TRAINING MANUAL- PIPING DOC No.

: 29040-PI-UFR-0010

Rev. : R0
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Uhde India Limited Page : 1

CONTENTS

Page

0.0 Cover Sheet 1

1.0 General 2

2.0 Classification 2–6

3.0 Standards 6–7

4.0 Plate Fabricated Flanges 7

5.0 Flanges as per DIN/ 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 9 - 11

Applicable Revision:
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1.0 GENERAL:

Flanges 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 etc.

A flanged joint is composed of three 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 a joint, which has acceptable leak tightness.

2.0 CLASSIFICATION:

Flanged joints may best be classified by dividing them into two general parts (Refer
Annexure-1)

• Methods of attachment of Flange to Pipe.

• Type of Facing on contact surface of flange proper.

2.1 Methods Of Attachment Of Flange To Pipe

2.1.1 Screwed flanges:

i. This flange can be rapidly connected to threaded pipe without welding.

ii. Screwed flange joints have the following inherent weaknesses and disadvantages
which restrict their use to moderate operating conditions.

a. Necessity of careful alignment of bolt holes.

b. Flange faces may become distorted when attaching flanges to pipe.
c. Pipe frequently extends through flange beyond the face.
d. Tests indicate that in tension a threaded joint has less than 60% of the
strength of the pipe.
e. Material removed in threading results in a thinner wall section readily affected
by erosion and corrosion.

iii. Threaded connection is susceptible to leakage under any type of cylic operation. This
flange is not recommended for use on services which involve bending or thermal
cycles.

iv. Usually screwed flanges are used for Galvanized piping.

v. Sometimes, steel screwed flanges are seal welded to guard against leakage through
the threads.

2.1.2 Slip on Flanges:

i. Slip on type of flange is widely used because of its low initial cost.

ii. Slip on flange is attached to pipe by fillet weld. The welding is either at the back or at
back and face. Usually this flange is double welded and vented with the use of 1/8”
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pre drilled holes through hub. During welding at the face, care should be taken so as
to avoid distortion and refacing.

iii. The strength of this flange as calculated from internal pressure consideration is
approximately two-thirds that of a corresponding welding neck type of flange.

iv. The use of this type of flange is usually limited to moderate services where pressure
fluctuations, temperature fluctuations, vibrations and shocks are not expected to be
severe. The fatigue life of this flange is approximately one third that of a welding neck
flange.

v. Slip on flange is not recommended for corrosive and/or critical services.

vi. Use of slip on flange is usually limited to class 300 (refer para on pressure temp.
rating) and design temperature not exceeding 500° F.

vii. It is essential to ensure proper alignment of bolt holes before welding this type of
flange.

2.1.3 Welding - neck Flanges :

i. 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.

ii. This type of flange is attached to pipe by having butt weld which can be radiographed
if required.

iii 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.

iv. 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.

v. While ordering this type of flange it is necessary to indicate schedule number

thickness or I.D and O.D. of connected pipe so that bore of the flange as well as butt
welding ends can be machined to suit pipe.

vi. The welding neck flange also requires accurate alignment of bolt holes before
welding.

2.1.4 Lap - Joint Flanges :

i. Lap joint flanges are used with a lap -joint stub.

ii. The combined cost of the two parts is generally greater than the cost of a welding
neck flange of 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
sacrificing 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.
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iii. This type of flange is used for all plastic piping. Sometimes plastic piping handling
corrosive fluids have galvanized backing flanges in order to have better corrosion
resistance against spillages etc.

iv. 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.

iii. 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 stresses exist.

iv. This type of joint avoids the necessity of accurate alignment of bolt 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.

vi. These type of flanges are also useful in cases where frequent dismantling for
cleaning or inspection is required or when it is necessary to rotate the pipe by
swiveling the flange.

2.1.5 Socket-welded flanges:

i. These flanges are usually used upto 2” size for lines where socket welded joints are
permitted.

ii. In this type of flange, hub part has a socket to suit pipe and flange is attached to pipe
by having a fillet weld at the back. There is no provision for face welding in this type of
flange.

iii. Their use and limitations are same as those applicable to slip-on flanges.

2.1.6 Blind Flanges:

i. 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.

ii. Blind flanges absorb high bending stresses but do not have to absorb stresses
caused by thermal expansion or by weight of the piping system.

2.2 Flange Facings:

2.2.1 Raised Face:

i. Steel flanges with a raised face are extensively used because of the simplicity of the
design.

ii. Moderate unit gasket pressure is maintained with conventional machining and
assembly methods and facing is suitable for average service conditions. However for
severe service involving high pressure, high temperature, thermal shock or cyclic
operation, this type of flange facing may not be satisfactory.

iii. Flanges with rating of ASME 150 and 300lbs 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 which is additional to the minimum flange thickness.
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iv. The raised face is machined with spiral or concentric grooves. Depth and spacing of
these grooves 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.
As per ASME B16.5, for raised face, either a serrated concentric or serrated spiral
finish having from 24 grooves/inch to 40 grooves/inch shall be used. The cutting tool
employed shall have an approx.0.06 inch or larger radius. The resultant surface finish
shall have a 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
instruments having stylus tracers and electronic amplification (Refer ASME B46.1)

v. The facing should not have any radial tool mark since the same would provide
shortest path for fluid to escape.

vi. The facing should be properly protected during transportation and handling at site.

vii. Flat ring composition gaskets are normally used having a width equal to the width of
the raised face where as flat metal gaskets may be used having a width equal to that
used with large tongue-and-groove type face.

2.2.2 Flat face:

i. Flanges with flat faces using full-face gaskets are usually used for making
connections to ASME 25lb and 125 lbs. Cast iron flanges and flanged components.
This decreases the leverage in bolting, thereby reducing the tendency for the flange
to crack.

2.2.3 Male & Female Facings:

i. They have the disadvantage that the two mating flanges are not identical. For this
reason, these flanges are not as widely used as raised face flanges.

ii. Male & female facings have the advantage of confining the gaskets thereby
minimizing the possibility of blow-out of the gaskets. The outer diameter of the female
face serves to locate and retain the gasket.

iii. Male & female facings offer no protection against forcing the gasket into the line or
vessel.

iv. Two type of facings are available under this category:

a. Small Male & Female:

This type face is usually used in small lines for hydraulic service to effect a
high unit gasket pressure in a confined area. However, the facing is
unsuitable to withstand bending stress, nor recommended for lines subjected
to high temperatures.

b. Large Male & Female:

This type face affords the same loading and resulting unit gasket pressure as
the raised face. Flat ring composition gaskets are normally used. The width of
the face is so large that full face metal gaskets can not be used because of
the excessive tightening load required to seat the gasket.

2.2.4 Tongue-and-Groove Facings:

i. They have the disadvantage that the two mating flanges are not identical.
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ii. Tongue-and-Groove facings have the advantage of confining the gasket. The
presence of retaining metal on either side of the gasket gives protection against
possibility of blow out of the gasket as well as protection against deforming soft
gaskets into the interior of the line or vessel. This is an advantage over the male-and-
female type of face.

iii. The Gasket is less subject to erosive or corrosive contact with the fluid.

iv. In service, the tongue is more likely to get damaged than the groove, therefore the
tongue should be placed on the part that can be easily replaced.
Usually for services, where tongue-and-groove facings are used, all equipment
nozzle flanges, valve flanges, and instrument flanges etc. are provided with groove
face and mating piping flanges with tongue face.

v. Two type of facings are available under this category:

a. Small Tongue-and-Groove:

This type of facing is generally used for small lines in hydraulic service to
effect a high unit gasket pressure in a confined area. It has the disadvantage
of excessive gasket pressure under temperature change and pipe deflection.
The facing is unsuitable for lines subjected to high temperatures.

b. Large Tongue-and-Groove:

This type face provides the minimum area that it is advisable to use with flat
gaskets. Therefore this type of facing provides the minimum bolting load for
compressing a flat gasket. Also the gasket area is nearer the bolt circle
making it slightly more resistant to flange stresses and bending moments.

vi. Due to constructional limitations, minimum flange rating available with tongue-and-
groove facing is ASME 300 lbs.

2.2.5 Ring Joint Faces:

i. Ring joint type of facing offers the greatest protection under severe service conditions
or with the use of hazardous fluids.

ii. This type face employing a metal ring of either oval or octagonal cross section as a
gasket, permits very high unit gasket pressure.

iii. This type of facing requires close tolerances and high standards of machining making
it the most expensive gasket face.

iv. Internal pressure acts on the ring to increase the sealing force on the joint.

v. Mating flanges are identical.

vi. Gasket contact surfaces are below the flange face, thereby they get protected from
damage.

3.0 STANDARD:

There are a variety of Standards used in the design and selection of Flanges. The following
Codes and Standards relate to the pipe flanges:
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ASME B 16.1 Cast Iron Flanges and Flanged Fittings

ASME B 16.5 Pipe Flanges and Flanged Fittings
ASME B 16.42 Ductile Iron Pipe Flanges and Flanged Fittings – 150 and 300
Classes
ASME B 16.47 Large diameter steel Flanges

The most commonly used standard for flanges and flanged fittings is ASME B16.5. It covers
pressure temperature ratings, materials, dimensions, tolerances etc. for pipe flanges and
flanged 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 Table – 1A

3.1 Pressure-Temperature Ratings:

i. Pressure-Temperature ratings are determined as per Annexure D of ASME B 16.5

For easy reference, ASME B16.5 Table 1A and Table 2 - 1.1 (rating for Group 1.1
material) are attached in section 7.0.

ii. For any temperature below -20°F, the rating shall be no greater than the rating shown
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for –20 F.
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iii. Socket welding and screwed flanges are not recommended for service above 500 F
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or below –50 F if severe thermal gradients or thermal cycling are involved.

iv. At temperature 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.
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v. When used above 400 F, class 150 flanged joints may develop leakage unless care
is taken to avoid imposing severe external loads and/or severe thermal gradients. For
other classes, similar consideration should be given above 750° F.

4.0 PLATE FABRICATED FLANGES:

Some times on cost consideration for low pressure, low temperature, non-critical 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 B16.5 but one can specify
standard B.S.1560 which cover carbon steel plate flanges having flange dimensions identical
to ASME 150 lbs. The plate used is B.S 1501-224 Gr.32A or its equivalent ASTM A516 grade
70 or IS 2062.

5.0 FLANGES AS PER DIN/BS:

Though the flanges as per ASME Standard are most common, sometimes, we may require a
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 PN6,
PN10, PN16, PN25, PN40, PN100.

Flanges conforming to BS standard are available in various pressure ratings. Refer BS 10;
1962 and BS 1560; 1989.
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6.0: SKETCH SHOWING VARIOUS TYPE OF FLANGES:

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7.0 RATING TABLE FOR GROUP 1.1 MATERIAL AS PER ASME B 16.5:
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