high strength bolting and proper bolting up procedures.
The use of gaskets with inner rings also increases the required bolting load.
Spiral Wound Section
This part of the gasket creates the seal between the flange faces.It is manufactured by spirally
winding a preformed metal strip and a filler material around a metal mandrel. Normally the
outside and inside diameters are reinforced by several additional metal windings
with no filler. When compressed,the combined effect of the metal winding and the filler
material will make the seal.The filler material will flow into the grooves on the flange face
and the metal winding will then strengthen and support the filler against the flange face.
Inner Metal Ring
The inner metal ring provides inner confinement to the gasket. Being of a specified thickness
smaller than that of the uncom-pressed spiral windings, it acts as a compression stop, i.e. it
pre-vents the windings from being over-compressed say due to over-tensioning of the
studbolts or thermal growth of the pipework when in operation.The inner ring also fills the
annular space between the flange bore and the ID of the spiral wound section and therefore
minimises turbulence of the process fluids at that location and pre-vents erosion of the flange
faces. Note that the spiral windings should never be exposed to the flow of the process fluids.
The IDof the inner ring should be flush with the bore of the flange and this should be checked
prior to bolting up.
Outer Metal Ring
The outer metal ring acts as a compression stop and an anti-blowout device.It also centres the
gasket on the flange face. The spiral wound gasket should be centred on the flange with the
outer ring resting against the studbolts. If this is not the case, the incorrect gasket has been
chosen and should be changed.
 Filler Material
For most applications in the petro-chemical industry, an asbestos filler was usually
specified.Asbestos is hazardous to health and even though trapped within the spiral
winding,SW gaskets should be handled with care.Full procedures are available and should be
consulted.Piping specifications now quote a “non-asbestos”filler instead of asbestos. Graphite
filler has now taken over as being the preferred filler material. For special applications other
materials are available, such as graphite and ceramic fillers.

RTJ (Ring Type Joint) Gaskets

RTJ gaskets are forged rings that fit into the machined groove of an RTJ flange.RTJ gaskets
are generally used for high pressure appli-cations. Sealing is by metal-to-metal contact
between gasket and flange.Solid metal joint rings have excellent tightness and tolerance to
temperature and pressure changes once correctly bolted up.Very close attention must be
given to their bolting up. Rings and groove faces must be free of imperfections.
There are four different types of ring commonly available:Types R, RX,BX.The most
commonly used is Type R. This gasket is also used in tcl babrala.

RType
These are either oval or octagonal in cross-section.The oval RTJ is the original design.The
octagonal RTJ is a modification to the oval design and provides better sealing. Rtype rings
may be specified for Class 150 to 2500 flanges though are typically found on Class 1500
flanges and often Class 900.The piping specification will state whether an octagonal or an
oval joint is to be used.R type rings may be used on either flat face or raised fact RTJ flanges.
Lens Ring Gasket
The Lens Ring provides a metallic gasket design incorporating spherical seating faces designed to suit
specifically mating flange recesses, providing the user with a high integrity, high pressure/temperature metal to
metal seal. As with all metallic gaskets, the Lens Ring material should be specified softer than the flange
material, thus ensuring applied compressive load leads to the elastic/plastic deformation of the lens ring and not
the flange sealing face. The distribution of high compressive loads leads to the spread of the gasket facings,
ensuring over stressing of the gasket is prevented.