Flanges

A flange is a kind of mechanical component which is applied to join and seal two pipes or other equipment. Usually they are made of metal and have the form of a disc with openings for bolts. The flanges are screwed together with a gasket in between to ensure that there is no leakage between the two flanges. They are available in different types and sizes, and are used to bear different pressures and temperatures, and are very important in piping system for integrity of the system and for ease in carrying out maintenance.

Different types of Flanges

Flanges come in several types based on their manufacturing methods and applications:

Weld Neck Flanges: These flanges are used for high pressure systems, they have a long shank which can be butt welded to the pipe, thus making a strong joint.
Slip-On Flanges: These flanges are fitted over the pipe and are welded on one side and at the other side also. They are easier to align than the other types of alignments, but they are mainly used for the low priority applications.
Blind Flanges: It is applied in order to shut the end of a piping system or vessel. They do not possess a central opening and are either welded or bolted for closing the line.
Threaded Flanges: It has internal threads which screw on the pipe. They are employed where welding is not possible though they are more suitable for low pressure services.
Socket Weld Flanges: The pipe is fitted in the flange and then the weld is made around the junction. These are used for high pressure and provide good sealing.
Lap Joint Flanges: These are made up of a thin flange that is placed over a stub end, thus making it easy to adjust the alignment and remove them. They are usually applied where the regular disassembly of the assembly is necessary.
Forged Flanges: They are of single piece metal formed by forging and hence are very strong and reliable.
Seamless Flanges: These flanges are made from a single piece of metal without the use of any welds, thus they offer high reliability and strength.
Welded Flanges: They are produced by welding a flange ring to a pipe or fitting depending on the welding process and material used.

Different kinds of flanges are used depending on the pressure, temperature, and accessibility of the flange for maintenance.

Different Flanges Materials

Flanges are available in various metal materials, each suited for different applications:

Carbon Steel Flanges: They are normally used for general purposes and provide reasonable strength at reasonable cost.
Stainless Steel Flanges: These are well known for their ability to withstand corrosive and high temperature atmospheres making them suitable for such conditions.
Alloy Steel Flanges: Produced from metals that have been combined to improve certain characteristics such as strength, durability or high heat resistance.
Duplex Steel Flanges: Used in conditions that are difficult, the stainless steel and high strength properties are incorporated in them.
Copper Flanges: Applied in areas where electric current is required and where the material is exposed to specific corrosive conditions.
Brass Flanges: Having good machinability and corrosion resistance, these pipes are suitable for use in low pressure systems.
Monel Flanges: These flanges are manufactured from nickel copper alloy and thus possess high corrosion resistance and high temperature properties and therefore used in marine and chemical industries.
Hastelloy Flanges: These flanges are made from nickel-molybdenum-chromium and these are used in severe corrosive and oxidation services.
Titanium Flanges: They are light weight, strong and do not corrode easily, thus their application in the aerospace, chemical processing and marine industries.
Inconel Flanges: These flanges are manufactured from nickel-chromium alloys and can therefore withstand high temperatures and other difficult conditions, ideal for use in conditions where high stress is expected.
Plastic Flanges: These flanges are manufactured from PVC, CPVC, PTFE and other similar materials where chemical resistance and light weight are critical.
Bronze Flanges: Usually applied in marine industries because of their ability to resist corrosion and last longer especially when in contact with seawater.

Each material type is chosen with respect to the characteristics of the application such as temperature, pressure, and corrosive environment.

Features of Flanges

Flanges come with several key features that make them essential in piping systems:

Sealing Capability: Flanges are used to connect pipes or equipment with the other and they ensure that there is no leakage by using gaskets.
Ease of Assembly: Flanges can be easily connected and disconnected from the pipes and therefore installation and maintenance is not a complicated process.
Pressure Handling: Depending on their type and material, flanges are manufactured to work under different pressure range as required in high pressure systems.
Temperature Tolerance: Flanges are made in a manner that they are suited for certain temperature ranges and they include both high and low temperature flanges.
Versatility: There are different types of flanges available in the market in terms of shape, size and material which makes them suitable for use in many industries.
Durability: Flanges are manufactured from strong and durable materials making them resistant to wear, corrosion and mechanical forces, which increases the life of the piping systems.
Customizability: It is possible to have flanges made to certain size and specification depending on the need of the application in question.

Such characteristics make flanges suitable for use in a wide range of applications.

Applications of Flanges

Flanges are used in a wide range of applications due to their versatility and reliability:

Piping Systems: They are widely used to join pipes together to form a strong and tight coupling in different industrial and commercial applications.
Pressure Vessels: They are used to join pressure vessels parts like heads and nozzles through which pressure vessels can be accessed for service and checking.
Chemical Processing: Flanges are applied in chemical processing industries for joining equipment and pipelines where material resistant to corrosion is required.
Oil and Gas: In the oil and gas industry, flanges play a great role in joining pipelines and equipment and they are designed to withstand high pressures and temperatures.
Water Treatment: The flanges are used in water treatment plants to join the pipes and tanks in order to regulate the flow of water and other activities.
HVAC Systems: HVAC flanges are employed to connect ducts and other related parts to ensure that they are tightly sealed.
Marine Applications: Marine applications use flanges due to their durability and high tolerance to the surrounding environment.

These applications show how flanges are used in different systems and how they help in the proper and safe functioning of the systems.