What is a flange
What is a flange? A flange is a hollow, circular disc that is used to connect 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.
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. Performance Guarantee Our products are backed by our hassle-free guarantee. We offer free installation support and free finishing accessories on all elements sold through our website.
Types of Flanges
The most used flange types in Petro and chemical industry are:
All types except the Lap Joint flange are provided with a raised flange face.
Special Flanges
Except the most used standard flanges, there are still a number of special flanges such as:
Image of most common flange types.
Flanges are manufactured in different materials like stainless steel, cast iron, aluminium, brass, bronze, plastic and so on but the most commonly used material is forged carbon steel and have machined surfaces. Lined flanges are sometimes used for specific purposes. 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. Flanges fall under ASME en ASTM standards
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 6″-150#-S40 ASME B16.5, then it goes over the flange which in the image here on the left 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:
Welding Neck flange 6″-150#-S40-ASME B16.5 / ASTM A105.
Bolted Flange connections
A bolted flange connection is a complex combination of many factors (Flange, Bolts, 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.
a typical bolted flange connection.
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 1591 Part 4 entitled “Flanges and their joints. Design rules for gasketed circular flange connections. Qualification of personnel competency in the assembly of bolted joints fitted to equipment subject to the Pressure Equipment Directive (PED)”.
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.
The gasket is but one of many reasons a bolted flange joint connection can leak. The single most important factor leading to success or failure of that bolted flange connection will be attention given to proper installation and assembly procedures by the person installing the gasket. If done properly, the assembly will remain leak-free for the target life expectancy.
Flange joints allow pipes to be dismantled quickly and easily for inspection, modification or replacement. This is an important advantage in systems that require frequent inspection. Flanged joints are also widely used where the piping system passes through areas where a possible fire hazard exists. Because standard flanges can be used with a variety of gasket materials, they are suitable for a wide range of applications in many different services.
Flange and threaded connections are used in many parts of the piping systems e.g. pipelines, subsea systems, gas station etc. Unions, Swage Nipples and Bull Plugs are also used for special applications where flanged joints are not suitable (like hot tapping).
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Knowledge About Butt weld Fittings
A pipe fitting is defined as a part used in a piping system, for changing direction, branching or for change of pipe diameter, and which is mechanically joined to the system. There are many different types of fittings and they are the same in all sizes and schedules as the pipe.
Fittings are pided into three groups:
elbows, tees, reducers, caps, bends and many others from 1/2″ to 120″ diameter in all material grades, according to international standards and clients’ requirements.
The ASME B16.9 standard covers the dimensions and tolerances of carbon steel butt-weld fittings. The MSS SP 43 standard includes the overall dimensions, tolerances, ratings, testing, and markings for wrought stainless steel butt-welding short radius elbows and returns. The ASME/ANSI B16.28 standard covers short radius elbows that are intended for limited space applications.
WILSON PIPELINE manufacture of flange fittings&pipes
· Butt weld (BW) fittings whose dimensions, dimensional tolerances et cetera are defined in the ASME B16.9 standards. Light-weight corrosion resistant fittings are made to MSS SP43.
· Socket Weld (SW) fittings Class 3000, 6000, 9000 are defined in the ASME B16.11 standards.
· Threaded (THD) fittings Class 2000, 3000, 6000 are defined in the ASME B16.11 standards.
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Most used buttweld fittings.
1. Elbow 90° long radius 2. Elbow 45° 3. Elbow 90° short radius
4. Elbow 180° long radius 5. Elbow 180° short radius
6. Tee straight 7. Tee reducing
8. Reducer concentric 9. Reducer eccentric
10. End cap 11. Lap joint Stub End
Applications of Butt weld Fittings
A piping system using buttweld fittings has many inherent advantages over other forms.
· Welding a fitting to the pipe means it is permanently leakproof
· The continuous metal structure formed between pipe and fitting adds strength to the system
· Smooth inner surface and gradual directional changes reduce pressure losses and turbulence
and minimize the action of corrosion and erosion
· A welded system utilizes a minimum of space
·
Bevelled Ends
The ends of all buttweld fittings are bevelled, exceeding wall thickness 4 mm for austenitic stainless steel, or 5 mm for ferritic stainless steel. The shape of the bevel depending upon the actual wall thickness. This bevelled ends are needed to be able to make a “Butt weld“.
Typical bevel types.
ASME B16.25 covers the preparation of buttwelding ends of piping components to be joined into a piping system by welding. It includes requirements for welding bevels, for external and internal shaping of heavy-wall components, and for preparation of internal ends (including dimensions and dimensional tolerances). These weld edge preparation requirements are also incorporated into the ASME standards (e.g., B16.9, B16.5, B16.34).
Material and Performance
The most common materials used in fittings produced is carbon steel, stainless steel, cast iron, aluminium, copper, glass, rubber, the various types of plastics, etc..
In addition, fittings, like pipes, for specific purposes sometimes internally equipped with layers of materials of a completely different quality as the fitting themselves, which are “lined fittings”.
The material of a fitting is basically set during the choice of the pipe, in most cases, a fitting is of the same material as the pipe.
Materials used and related International Standards
Design Codes Manufacturing Standards
ASME B31.1 -ASME B31.3 ASME B16.9-ASME B16.25
ASME B31.4-ASME B31.8 MSS-SP43 — MSS-SP75
EN 13445–13480–12952 (former BS PD 5500 Swedish ordinance AFS 1994:39 ) DIN 2605–2606–2615 2616–2617 — BS 1640
DIN 2413 — TRD301 GOST 17374–17375 17376–17377–17378 17379–17380
AD 2000 Merkblatt B2-B3-B9 EN 10253
STOOMWEZEN rules for pressure vessels ISO 15590
MSS- SP-75 BS/EN 14870
CARBON AND ALLOY STEEL FOR ROOM, MODERATE AND ELEVATED TEMPERATURES STAINLESS STEEL HIGH YIELD STEEL FOR PIPELINE AND OFFSHORE CARBON AND ALLOY STEEL FOR LOW TEMPERATURE SERVICE AUSTENITIC/FERRITIC STAINLESS STEEL COPPER ALLOY NICKEL ALLOY TITANIUM ALLOY
ASTM / ASME A/SA 106 ASTM / ASME A/SA 312: TP304 -TP304L -TP304H TP304LN -TP304N TP316-TP316L-TP316H TP316LN -TP316N -TP317 TP317L -TP321 H -TP347 TP347H — S31254 and equivalent grades API 5L: Gr. X42 — X46 — X52 X60 — X65 — X70 — X80 ASTM / ASME A/SA 333: Gr. 6, Gr. 3, Gr. 8 and equivalent grades ASTM / ASME A/SA 790: UNS 31803 (duplex) — UNS 32750 (superduplex) UNS 32760 (superduplex) UNS 32550(superduplex) and equivalent grades Copper-nickel ASTM /ASME B/SB 466: UNS C70600 (Cu Ni 90/10) UNS C71500 (CuNi 70/30) and equivalent grades. ASTM / ASME B/SB 366: UNS N04400 — UNS N06600 UNS N06625 — UNS N08020 UNS N08800 — UNS N08811 UNS N08825 — UNS N10276 and equivalent grades. ASTM / ASME B/SB363: WPT2-WPT12 and equivalent
ASTM / ASME A/SA 106 ASTM / ASME A/SA 403: WP304 -WP304L -WP304H WP304LN -WP304N WP316 -WP316L-WP316H WP316LN -WP316N WP317 -WP317L -WP321 WP321 H -WP347 WP347H -WPS31254 EN 10208–2: L245NB L290NB — L360NB — L415NB L360QB — L415QB — L450QB L485QB — L555QB — L360MB L415MB — L450MB L485MB and equivalent grades. ASTM / ASME A/SA 420 WPL6 -WPL3 ASTM / ASME A/SA 815: UNS 31803 (duplex)
ASTM / ASME A/SA 335: Gr.1 — Gr.11 — Gr.12 — Gr.5 Gr.22 — Gr.9 — Gr.91 RCC-M: CL 1 — CL2 — CL3 grades Z2CND17.12 Z2CN18.10 — Z2CND18.12N (other grades can be supplied upon request) ASTM A860/MSS-SP75: WPHY 42 WPHY 46 -WPHY 52 -WPHY 60 -WPHY 65 WPHY 70 grades-WPHY 80 only as per MSS-SP75
EN 10216–2: P195GH P235GH — P265GH 20MnNb6–16Mo3–8MoB5 4- 14MoV63 1 0CrMoS-5–13CrMo4–5 10CrMo9–10 15NiCuMoNb5–6–4 X11 CrMo5 — X11 CrMo9–1 X1 0CrMoVNb9–1 X1 0CrWMoVNb9–2 X20CrMoV11–1 and equivalent grades Equivalent grades of EN 10253–3 EN 10253–4 (former AFNOR-DIN-BS equivalent grades).
EN 10253–1 EN 10253–2 RCC-M: CL2 — CL3 — NC grades P265GH — P280GH P295GH — P355NH -TU42C AE250B1 (other grades can be supplied upon request).
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Classification of Seamless Pipes for Low and Medium Pressure Boilers
Seamless steel pipes are divided into hot-rolled (extruded) and cold-drawn (rolled) seamless steel pipes. Hot rolled seamless steel pipe is named after hot rolling (extrusion) at a very high temperature of more than 900 degrees Celsius. In contrast, the cold rolling process is performed below the recrystallization temperature. Under normal circumstances, the phenomenon that blank fracture and crack formation occur in the rolling process of steel pipe can be prevented through air cooling method. Therefore, the requirements for raw materials are relatively high and the price is higher; in addition to tolerance values, because the cracks generated in hot rolled products do not exist, cold drawn steel pipes can reach GB — 3087.
Cold rolled (disc-shaped) seamless steel pipe is divided into ordinary steel pipe, medium and low pressure boiler steel pipe, high-pressure boiler steel pipe, alloy steel pipe, stainless steel pipe, petroleum cracking pipe and other steel pipes, as well as carbon thin-walled steel pipe, alloy thin-walled steel pipe, stainless steel thin-walled steel pipe and special-shaped steel pipe. The outer diameter of hot-rolled seamless steel pipe is generally greater than 32mm and the wall thickness is 2.5–75mm. The diameter of cold rolled seamless steel pipe can reach 6mm and the wall thickness can reach 0.25mm. The outer diameter of thin-walled pipe can reach 5mm and the wall thickness is less than 0.25mm. Cold rolling has higher dimensional accuracy than hot rolling.
Ordinary seamless steel pipe: it is made of high-quality carbon steel such as 10, 20, 30, 35 and 45, such as low-alloy structural steel such as 16Mn and 5mnv or alloy steel such as 40Cr, 30CrMnSi, 45Mn2 and 40MnB, which is hot rolled or cold rolled. Seamless pipes made of low carbon steel, such as 10 and 20, are mainly used for fluid transmission pipelines. Seamless pipes made of medium carbon steel such as 45 and 40Cr are used to manufacture mechanical parts, such as stressed parts of automobiles and tractors. In general, seamless steel pipes must be used for strength and flattening tests. Hot rolled steel pipes shall be delivered in hot rolling or heat treatment state; Cold rolled steel is delivered in heat treated condition.
1. Medium and low pressure boiler tubes: used for manufacturing various medium and low pressure boilers, superheated steam tubes, boiling water tubes, water wall tubes, superheated steam tubes of locomotive boilers, large smoke tubes, small smoke tubes, arched brick tubes, etc. Hot rolled or cold rolled (dial-up) seamless steel tubes made of high-quality carbon structural steel. It is mainly made of 10 and 20 steel. In addition to ensuring chemical composition and mechanical properties, hydraulic tests such as crimping, flaring and flattening are also required. Hot rolled products shall be delivered in hot rolling state, and cold rolled products shall be delivered in heat treatment state.
2. High pressure boiler steel pipe: high quality carbon structural steel, alloy structural steel and stainless steel heat-resistant seamless steel pipe, which are mainly used to manufacture high-pressure and above steam boiler pipes. These boiler pipes are often under high temperature and high pressure. Under the action of high-temperature flue gas and steam, the project and pipeline will also undergo oxidation and corrosion. Therefore, steel pipes are required to have high durability, high oxidation resistance and good structural stability. The steel grades used are: high quality carbon structural steel grades are 20g, 20ng and 25mng; Alloy structural steel grades: 15mog, 20mog, 12crmog, 15CrMoG, 12CR2MOG, 12crmovg, 12cr3mov, etc.; 1Cr18Ni9 and 1cr18ni11nb high-pressure boiler tubes are commonly used for rust proof and heat-resistant steel. In order to ensure chemical composition and mechanical properties, in addition to hydrostatic test one by one, flaring and flattening test shall also be carried out. Steel pipes are delivered in heat-treated condition. In addition, there are certain requirements for the microstructure, grain size and decarburization layer of the finished steel pipe.
3. Seamless steel pipe for geological drilling and oil drilling: drilling with drilling rig to explore underground rock structure, groundwater, oil, natural gas and mineral resources. The exploitation of oil and gas is inseparable from drilling. Seamless steel pipe for geological drilling is the main drilling equipment, including core outer pipe, core inner pipe, casing and drill pipe. Because the drill pipe needs to go deep into the formation for several kilometers, the working conditions are extremely complex. The drill pipe bears the stress of tension, compression, bending, torsion and uneven impact load, as well as mud and rock wear. Therefore, the pipe is required to have sufficient strength, hardness, wear resistance and impact toughness. The steel used for the steel pipe is “DZ” (Geological Chinese Pinyin prefix) plus a number to represent the yield point of the steel. The commonly used steel grades are 45mnb and 50Mn of dz45; 40Mn2 and 40mn2si of dz50; 40mn2mo, 40mnvb of dz55; DZ60 is 40mnmob and dz65 is 27mnmovb. Steel pipes are delivered in heat-treated condition.
4. Petroleum cracking pipe: seamless pipe used for furnace pipe, heat exchanger pipe and pipeline of refinery. It is usually made of high-quality carbon steel (10,20), alloy (12CrMo, 15CrMo), heat-resistant steel (12cr2mo, 15cr5mo) and stainless steel (1Cr18Ni9, 1Cr18Ni9Ti). In addition to the certified chemical composition and various mechanical properties of steel pipes, it is also necessary to ensure water pressure, flattening, flaring and other tests, as well as surface quality and nondestructive testing. Steel pipes shall be delivered after heat treatment. Stainless steel pipe: all kinds of hot-rolled and cold-rolled stainless steel pipes are widely used in petroleum and chemical equipment pipes and stainless steel structural parts for various purposes. In addition to ensuring chemical composition and mechanical properties, they are also used as steel pipes that can withstand fluid pressure. Ensure that the hydrostatic test is qualified. Various special steel pipes shall be guaranteed according to the specified conditions.
Tip: ASTM A53 includes seamless and welded steel pipes with nominal wall thickness. The surface condition is usually black and hot-dip galvanized. ASTM A53 is mainly used for pressure and mechanical applications, and also for the transportation of steam, water and gas pipelines.
According to this specification, A53 grade B seamless pipe is our most competitive product. A53 pipe usually passes the double certification of A106 B seamless pipe.
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The Advantages Of Alloy Steel Pipe
The alloy steel pipe adopts high quality carbon steel, alloy structural steel and stainless steel as raw material by hot rolling or cold drawing to be manufactured. The main applications of alloy steel pipe are power plant, nuclear power plant, high pressure boiler, high temperature superheater and reheater coil etc of high temperature pipeline and equipments.
The material of alloy steel pipe is coarse: 16–50 mn, 27 simn, 40 cr, 12–42 crmo 16 mn 12 cr1mov T91 27 simn 30 crmo 15 g Cr9Mo 10 crmo910 15 mo3 15 35 crmov 45 crmov crmo, 15 crmog, 12 crmov, 45 crnimo 45 50 cr, cr, etc.
Alloy Steel Seamless tubes
ASMES SA335 P9 /P11 / P12 / P22 / P91 & T5 / T9 / T11 / T22 / T91
Low temperature alloy steel series，LTAS designated by ASTM A333/A335, is usually used for the pressure piping of low temperature service. Our LTAS series products are seamless pipe with material grade in A333 GR.3/6, GR.1/3/7 and GR.8 class specification, used for the pressure piping of low temperature service. The product can be widely applied in areas such as chemical fertilizer plant, natural gas transmission, coal & oil industry, pipelines of heat supply station and city network station etc.
Heat resistance
Some nickel alloys can withstand extreme conditions and high temperatures. For example, nickel-chromium alloys consisting of more than 15% chromium have been used at temperatures that can exceed 760 Celsius. This ability to withstand heat makes nickel alloy tube a go-to material in machines or structures that produce extreme temperatures.
Corrosion resistance
When metals encounter oxygen, they can undergo oxidation reactions. This in turn causes corrosion.
However, nickel has a slow oxidation rate, making nickel alloys more resistant to corrosion than most metals. This allows them to maintain their integrity longer than other metals, especially in marine environments where corrosion is particularly problematic.
Low expansion
Some nickel-iron alloys have an extremely low thermal expansion rate or a very consistent and predictable expansion pattern in certain temperature ranges. This makes them useful when you need a pipe that can maintain a uniform shape and size despite hot environments.
For example, iron-36% nickel alloy hardly expands at all with moderate temperature fluctuations. And if you add cobalt to nickel and iron, you get a high-strength alloy that has a constant modulus of elasticity and a low coefficient of expansion.
Form memory
Sometimes a metallic material is needed, which can return to its previous form in heat. This type of material is called a shape memory alloy, and there are very few available on the market. However, some nickel alloys have this property, with nickel-titanium alloys being one of the most prominent shape memory alloys.
Magnetic permeability
Nickel-iron alloys also have unique and interesting magnetic permeability properties. As a result, they have become an integral part of switchgear designs as well as DC motors and generators.
These advantages have made nickel alloys a popular material in a number of applications, including:
• The petrochemical industry
• Aircraft turbines
• Medical technology
• Steam turbine power plants
• Nuclear power plants
The advantages of alloy steel pipe: 100% recycled, it is suitable for the national strategy of environmental protection, energy saving and resource saving. Therefore, national policy promotes the expansion of high pressure alloy steel pipe applications.
At present, the proportion of total alloy steel pipe is half of the developed countries. The applications of alloy steel pipe provide a wide space for industrial development. According to the research of China Association of special steel alloy pipe experts group, the material demand of our country with high pressure alloy steel pipes grows on average up to 10–12%.
ASTM A210 Gr A1 Seamless Medium Carbon-Molybdenum Alloy Steel Boiler Cold Drawn
stainless steel & duplex steel & alloy steel tubes and pipes i.
Standard Specification
ASTM A210 / A210M, ASME SA210, A210 A1, SA210 A1
Grade
Grade A-1
JIS G 3467
STFA 10
Size Range
1⁄2 in. to 16 in. [12.7 to 406.4mm]
Wall Thickness
1.5mm-50mm
Shape
Round
Manufacturing method
Hot and cold finished
Length
max 25 m, Single / Double random length
Terms
Mill test certificates will be issued according to EN10204.3 3.1 or 3.2
A210 GR.A1 tubes Shall be Seamless, and the testing shall be as per A 450 / A450M.
Common uses
Boiler Tubes, Seamless Steel Tubes, Steel Tubes, and Superheater Tubes.
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