Flanges are a type of fitting that is used in pipe and tubing systems. It's often used in metalworking and engineering for joining pipes, valves, pumps and other equipment together so that they can work smoothly as one unit. They offer the advantages of being able to connect different types of materials together, while also allowing flexibility for when components need to be removed or replaced. A flange can have female ends (such as on a steel beam) where it would receive bolts from another component, or male ends (such as on a steel pipe) where it would connect to another component.
What are Flanges Used For?
To reduce pressure or strain exerted on pipelines without reducing fluid flow rate - Connecting large diameter piping systems together in power plants, refineries, chemical plants - To connect and disconnect piping systems
Facilitating repairs in pipelines by making it easier to access them (e.g., when an emergency shutdown is required) or relocating a pipeline
Materials for Flanges
Our Flanges are forged in various materials like Stainless Steel, Alloy, Carbon and have machined surfaces. The material of a Flange, is essentially set in accordance with the choice of the pipe, and as a rule, a Flange is of a similar material as the pipe in use. All of our Flanges material and product range, fall under the IS, ASTM, JIS, DIN, IS and other international standards norms. Each product depending on the material portrays distinct measurements, dimensional resilience and material characteristics.
Types of Flanges
Their are many different types of flanges are determined by their shape, thickness and other properties. We manufacture 6 different kinds of forged steel flanges. get more details about each type below:
1. Welding Neck Flanges:
Our Stainless Steel Welding Neck Flanges have long tapered core that goes steadily over to the barrier width from a pipe or fitting. The long tapered hub provides an important reinforcement for use in several applications involving high pressure, sub-zero and / or elevated temperatures. These Weld Neck flanges are ribbedto match the inside diameter of the mating pipe or fitting so there will be no restriction of product flow. This forestalls disturbance at the joint and decreases disintegration. They additionally give phenomenal pressure conveyance through the tightened center and are effectively monitored for flaws, if any.
2. Slip on Flanges:
Our SS Slip on Flanges are easy to install and thus the most wide spread application of it, along with the low material costing. These flanges may also act as a replacement for Lap Joint Flanges. Slip On Flange is essentially a ring that is placed over the pipe end, with the Flange face extending from the end of the pipe by enough distance to apply a weld bead on the inside diameter. Our product is the perfect choice when it comes to usage for fluids at low pressure and with little to no risk of leakage.
3. Socket Weld/Counter Bore Flanges:
4. Lap Joint Flanges:
Our Stainless Steel Lap Joint Flanges are the type of flanges which are particularly useful for large or difficult to adjust flanges. It is a assembly type flange with two components. It has a stub end with a ring to which a flange is placed over. This end is then welded to the pipe, and the ring can be turned to line up with the mating flange. Our Lap Joint Flanges are usually used in low pressure application with little load resilience.
5. Threaded/ Companion Flanges:
Our SS Threaded Flanges also known as Companion Flanges are specially forged to be attached to the pipe without needing to be welded. These flanges are threaded or has a socket like make in its bore and are a perfect match to the threads on the external side of a pipe. Threaded Flanges are similar to the Slip On Flanges. Because of its No weld application it can be used easily and are used for a smaller diameter and often for a high pressure requirement.
6. Blind Flanges:
Our Steel Blind Flanges are similar to any flanges thickness or bolting pattern but does not have a bored center. The purpose of Blind flanges is to act as block off for pipes or nozzle that is not used. It is mostly used at the end of a piping network. It is built to withstand high pressure.
More FAQ's Abour Our Flanges Products
What Are The Advantages of Flanges?
Flanges have a number of advantages for different industries, from oil and gas to automotive. The advantage they offer is the possibility of an easy connection between two different pieces or parts that are not necessarily in direct contact with one another. They can be used as connectors due to their quality construction which ensures durability over time. One example of how flanges are used in the modern world is to connect a piping system with the best possible seal.
Is Flange a Fitting?
Flanges are often mistaken as fittings, but they are not. Flanges come in a variety of types and sizes like any other fitting does. They have the same basic function to connect two pipes or components together securely. The difference is that flanges sit on top of the pipe while creating this connection whereas a fitting sits inside the pipe and creates a tight seal. A flange is made up of two components: the face and the gasket, which helps to create a watertight connection between pipes.
What is a Male Flange?
A male flange is a raised surface that fits into the opening of another object. This means it can be used to connect pipes, valves and other equipment together with screws or bolts. A Male Flange may also have pipe inserts which are then secured in place by tightening nuts on either side of the flange . The use of a male flange is to create a seal between two objects.
Male flanges are sometimes referred to as "flat flanges" because they have little depth, although there are also deep-drawn male flanges that extend below the plane of the connecting surfaces . These may be used for pressure purposes or simply due to design preference . Male Flanges come in different sizes and shapes to accommodate a range of connections.
What is a Female Flange?
A female flange is the opposite of a male flange; it has an opening where other objects can fit into, rather than having any kind of raised surface . This means that bolts or screws are used to hold two pieces together instead of the flange itself creating a seal between them. Female Flanges are also sometimes referred to as "flanged fittings" or simply plain "flanges".
A female flange is used when it's important that the connection can easily be disassembled and removed . This may include changes to existing systems, repairs or upgrades . A female flange does not always need to be attached to a raised surface like the male flange. It can simply connect two objects together .
Females are made in many different shapes and sizes, depending on what they will be used for. For example, an elbow female flange is commonly found at 90 degree angles because this allows it to fit into a corner of two surfaces.
Why Do Flanges Have a Raised Face?
A flange is a raised face that allows for quick and easy coupling of two objects. Flanges are typically used in the piping industry to connect pipes or fitting together with fasteners so that they can be securely connected using not just one joint, but rather several joints. This type of connection provides added stability when it comes to high pressure applications, which require a secure connection to be maintained.
What Is an Adapter Flange?
An adapter flange is the type of flanges that converts one size into another, and also called as reducer or sleeve coupling. This means when you have two different sizes or types, this product will help you connect them together so it can be used. These are mostly used in high pressure systems, and the flange allows for different types of piping to be joined together seamlessly.
An adapter Flange is Adapted Coupling which can connect two pipes with different outer diameters or wall thicknesses such as copper tube and steel pipe etc., Converts one size into another like reducing a large size to a small size etc.
What Is an Expansion Flange?
Expansion flanges are used in pipelines and vessels, the expansion flange can compensate for thermal growth which allows for increased stress tolerance than other type of flanges. A typical application is found when there needs to accommodate changes within temperature variations that may grow or shrink the piping, vessels or other equipment.
The expansion flange is used to prevent damage due to thermal growth of pipes and vessel that occurs when they are heated up or cooled down. It can make large variations in temperature between hot and cold water crossings with no problems for your pipeline.
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How Do I Know What Flange I Have?
One of the most common questions we get is "How can I tell what size flange my appliance has?" The good news is that it's usually easy to find out. Flanges are typically labeled in three ways: with a series of letters and numbers, stamped into aluminum or steel plates on each side of the tank; by stamping or engraving the name or model of a flange directly on one side; and by attaching an identification tag to the appliance.
Is Flange a Standard?
Flange is a cylindrical device with an opening at one end. The flanges are designed to be attached to pipes and other tubing that require enhanced strength for connecting different pieces of equipment together, ensuring proper airtightness in the system, preventing leakage due to corrosion or heat stress among others reasons. They are machined from thin metal plates, and they can be attached to the pipe or tube by welding, bolting them on using bolts with their heads cut off
Our Range Of Steel Flanges
We are leading flanges manufacturers and we offer our flanges in a wide variety and different dimensional size ranging from ½&#; to 24&#; with a pressure rating ranging from 150 to lbs. We follow standard international and national dimensional standards or any other as per the customer&#;s request.
We at Shacha Technologies Pvt. Ltd. constantly seek perfection in our practices of administration and production thus making our Global presence felt across 6 continents with number of countries and multiple satisfied customers.
A flange is a method of connecting pipes, valves, pumps and other equipment to form a piping system. It also provides easy access for cleaning, inspection or modification. Flanges are usually welded or screwed. Flanged joints are made by bolting together two flanges with a gasket between them to provide a seal.
Pipe flanges are manufactured in all the different materials like stainless steel, cast iron, aluminium, brass, bronze, plastic etc. but the most used material is forged carbon steel and have machined surfaces.
In addition, flanges, like fittings and pipes, for specific purposes sometimes internally equipped with layers of materials of a completely different quality as the flanges themselves, which are "lined flanges".
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.
All flanges, discussed on this website fall under the ASME en ASTM standards, unless otherwise indicated. ASME B16.5 describes dimensions, dimensional tolerances etc. and ASTM the different material qualities.
Dimensions of Flanges
Each flange ASME B16.5 has a number of standard dimensions. If a draftsman in Japan or a work preparer in Canada or a pipefitter in Australia is speaking about a Welding Neck flange NPS 6, Class 150, Schedule 40 ASME B16.5, then it goes over the flange which in the image here below is shown.
If the flange is ordered, the supplier want to know the material quality. For example ASTM A105 is a forged carbon steel flange, while A182 is a forged stainless steel flange.
So, in a correct order to a supplier two standards must be specified..
The flange above has 8 bolt holes, and a welding bevel of 37.5 degrees (red circle). All given dimensions are in millimeters. The raised face (RF) does not need to be specified, because ASME B16.5, each flange is standard delivered with a raised face. Only a different design (Ring Type Joint (RTJ), Flat Face (FF) etc., should be specified.
Bolted Flange connections
A bolted flange connection is a complex combination of many factors (Flange, Bolts, Gaskets, Process, Temperature, Pressure, Medium). All these various elements are interrelated and depend upon one another to achieve a successful result.
The reliability of the flanged joint depends critically upon competent control of the joint making process.
Typical bolted flange connection
Quoting from John H. Bickford's book, 'An Introduction to the Design and Behavior of Bolted Joints'..
That all important clamping force which holds the joint together - and without which there would be no joint - is not created by a good joint designer, nor by high quality parts. It is created by the mechanic on the job site, using the tools, procedures, and working conditions we have provided him with.. And further.. The final, essential creator of the force is the mechanic, and the time of creation is during assembly. So it's very important for us to understand this process.
The industry has recognized the critical nature of installation and assembly for several years.
In Europe, the emphasis has been on ensuring that joint making is undertaken by trained and validated technicians and this has led to the publication of a European Technical standard TS EN Part 4. This standard is applicable to the bolting technicians, and their supervisors, the responsible engineers, who disassemble, assemble and tighten the bolted connections of whatever shape of critical service pressurised systems.
The standard provides a methodology for the training and assessment of technicians involved in the making and breaking of flange joints and can be viewed as being analogous to the training required for welders involved with pressure vessel work. Its publication demonstrates the importance placed upon the competent control of joint making process in ensuring leak-free performance from the flange.
The gasket is but one of many reasons a bolted flange joint connection can leak.
Even when all the complex inter-related components of a bolted joint flange connection work in perfect harmony, the single most important factor leading to success or failure of that bolted flange connection will be attention given to properinstallation and assembly procedures by the person installing the gasket. If done properly, the assembly will remain leak-free for the target life expectancy.
There are still a number of special flanges such as..
Orifice flange
Orifice flange
Long Weld Neck flange
Long Weld Neck flange
Expander flange
Expander flange
Nipo flange
Nipo flange
Reducing flange
Reducing flange
Pad flange
Pad flange
You will find more about this specials in the Menu Flanges
Remark(s) of the Author...
Flanged connections versus Welded connections
There are no standards that define whether or not flange connections may be used.
In a newly built factory is customary to minimize flange connections, because only one weld is needed to connect two pieces of pipe. This saves the costs of two flanges, the gasket, the Stud Bolts, the second weld, the cost of NDT for the second weld, etc..
Some other Disadvantages of flange connections..
Each flange connection can leak (some people claim that a flange connection is never 100 percent leak proof).
Flanged pipe systems need much more space (just think of a pipe rack).
Insulation of flanged pipe systems is more expensive (special flange caps).
Of course, flange connections have great benefits; some examples..
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.
NDO (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
(only paint damages during installation should be repaired).
As with many things, everything has its pros and cons.
Understanding Flanges: A Comprehensive Guide to Types, Uses, and Benefits in Industrial Applications
A flange is a mechanical piece used to connect pipes, valves, pumps, and other equipment in a piping system. It&#;s a crucial part that ensures systems are securely connected and can be easily assembled or disassembled for maintenance. Flanges usually come with gaskets and bolts to prevent leaks, especially in high-stakes industrial environments.
Flanges offer several advantages that make them vital in industrial settings:
There are different flange types designed for specific applications. Here&#;s a breakdown of the most common types:
With a long, tapered hub, weld neck flanges are perfect for high-pressure applications and are welded directly to the pipe.
Slip-on flanges slide over the pipe and are welded in place. They&#;re easy to install and ideal for lower-pressure environments.
Blind flanges are used to close off the end of a pipe or valve. They are common in systems requiring maintenance or future expansion.
These flanges are used for smaller, high-pressure systems and are welded to the pipe after it&#;s inserted into a recessed area.
Lap joint flanges work with a stub end and are great for systems requiring frequent disassembly. They&#;re not welded, making them easy to remove.
Threaded flanges are used in low-pressure systems where welding isn&#;t an option. They are screwed onto the pipe, making them ideal for small systems.
Orifice flanges are used in systems where liquid or gas flow needs to be measured. Paired with orifice plates, these flanges allow for precise measurements.
See Also Exploring the Best Flanges Manufacturers in India: A Comprehensive Guide for Buyers
Flanges come in a variety of materials, each suited for different industrial conditions:
Flanges are essential across multiple industries:
Flanges are an essential yet often overlooked component in industrial systems. Whether in high-pressure pipelines or sanitary food systems, flanges provide secure connections and prevent costly leaks. By selecting the right flange for your application, you ensure that your system will operate efficiently and safely.
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