INTRODUCTION

A Flange is an external or internal rib, or rim, for strength, as the

flange of an iron beam; or for a guide, as the flange of a car wheel; or for
attachment to another object, as the flange on the end of a pipe, steam
cylinder etc. Alternatively, a flange can be a plate or ring to form a rim at
the end of a pipe when fastened to the pipe.

In relation with piping connections, Flange is a kind of coupling,

used to join two lines together, using bolts and a gasket in between them.
Thus, it is clear that it is not the flange alone, which makes the joint. It is
the assembly of flanges, gasket and bolts, which forms the flanged joint,
which are assembled by yet another influence, the fitter. Special controls
are required in the selection and application of all these elements to attain
a joint, which has acceptable leak tightness.

USES AND NECESSITIES

Flanges’ usage is more and more wider, now a days. It is one of the best
coupling methods to join two pipes. Almost all the fluids are transported
conveniently using pipelines. Even economically, pipeline transfers are
becoming more popular. With this emerging trend, the usages of flanges
are also becoming more and more important. A flange can work
successfully, only if the flanged joint components work efficiently.
Researches are going on to make the flanged joint more efficient than the
current stage. With the current efficiency level, the flanged joint should
be used with more concern, so that virtually no leak occurs.

The usage of flanged joint can be elaborated in many sentences.

Precisely, a flanged joint is preferred for ease of maintenance. Flanges are
used, when the joint needs dismantling. Theses are used mainly at
equipments, valves and specialties. In certain pipelines, where
maintenance is a regular feature, breakout flanges are provided at definite
intervals on pipelines.

In petroleum refinery, where the fluids carried are mostly

flammable nature, the use of flange is not advisable, to prevent any
leakage of fluid to the atmosphere, combining with air to form a
flammable mixture. But, its use is unavoidable, due to corrosive nature of
the fluid and environment, temperature of flow, pressure inside the line,
loadings on the pipeline etc., which recommend periodic replacements of
pipelines, in order to prevent pipe ruptures due to reduction in thickness
beyond the safe value. Also, a line can’t function without a valve. For
lines of smaller diameters (less than 2 inch), welded valves can work
efficiently. But, for higher diameter pipes, a suitable coupling needs to be
given to hold the valve in line with the pipeline. Such a suitability and
convenience is got from the usage of flange coupling. Whether it be a
valve change or the line change or any other accessories of a line need to
be changed, the line need to be isolated from the process unit, storage
tanks and routing distributions. Such a facility can be availed only when
the line is having a flanged end, which can be blinded to make the line
positively isolated from the probable sources of fluid entry into the line at
times of any work been carried out on the line. Thus, it is clearly proved
that, though unacceptable, the usage of flange is unavoidable anywhere,
particularly in a refining sector.

TYPES OF FLANGES

Flanges can be classified according to various criteria like pipe

attachment, pressure-temperature rating, facing, face finish, material of
construction and standards followed. A brief description of the
classification is given below.

Based on Pipe Attachment:

Flanges can be classified based on the attachment to the piping as given

below:
Welding Neck
Slip-on
Socket weld
Lap Joint
Screwed or Threaded
Orifice
Reducing
Integral
Blind

1. Welding Neck Flanges:

These are the most commonly used high cost, high strength
flanges. These have a distinctive long tapered hub (for extra strength and
reinforcement to the flange) and a smooth transition of thickness local to
weld end preparation (important when operating conditions impose
repeated bending and variable forces to the joint). Their design features
suggest suitability for class 1 pipe work and other conditions where 100%
radiography is necessary. These are costlier than slip on flanges during
purchase, but welding cost is less, resulting in negligence difference. The
butt-welding done provides equal strength as that of the butt-welding
between pipes, which is literally equal to the pipe strength itself. Thus,
this type of flange is preferably used in places where strength
consideration takes top priority.

2. Slip-on Flanges:

These are attached by welding inside as well as outside. Normally,

these flanges are of forged construction and are provided with hub.
Sometimes, these flanges are fabricated from plates and are not provided
with the hub. These are used for all sizes of piping and wide range of
applications. The plate used (when fabricated from plates) may distort
during welding, which insists machining to recover flatness. These are
readily manufactured from standard plates.
These flanges are predominantly used when, initial cost is low;
tube need not be cut to accurate lengths; ease of alignment is considered.
But, these flanges’ usage is limited due to the following reasons:
Inferior strength of the joint
More difficulty for radiographic inspection of fillet weld.
Large temperature cycles anticipated in the system (esp. when flanged
joint is not lagged), which may lead to failure of one of the welds on the
flange
Irregularity in bore of pipe, which results in inside weld being more liable
to suffer from corrosion than a weld-neck arrangement.

X – Diameter at base of hub.

B – Slip on bore
C – Thickness *
T – Length through hub *
O – Outside Diameter
R – O.D. of raised face

*Raised face is not included in thickness C and length through hub T.

3. Socket Welded Flanges:

These are welded on one side and are not recommended for severe
services. These are used for small-bore lines only. The thickness of
connecting pipe should be specified for this type of flanges to ensure
proper bore dimension. Initially, these are developed for small bore high
pressure pipe works. There usage is frequent in case of chemical process
piping and other places where leakage must not present. These are
guaranteed containment for radioactive, toxic and flammable fluids.
These can provide smooth pocket less condition, if internal weld is
ground smooth. Though these are costlier than Slip-on flanges of same
static strength, the fatigue properties of these flanges are greater,
permitting it to convey dangerous fluids more conveniently, when
variable forces act.

X - Diameter at Base of Hub

D - Depth of Socket
B - Slip on Bore
B2 - Weld Neck Bore
C - Thickness *
T - Length thru Hub *
O - Outside Diameter
R - O.D. of Raised Face
* Raised face is not included in thickness C and length through hub T.

4. Lap Joint Flanges:

These flanges are used with stub ends, when piping is of a costly
material, avoiding the usage of expensive solid flange of the same
material. This stub ends will be butt-welded to the piping and the flanges
are kept loose over the same (hence called as Loose Backing Flanges)
The inside radius of these flanges is chamfered to clear the stub end
radius. Unlike other flanges, the bolt holes can be aligned to any desired
position after fixing the pipe, a useful consideration on pipe work
requiring frequent dismantling for inspection and cleaning. At locations
where severe bending stresses are present, these flanges can’t be used.
l

X - Diameter at Base of Hub

B - Lap Joint Bore

C - Thickness *
T - Length thru Hub *
O - Outside Diameter
r - Lap Radius

• Raised face is not included in thickness C and length through hub

T.