TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE

TCE.M6-ME-590-418
GUIDE FOR THE SELECTION AND
APPLICATION OF FLANGES
SHEET i OF iii
REV. NO. R0 R1 R2 R3
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.
ISSUE
PPD. BY PGK Sd/- KKV Sd/- KKV Sd/- NP
CHD. BY RVR Sd/- RVR Sd/- RVR Sd/- SGG
APD. BY GS Sd/- RL Sd/- RL Sd/- RL
DATE 14.02.1986 18.03.1998 02.01.2001 02.02.2004
R3
TCE FORM NO. 020R2
GUIDE FOR THE SELECTION AND
APPLICATION OF FLANGES
TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M6-ME-590-418
GUIDE FOR THE SELECTION AND
APPLICATION OF FLANGES
SHEET ii OF iii
REV. NO. R0 R1 R2 R3
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.
ISSUE
PPD. BY PGK Sd/- KKV Sd/- KKV Sd/- NP
CHD. BY RVR Sd/- RVR Sd/- RVR Sd/- SGG
APD. BY GS Sd/- RL Sd/- RL Sd/- RL
DATE 14.02.1986 18.03.1998 02.01.2001 02.02.2004
R3
TCE FORM NO. 020R2
FILE NAMES: M6ME418R3.DOC AND
M6ME418R3.DWG
TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M6-ME-590-418
GUIDE FOR THE SELECTION AND
APPLICATION OF FLANGES
SHEET ii OF iii
TCE FORM NO. 120 R1
ISSUE
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CONTENTS
SL. NO. TITLE SH. NO.
1.0 SCOPE 1
2.0 GENERAL 1
3.0 STANDARDS 1
4.0 MATERIALS 2
5.0 TYPES OF FLANGES 3
6.0 TYPES OF FACINGS 3
7.0 SELECTION OF FLANGES 4
8.0 SELECTION OF FACINGS 5
9.0 FLANGE GASKET CONTACT FACE FINISH 5
10.0 GASKETS 6
11.0 BOLTING 6
FIGURES
1. TYPES OF FLANGES 7
2. TYPES OF FACINGS 8 & 9
TCE CONSULTING ENGINEERS LIMITED SECTION: REV. STATUS
TCE.M6-ME-590-418
GUIDE FOR THE SELECTION AND
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TCE FORM NO. 120 R1
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REVISION STATUS
REV. NO. DATE DESCRIPTION
R0 14.02.1986 - -
R1 18.03.1998 Document number changed and generally revised.
R2 02.01.2001 Minor editorial revisions made.
R3 02.02.2004 Reformatted.
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1.0 SCOPE
This design guide describes various types of commonly used rated pipe flanges, their
standards, materials, the code restrictions and gives recommendations for selection and
application. This guide does not cover flanges used for ducting and similar applications.
Flanges not made or not available as per standards shall be designed as per the
applicable code, for example, ASME Section VIII, Division 1.
2.0 GENERAL
2.1 A flanged joint is composed of three (3) separate and independent, although
interrelated components: the flanges, the gasket and the bolting, which are assembled
by yet another influence, the assembler. Proper controls must be exercised in the
selection and application for all these elements to attain an acceptable leak-tight joint.
In some cases, controlled tightening, using torque wrenches may be necessary to
achieve a proper joint.
2.2 Flanged joints are generally used at the following locations:
(a) At flanged valves, flanged instruments etc.,
(b) At equipment connections,
(c) Where welding is not recommended - lined piping (plastic-lined, rubber-lined
etc.), galvanised piping etc.,
(d) Where frequent dismantling is required for maintenance, cleaning, flushing,
sterilising etc. for example, in sanitary piping.
3.0 STANDARDS
3.1 Flanges are available as per various standards such as ASME, BS, IS, JIS, DIN,
AWWA etc. Flanges as per JIS and DIN standards are not covered in this guide, as
their usage is not common.
3.2 The following standards are commonly used in jobs engineered by TCE:
(a) ASME B16.5 for sizes < 600 mm (24 in.) in classes 150, 300, 400, 600,
900, 1500 and for sizes < 300 mm (12 in) in class 2500
(b) ASME B16.47 for sizes > 650 mm (26 in.) in classes 75, 150, 300, 400,
600 and 900
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(c) AWWA C 207 for water works service - sizes 100 mm (4 in.) and larger in
class B (86 psig), class D (175/150 psig depending on size) and class E (275
psig). Pressure ratings are for conditions and temperatures customary in
water works service.
(d) ASME B16.1 for cast iron pipe flanges and fittings in class 125.
(e) BS 4504, Section 3.1 covers PN designated steel flanges in the ranges of
nominal pressure PN 2.5 to PN 40.
(f) IS 6392 - for general applications and also as an alternative to AWWA C
207. This standard covers flanges for use in industry for oil, water, steam, air,
gas and chemical services but are generally confined to industrial jobs. The
standard covers rating classes 0.1 to 16.0 (N/mm
2
).
3.3 It shall be noted that the pressure ratings given in the standards are non-shock
pressures. If surges are expected, suitable allowance shall be made in the design
pressures.
3.4 Where the collaborator or the client has specific requirements or where the equipment
connections demand a specific type of flange to be used, the same shall be followed.
4.0 MATERIALS
The basic materials for flanges are similar to the materials used for piping except as
explained in the following paras.
4.1 For stainless steel or other high alloy piping, lap joint flanges of carbon steel are used
with stainless steel or high alloy stub ends (within the temperature limitations of carbon
steels).
4.2 Flanges integral with valve castings, cast fittings and pumps are normally of cast
material.
4.3 For plastics, flanges may be of plastics or plastic pipe ends with steel back-up flanges
may be used.
4.4 Flanges are normally made of forgings, castings, or of plate material, depending on the
standard and the code of application.
4.5 Flanges rated as per ASME B16.5 and B16.47 shall be of forgings or castings except
that blind flanges and certain reducing flanges may be out of plate.
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4.6 AWWA C 207, BS 4504 and IS 6392 allow use of plates under certain guidelines.
Refer to the standards for details.
5.0 TYPES OF FLANGES
5.1 The following types of flanges are based on the type of connection to pipe: (See Figure
1)
(a) Welding neck,
(b) Slip-on,
(c) Socket welding,
(d) Threaded,
(e) Lap joint,
(f) Reducing and
(g) Blind
5.2 Blind flanges are used with ring flanges to blank the end of a pipe, a flanged valve, a
spare tank nozzle etc.
6.0 TYPES OF FACINGS
The following types of facings are possible: (See Figure 2)
(a) Raised face,
(b) Flat face,
(c) Tongue and groove (small and large),
(d) Male and Female (small and large), and
(e) Ring joint.
6.2 The type of facing selected depends on various factors as described in paragraph 8.0.
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6.3 Tongue and groove and male and female flanges are generally applicable for sizes <
600 mm (24 in.)
6.4 Large male and female and large tongue and groove flanges as per ASME B16.5 are
not applicable to 150 class due to dimensional constraints.
7.0 SELECTION OF FLANGES
7.1 The selection of a particular type of flange depends on various factors such as
pressure, temperature, nature of the fluid, cyclic conditions and code requirements.
7.2 The common types used are as follows:
(a) Slip-on flanges : Classes 150 and 300
(b) Welding neck : Classes higher than 300
(c) Socket welding : Classes 150 and 300 (for sizes < 50 mm)
(d) Lap joint : Stainless steel classes 150 and 300 in sizes 80 mm
and larger (use slip-on for sizes < 50mm)
(e) Threaded : for galvanised piping
(f) Reducing : for size reductions and jacketed piping
7.3 Welding neck flanges are recommended for the following applications:
(a) Where temperature exceeds 260
o
C,
(b) For toxic, lethal and hazardous fluids (keep flanged joints to a minimum),
(c) For IBR services in sizes 12 in. and larger for all pressures, and
(d) For services such as slurries, where crevices are to be avoided.
7.4 Socket welding flanges are to be avoided where severe erosion or corrosion is
expected. These are also not recommended for service above 260
o
C if severe thermal
gradients or thermal cycling are involved. These flanges are also not recommended for
slurry service for which welding neck flanges are preferred.
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7.5 For temperatures above 200
o
C, 150 class flange joints may develop leakage unless
care is taken to avoid imposing excessive external loads on the joints. This applies to
other classes for temperatures above 400
o
C.
7.6 It shall be noted that flanges without hubs are weaker than flanges with hubs.
7.7 ASME B16.47 covers only welding neck type of ring flanges. Two (2) series are
covered, Series A and Series B. Series A corresponds to flanges as per MSS-SP 44
and Series B flanges as per API 605(API 605 has been withdrawn). These two (2)
series are not interchangeable.
7.8 Reducing flanges in the place of reducers shall be used with the approval of the
process engineer.
8.0 SELECTION OF FACINGS
Recommendations for various types of facings are explained in the following paras:
8.1 For steel flanges, for normal fluid applications, a raised face with serrated finish is
preferred.
8.2 While bolting a steel flange to a flat-faced cast iron valve or pump flange, the steel
flange shall have a flat face with smooth finish.
8.3 For toxic and flammable fluids and for vacuum applications, tongue and groove type
flanges with confined gaskets are recommended. Examples of such applications are
chlorine, thermic fluids such as Dowtherm etc. For mild vacuum applications (say up to
100 Torr, raised face flanges may be used).
8.4 For high pressure flammable gases (600 class and higher), ring joint type flanges are
recommended.
8.5 AWWA C 207 covers only flat faced flanges and are intended, as explained earlier,
for water service.
9.0 FLANGE GASKET CONTACT FACE FINISH
9.1 The following finishes are generally recommended:
9.1.1 Raised face - serrated concentric/spiral with details as follows:
(a) ASME B16.5
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Resultant average surface finish between 3.2 and 6.3 microns (125 and 250
in). Cutting tool shall have an approximate radius of 1.5 mm or larger and
the number of grooves shall be between 45 to 55 per inch.
(b) ASME B16.47
Resultant surface finish between 3.2 and 12.7 microns (125 and 500 in).
Cutting tool radius ~ 1.5 mm
Number of grooves per inch = 24 to 40
9.1.2 The above surface finishes can be used for flanges as per other standards.
9.2 Where spiral-wound gaskets are used, the following finishes are recommended:
(a) General purpose application : 3.2 to 5 microns (125 to 200 in)
(b) Hazardous : 3.2 microns
(c) Vacuum : 2.0 microns (80 in)
9.3 For other types of facings, refer to applicable standards for the finish required.
9.4 'Smooth' finish refers to average values between 3.2 and 6.3 microns of roughness.
10.0 GASKETS
Materials for gaskets shall be suitable for the fluid at the design temperature and
pressure. For general guidelines for the selection of gaskets, refer TCE.M6-ME-590-
419.
11.0 BOLTING
11.1 The following bolting materials are generally recommended with flanges:
(a) 150 classes : ASTM A307 Gr. B & A563 Gr. A or equal.
(b) 300 and higher classes : ASTM A 193 Gr. B7 & A194 Gr. 2H
11.2 When bolting to components having cast iron flanges, bolting as per 11.1 (a) is
recommended.
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11.3 For applications, involving temperatures below (-) 29
o
C, bolting materials shall be as
per ASTM A320 of a grade suitable for the actual temperature involved.
11.4 Carbon steel bolting as per Indian Standards can also be used for 150 class
application. These are as per IS 1364. It may be noted that bolting of class 4.6 as per
Indian Standards has approximately the same minimum tensile strength, as ASTM
A307 Gr. B. Use of carbon steel bolting shall be limited to temperatures 200
o
C and
less.