TRAINING MANUAL- PIPING DOC No, : 29040-P-UFR-0010 DEES ri s Unde tndia Limited Page 1 CONTENTS Poge 00 Cover Sheet 1 1.0 General 2 20 Classification 2-6 30 Standards o-7 4.0 Plate Fabricated Flanges a 7 5.0 Flanges as per OIN/ BS 7 6.0 Sketch showing various type of Flanges 8 7.0 Rating Table for Group 1.1 Material as per ASME B 16.5 on Applicable Revision: Prepares ‘Checked ‘Approved: Date Date: Date: First Edition: RO Prepared: ONL Checked: AKB Rpproved: RUD Date: = Date: File Name: 6-70 = PUNE: KUMUS 207 VKO: KUMUS 209 Directory: PUNE: Refer | Pi\ Training Manual VKO: Refer \ Training Manual6 TRAINING MANUAL- PIPING DOC No. : 290404 aE Fines fev. Ro Unde Indis Limited Page: 2 1.0 GENERAL: 20 24 [ranges are used in piping for making joints which can be opened at a later date. They are usually used for connecting piping to equipment, valves & control valves ete S.anged joint is composed of three separate and independent, although interretated iuoeee tae ne anges: the gasket, and the bolting, which are assembled by yol avethar influence, the assembler. Proper controls must bo exorcised in the eelectin ¢28 application {or al these elements to atain a joint, which has acceptable leak tightness CLASSIFICATION: Armaan apts May Best be classiied by dividing them into two genefal“pars (Refer Annexure-1) + Methods of attachment of Flange to Pipe. * Type of Facing on contact surface of fiange proper. Methods Of Attachment Of Flange To Pipe 24.1 Screwed flanges: i ‘This fange can be rapidly connected to threaded pipe without welding ii Screwed flange joints have the following inherent weaknesses end disadvantages which restrict their use to moderate operating conditions Necessity of careful alignment of bolt holes. Prange faces may become distorted when attaching flenges to pipe Pipe frequently extends through flange beyond the face [sts indicate that in tension a threaded joint has less than 60% of the strength of the pipe. & Meloni removed in threading results in a thinner wall section ready affected by erosion and corrosion sn Jekeeded connection is susceptible to leakage under any type of eye opetation. This EpaRe |S Pot recommended for use on services which iolve bending or warty cycles. v _ Usually sewed flanges are used for Galvanized piping * Forpetimes, sleet screwed anges are seal welded to guard against leakage through the threads, 21.2 Slip on Flanges: i Sto on type of flange is widely used because of,ts low intial east fi ph on lange is attached to pipe by filet weld. The welding is either atthe back or at ‘ack and face, Usually this flange is double welded and vented withthe wee caeTRAINING MANUAL- PIPING DOC No. : 29040-P-UFR-0010 FLANGES. iagugeseintaa Pago: 3 pro driled holes through hub. During welding at the face, caro should be taken so as to avoid distottion and refacing. The strength of this flange as calculated from internal pressure consideration is approximately two-thirds thal of a corresponding welding neck type of lange. “The use of this type of flange is usually imited to moderate services where pressure fluctuations, temperature fluctuations, vibrations and shocks are not expected to be severe. The fatigue lie of this flange is approximately one third that of a welding neck flange. ‘Slip on flange is not recommended for corrosive andlor critical services, Use of slip on flange is usually fimited to class 300 (refer para on pressure temp. rating) and design temperature not exceeding 500" F. It is essential to ensure proper alignment of bolt holes before welding this type of flange. Welding - neck Flanges : ‘Welding-neck flanges have a long, tapered hub between flange ring & weld joint. This hub provides a more gradual transition from the flange ring thickness to the pipe wall thickness, thereby decreasing the discontinuity stresses and consequently increasing the strength of the flange. Also welding area is sufficiently away from the face to avoid undue distortion, ‘This type of flange is attached to pipe by having butt weld which can be radiogcaphed if required i ‘This type of flange is preferred for extreme service conditions such as repeated bending from line expansion or other forces, wide fluctuations in pressure or temperature, high pressure, high temperature and sub zero temperature. ‘This type of flange is, recommended for the handling of costly, inflammable or explosive fluids where failure or leakage of a flange joint might bring disastrous consequences. . While ordering this type of flange it is necessary to indicate schedule number thickness or 1.0 and 0.0. of connected pipe so that bore of the flange as well as butt welding ends can be machined to suil pipe. The welding neck flange also requires accurate alignment of bolt holes before welding Lap - Joint Flanges Lap joint anges are used with a tap “joint stub, ‘The combined cost of the two parts is generally greater than the cost of @ welding neck flange af the same size, rating & material. However, we have an option of using an ordinary steel flange behind the lap on alloy and stainless steel pipe without sacniticing internal corrosion protection, thereby, the combined cost of two parts may be less than the cost of a welding neck flange which necessarily has to be of the same material as that of pipe.TRAINING MANUAL- PIPING DOC No. : 29040-P1-UFR-0010 Uhde India Limited Page: 4 22 216 Flange 224 ‘his type of flange is used for all plastic piping. Sometimes plastic piping handing corrosive fiuids have galvanized backing flanges in order to have better corrosion resistance against spillages etc. ‘These flanges have about the same ability to withstand pressure without leaking as the slip-on flange, which is less than that of the welding neck flange. ‘These flanges have the disadvantage of having only about 10% of the fatigue life of welding neck flanges. For this reason, these flanges should not be used for connections where severe bending slresses exist. This type of joint avoids the necessity of accurate alignment of boll holes since the flange is free to revolve on pipe. This permits it to be readily aligned with bolt holes of mating flange whether they are on “straddle centre line™ or in some odd or special position, These type of flanges are also useful in cases where frequent dismantiing for Cleaning or inspection is required or when it is necessary to rotate the pipe by swiveling the flange. Socket-welded flanges: These flanges are usually used upto 2" size for lines where socket welded joints are permitted, {n this ype of flange, hub part has @ socket to suit pipe and flange is attached to pipe by having a filet weld at the back. There is no provision for face welding in this {ype of flange. ‘Their use and limitations are same as those applicable to slip-on flanges Blind Flanges: These are used to block-off the ends of piping and valves. These flanges are also Used extensively to blank off pressure vessel openings such as handholds and inspection ports, Blind flanges absorb high bending stresses but do not have to absor stresses ‘caused by thermal expansion or by weight of the piping system, Facings: Raised Face: Stee! flanges with a raised face are extensively Used because of the simplicity of the design, Moderate unit gasket pressure is maintained with conventional machining and assembly methods and facing is suitable for average service conditions. However Tor severe service involving high pressure, high temperature, thermal shock oF eycle operation, this type of flange facing may nat be satisfactory. Flanges with rating of ASME 160 and 200Ibs have 0.06 inch high raised face which is Included in the minimum flange thickness. However. flanges having higher ratings have 0.25 inch high raised face whic’ is additional to the minimum flange thickness‘TRAINING MANUAL- PIPING DOC No. : 29040:P-UFR-0010 ror Ree 380 FLANGES Uhde India Limited Page: 5 22.2 2.24 “The raised face is machined with spiral or concentric grooves. Depth and spacing of these groves vary depending upon finish required to suit the gasket used for making joint. The edges of these grooves serve to deform and hold the gasket Re per ASME B16., for raised face, either a serrated concentnc or serrated spiral finish having from 24 groovesiinch to 40 grooves/inch shail be used. The cutting toot Employed shall have an approx.0.06 inch or larger radius. The resultant surface finish Shall have 2 125 micron to 500 micron roughness. The finish of contact face shall be judged by visual comparison with Roughness Average “Ra! standards and not by smeLumenis having slyius tracers and electronic amplification (Refer ASME 846.1) ‘The facing should not have any radial tool mark since the same would provide shortest path for fuid to escape. “The facing should be property protected during transportation and handling at site, Flat ring composition gaskets are normally used having @ width equal to the width of the raised face where as flat metal gaskets may be used having width equal to that used with large tongue-and-groove type face. Fiat face: Flanges with flat faces using fullface gaskets are usually used for’ making Connections to ASME 25lb and 125 tbs. Cast iron flanges and flanged components. Five decreases the leverage in bolting, thereby reducing the tendency for the flange to crack. Male & Female Facings: ‘They have the disadvantage that the two mating flanges are not identical. For this reason, these flanges are not as widely ustd as raised face flanges. Male & female facings have the advantage of confining the gaskets thereby minimizing the posstilly of blow-out of the gaskets. The outer diameter of the female face serves to locate and retain the gasket. Male & female facings offer no protection against forcing the gasket into the line or vessel “Two type of facings are available under this category a, Small Male & Female: ‘This type face is usually used in small fines for hydraufic service to effect a high Unit gasket pressure in 2 confined area. However, the facing is Unsuitable to withstand bending stress, nor recommended for lines subjected to high temperatures, >, Large Male & Female: ‘This type face affords the same loading and resulting unit gasket pressure a the raised face. Flat ring composition gaskets are normally used. The width of the face is $0 large that full face metal gaskets can not be used because of the excessive lightening load required to seat the gasket. Tongue-and-Groove Facings: ‘They have the disadvantage that the two rating flanges are not identicalTRAINING MANUAL- PIPING DOC No. : 29040-PI-UFR-0010 UHOE Lee Rov. 20 Ubde India Limited Page 36 228 penve-and-Groov facings have the advantage of confining the gasket. the Posty oF menting Maal on either side of tho gasket gwes proton agama Geshe ior mc Of the gasket as well as protection agoitl deleoming ret Formate ye tne interior ofthe tne or vessel This isan advantage over thes has ook female type of face. atta Services, where tongue-and.groove facings sre Used, all equipment face angenges. valve flanges, and instrument flanges ete. are precclea wal groove face and mating piping flanges with tongue face. Two type of facings are available under this category: Small Tongue-and-Groove: Fe, 2Pe, OF Facing is generally used for smal lines in hycraute service to Gffecta high unit gasket pressure in a confined area. It hee te disadvantage The eegetve Gasket pressure under temperature change and sine sone The facing is unsuitable fr lines subjected to high temgerateree Large Tongue-and-Groove: iis {pe face provides the minimum area that iis advisable to use with frat Sats, Therefore this type of facing provides the minimum Boling ta ot making tatehay at S2sket. Also the gasket area is neare’ the bok cron imeking it sighlly move resistant to flange stressos and Bencirg mone te crea. anstctonal tinitations, minimum flange rating available with tongue-and r0ove facing is ASME 300 Ibs. Ring Joint Faces: £79 jin type of facing offers the greatest protection under severe sence conditions, or with the use of hazardous fluids ius Pe face employing @ metal ring of ether oval or octagonal eross section as a ‘gasket, permits very high unit gasket pressure, ZS type of facing requires close tolerances and high standards of Machining making it he most expensive gasket face. internal pressure acts on the ring to increase the sealing force on the joint Mating flanges are identical 3.0 STANDARD: Cae, 22 2 Vaity of Standards used in the design and selection of Flanges. The following Codes and Standards relate to the pipe flangesTRAINING MANUAL- PIPING DOC No. ETT eee FLANGES Rev. :RO Unde tndia Limited Page :7 ASME D 16.4 Cast ron Flanges ang Flanged Fitings ASME B 165 Pipe Flanges and Flanged Fttngs ASME B 16.42 ‘Ductile Iron Pipe Flanges and Flanged Fittings — 150 and 300 Classes ASME 8 16.47 Large diameter steel Flanges 34 40 50 The most commonly used standard for flanges and flanged fitings is ASME B16.5. It covers pressure temperature ratings, materials, dimensions, tolerances etc. for pipe flanges and Manged fittings in sizes 1/2" through 24” and in rating classes 150, 300, 400, 600, 900, 1500 and 2500. Flanges and flanged fittings may be cast, forged or ‘plate materials (For blind flanges and certain reducing flanges) as listed in Tabla — 1A, Pressure-Temperature Ratings: ‘ Pressure-Temperature ratings are determined as per Annexure O of ASME B 16.5 For easy reference, ASME B16.5 Table 1A and Tabie 2 - 1.1 (rating for Group 1.1 material) are attached in section 7.0, i, For any temperature below -20°F, the rating shall be no greater than the rating shown for 20°F. Socket welding and screwed flanges are not recommended for service above 500 °F or below -50 °F if severe thermal gradients or thermal cycling are involved. iv. Attemperature in the creep range, gradual relaxation of flanges, bolts & gaskets may progressively reduce bolt loads. It may be necessary to arrange for periodic tightening of bolts to prevent leakage. ¥, When used above 400 °F, class 150 flanged joints may develop leakage unless care is taken to avoid imposing severe exterhal loads and/or severe thermal gradients. For ‘other classes, similar consideration should be given above 750° F. PLATE FABRICATED FLANGES: ‘Some times on cost consideration for low pressure, low temperature, non-eritical services, we may use plate fabricated flange (slip on flange without hub) They are machined from plate of appropriate grade. These flanges are not covered under ASME 816.5 but one can specify standard 6.S.1560 which cover carbon siee! plate flanges having flange dimensions identical fo ASME 150 Ibs. The plate used is 8.S 1501-224 Gr.32A or its equivalent ASTM A516 grade. 70 of IS 2082. FLANGES AS PER DINIBS: Though the flanges as per ASME Standard are most common, sometimes, we may require 2 ‘mating flange to match an equipment flange which is either as per DIN or as per BS standard Flanges conforming to DIN standard are available in various pressure ratings such as PNG, PN10, PN16, PN25, PN4O, PN100. Flanges conforming to BS standard are avaitable in various pressure ratings. Refer BS 10; 1962 and BS 1560; 1989TRAINING MANUAL- PIPING DOC No. : 29040-P1-UFR-0010 FLANGES eee Unde India Limited Page: 8 6.0: SKETCH SHOWING VARIOUS TYPE OF FLANGES: I i A A | L | 1 r T THREADED FLANGE SLIP_ON WELDING FLANGE, SOCKET WELDING FLANGE LAPPED FLANGE BLIND FLANGE