Professional Documents
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Introduction:
Within industry, piping is a system of pipes used to convey fluids (liquids and
gases) from one location to another.
1. Pipes
2. Flanges
3. Gaskets
4. Bolts and nuts
FLANGES GENERAL
The most used flange types in Petroleum and chemical industry are:
SPECIAL FLANGES
Except the flanges, which are mentioned above, there are still a number of
special flanges such as:
Orifice Flanges
Spectacle Blinds
Spades and Ring Spacers
Long Welding Neck Flanges
Weldoflange / Nipoflange
Expander Flange
Reducing Flange
The most common materials used in flanges produced is carbon steel, stainless
steel, cast iron, aluminum, brass, bronze, plastic, etc..
The material of a flange, is basically set during the choice of the pipe, in most
cases, a flange is of the same material as the pipe.
Piping Standards
If the flange is ordered, the supplier wants to know the material quality. For
example ASTM A105 is a forged carbon steel flange, while A182 is a forged
stainless steel flange.
The gasket is one reason for flange joint connection cannot leak.
If done properly, the assembly will remain leak-free for the target life expectancy.
A new line can contain multiple pipe spools and can be manufactured in a
workshop.
This pipe spools can be assembled in the plant without the need to be
welded.
NDT (X-ray, Hydro test etc.) in the plant is not necessary, because this
has been done in the workshop.
Blasting and painting in the plant is not necessary, because even this has
been done in a workshop.
PRESSURE CLASS
The Pressure Class or Rating for flanges will be given in pounds. Different
names are used to indicate a Pressure Class. For example: 150 Lb or 150 Lbs or
150# or Class 150, all means the same.
The concept of flange ratings: A Class 300 flange can handle more pressure
than a Class 150 flange, because a Class 300 flange is constructed with more
metal and can withstand more pressure. However, there are a number of factors
that can impact the pressure capability of a flange.
Welding Neck Flanges are easy to recognize at the long tapered hub that goes
gradually over to the wall thickness from a pipe or fitting.
Socket Weld flanges were initially developed for use on small-size high pressure
piping. Their static strength is equal to Slip On flanges, but their fatigue strength
50% greater than double-welded Slip On flanges.
Socket Weld Flange.
Lap Joint Flanges have all the same common dimensions as any other flange
named on this page however it does not have a raised face; they are used in
conjunction with a "Lap Joint Stub End".
THREADED FLANGE
Threaded Flanges are used for special circumstances with their main advantage
being that they can be attached to the pipe without welding.
Threaded flange
BLIND FLANGE
Blind Flanges are manufactured without a bore and used to blank off the ends of
piping, valves and pressure vessel openings.
Blind flange
During the prefab of a flange, for example an elbow; the position of the bolt holes are of
particular importance.
That means:
For a vertical flange face (the flange face in the vertical and the line is horizontal)
the bolt holes should be orientated to be on the vertical and horizontal
centerlines.
For a horizontal flange face (the flange face is horizontal and the line is vertical
above or vertical down) the bolt holes should be orientated to be on the
Plant North centerlines. See below on this page, an image of a plant north
situation.
Correct vertical position incorrect vertical position
ASME B16.5 and B16.47 define various types of flange facings, including the
raised face, the large male and female facings which have identical dimensions
to provide a relatively large contact area.
The ring type joint flanges are typically used in high pressure (Class 600 and
higher rating) and high temperature services above 800°F (427°C). They have
grooves cut into their faces to fit steel ring gaskets. The flanges seal when
tightened bolts compress the gasket between the flanges into the grooves,
deforming the gasket to make intimate contact inside the grooves, creating a
metal to metal seal.
TONGUE-AND-GROOVE (T&G)
The tongue and groove faces of these flanges must be matched. One flange
face has a raised ring (Tongue) machined onto the flange face while the mating
flange has a matching depression (Groove) machined into it's face.
These are commonly found on pump covers and valve bonnets.
Tongue-and-groove joints also have an advantage in that they are self-aligning
and act as a reservoir for the adhesive. The scarf joint keeps the axis of loading
in line with the joint and does not require a major machining operation.
MALE-AND-FEMALE (M&F)
With this type the flanges also must be matched. One flange face has an area
that extends beyond the normal flange face (Male). The other flange or mating
flange has a matching depression (Female) machined into its face.
The female face is 3/16-inch deep, the male face is 1/4-inch high, and both are
smooth finished. The outer diameter of the female face acts to locate and retain
the gasket. Custom male and female facings are commonly found on the heat
exchanger shell to channel and cover flanges.
FLANGE FACE FINISH
The ASME B16.5 code requires that the flange face (raised face and flat face)
has a specific roughness to ensure that this surface be compatible with the
gasket and provide a high quality seal.
BOLTS
To connect two flanges with each other, also bolts are necessary. The quantity
will be given by the number of bolt holes in a flange, diameter and length of bolts
is dependent of flange type and Pressure Class of flange.
The most used bolts in Petro and chemical industry for ASME B16.5 flanges are
stud bolts. Stud bolts are made from a threaded rod and using two nuts. The
other available type is the machine-bolt that using one nut.
Dimensions, dimensional tolerances etc. have been defined in the ASME B16.5
and ASME 18.2.2 standard, materials in different ASTM standards.
TORQUE TIGHTENING
Correct tightening of a bolt means making the best use of the bolt's elastic
properties. To work well, a bolt must behave just like a spring. In operation, the
tightening process exerts an axial pre-load tension on the bolt. This tension load
is of course equal and opposite to the compression force applied on the
assembled components. It can be referred to as the "tightening load" or "tension
load".
Manual Wrench
Impact Wrench
Hammer Wrench
Hydraulic Torque Wrench
Manual Beam and Gear-Assisted Torque Wrench
Hydraulic Bolt-Tensioner
TIGHTENING SEQUENCE
The first pass, lightly tighten the first bolt then move directly across or 180
degrees for the second bolt, then move 1/4 turn around the circle or 90 degrees
for the third bolt and directly across for the fourth. Continue this sequence until all
bolts are tightened.
When tightening a four-bolt flange, use a criss-cross pattern.
Tightening Sequence
Before beginning a bolting process, the following preliminary steps will avoid
future problems:
Clean the flange-faces and check for scars; the faces must be clean and
free of defects (burrs, pits, dents, etc.).
Visually inspect all bolts and nuts for damaged or corroded threads.
Replace or repair bolts or nuts as necessary.
Remove burrs from all threads.
Lubricate the threads of the bolt or stud, and the surface of the nut face
adjacent to the flange or washer. Hardened washers are recommended in
most applications.
Install the new gasket and be sure gasket is properly centered. DO NOT
REUSE old gasket, or use MULTIPLE gaskets.
Check flange alignment according to ASME B31.3 Process Piping:
...flange faces must be parallel within 1/16" per foot of diameter, and flange
bolt holes must be aligned to within 1/8" maximum offset.
Adjust the position of the nuts to ensure that 2-3 threads are visible above
the top of the nut.
BOLT TENSIONING
General Procedure
ORIFICE FLANGE
Orifice Flanges are intended for use instead of standard pipe flanges when an
orifice plate or flow nozzle must be installed. Pairs of pressure "Tappings", mostly
on 2 sides, directly opposite each other, are machined into the orifice flange. This
makes separate orifice carriers or tapping in the pipe wall unnecessary.
On the image above a set Orifice Flanges is shown, where the tappings are
sealed with a plug, and where a jack screw is machined. This jack screw is used
to facilitate separating the flanges for inspection or replacement of the
"Orifice Plate" and gaskets.
The range of orifice flanges covers all standard sizes and ranges, and all
common flange materials. Flanges are available in Welding Neck, Slip On, and
Threaded form, and are typically supplied with two ½" NPT tappings in each
flange.
ASME B16.36 covers Dimensions and dimensional tolerances from orifice
flanges (similar to those covered in ASME B16.5) that have orifice pressure
differential connections. Coverage is limited to the following flanges:
ORIFICE PLATE
An Orifice Plate is typically a circular, flat plate with a handle. The most common
orifice plate is the square-edged concentric bored orifice plate, others are
Eccentric Orifice Plate, Segmental Orifice Plate etc. and typically, it is made of a
durable metal such as stainless steel.
Orifices Plates are used to create a differential pressure that relates to the
velocity of the gas from which a flow rate can be calculated. As the following gas
passes through the restriction in the line caused by the orifice plate, the
difference in the upstream and downstream pressure can be measured at set
points, called taps, and a flow rate at the point can be determined. As the plate
serve as a restriction in a pipeline, then we talk about a Restriction Orifice Plate,
abbreviated (RO).
SPECTACLE BLINDS
A Spectacle Blind is a steel plate cut into two discs of a certain thickness.
The two discs are attached to each other by section of steel similar to the nose
piece of a pair of glasses. One of the discs is a solid plate, and the other is a ring,
whose inside diameter is equal to that of a flange.
Spade.
Ring Spacer.
Spades and Spacers are applied in systems where maintenance is often not
necessary, or in applications with large pipe sizes. Depending on the flange size
and the Pressure Class, Spades can weigh hundreds of pounds. To prevent
unnecessary weight to flange connections, usually will be chosen not for a
Spectacle Blind, but for 2 separate parts.
The sealing surfaces of a Spectacle Blind, Spade or Ring Spacer are usually
conducted in accordance with the Face Finish from the flange. The diameter
always is slightly larger than the Raised Face of a flange; by a correct assembly,
the bolts are just not touched by the Blind or Spacer.
The diameter of them, is depending on the flange size, and the thickness from
the Pressure Class of a flange.
Dimensions from Spectacle Blinds, Spades and Ring Spacers, you will find in the
main menu "Flanges"
Spectacle Blinds, Spades and Ring Spacers should be made from a plate or
forging specification, approved for use by ASME B31.3, of essentially the same
chemical composition as the mating flanges and piping involved.
101.6
114.3
139.7 139.7 142.8
101.6 161.9 161.9 165.1
123.8 146.1 165.1 171.5 193.7
111.1 136.5 158.7
123.8 190.5 203.2 206.4 231.7
150.8 182.6 238.1 244.5 250.8 276.2
177.8 212.7 263.5 285.8 279.4 314.3
228.6 266.7 317.5 355.6 349.3 384.1
282.6 320.7 369.9 431.8 431.8
339.7 377.8 495.3 517.5 546.1
371.5 409.6 488.9 517.5 574.7
422.3 466.7 561.9 571.5 638.1
479.4 530.2 609.6 701.7
530.2 679.5 695.3 752.4
631.8 682.6 787.4 898.5
General notes:
101.6
114.3
139.7 139.7
161.9 161.9 165.1
107.8 146.1 165.1 171.5 193.8
131.8 190.5 203.2 206.5 231.9
152.4 238.2 244.6 250.9 276.3
190.5 263.6 285.8 279.4 314.5
238.3 317.5 355.6 349.3 384.3
285.8 396.9 431.8 431.8 473.2
342.9 454.1 495.3 517.6 546.1
374.7 517.6 574.7
425.5 571.5 638.2
609.6 701.8
533.4 679.5 695.5 752.5
641.4 787.4 835.1 898.6
General notes: