pipingdesigners.com Training Seminar Section - 1 D: Flanges, Gaskets & Bolts (Just t e !asics" B#: James $.

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&ote: This article covers ASME B 16.5 Standard Piping Flanges up to 24 !PS. Flanges larger than 24 "all under ASME B16.4# and $hile the% have the sa&e attri'utes the% $ill 'e covered at a later ti&e. De'inition: A "lange is de"ined as a plate t%pe device( nor&all% round( that is attached to the end o" a pipe( "itting( valve or other o')ect to "acilitate the asse&'l% and disasse&'l% o" a piping s%ste&. For &an% %ears the onl% practical &ethod o" )oining steel pipe had 'een '% connecting threaded pipe ends $ith couplings. *&prove&ents in the $elding o" car'on steel reduced la'or costs and provided a co&pletel% sealed and &uch stronger )oint. *n &ost present da% piping s%ste&s( threaded )oints are usuall% li&ited to pipe si+es 2 and s&aller. ,arger pipe -. and larger/ is nor&all% )oined '% 'utt0$elding o" continuous pipe and "ittings or '% "langes at )oints that &a% re1uire dis&antling. Flanges -. and larger/ are also the de"ault standard "or connecting to &ost e1uip&ent connections and valves. (aterials o' construction: Flanges are &anu"actured in all the di""erent &aterials to &atch the &aterial o" the pipe and "ittings to $hich the% are 'eing attached. 2hile so&e "langes are &ade o" 3ast *ron. The vast &a)orit% o" "langes are "orged car'on steel. Forged Flange )atings: Forged steel "langes are &ade in seven pri&ar% ratings. These pri&ar% ratings are as "ollo$s4 5 1567 5 .667 5 4667 5 6667 5 8667 5 15667 5 25667

The Pri&ar% 9ating is a pressure rating 'ased on a pressure:te&perature relationship. *+ample: A 1567 Forged Flange is used "or 1567 PS*; at 566< F. This sa&e "lange &a% also 'e used "or 2#57 PS*; at 166< F. This sa&e "lange could also 'e used at 1667 PS*; at #56< F. !ote the inverse relationship. 2hen the pressure goes up( the te&perature goes do$n and vice versa. Pressure ratings are used as a guide to sa"el% design piping s%ste&s and also to standardi+e &anu"actured piping co&ponents. The sa&e ratings hold true "or scre$ed and soc=et0$eld "langes. ,ast -ron Flange )atings: The t$o &ost co&&on ratings "or 3ast *ron "langes are 1257 and 2567. >ther "lange ratings are availa'le 'ut are not co&&on. 3ast *ron "langes are generall% "ound associated $ith lo$ pressure cast iron valves and no++les on cast iron e1uip&ent such as so&e pu&ps and tur'ines. Mating "orged steel "langes to cast iron "lange can pose a potential "or da&age to the $ea=er cast iron. The &ain point to re&e&'er no$ is that a 1257 3ast *ron "lange $ill &ate to a 1567 "orged steel "lange( and a 2567 3ast *ron "lange $ill &ate to a .667 "orged steel "lange. The solution to the potential da&age pro'le& $ill 'e discussed later in "lange "acings. Flange Dimensions: A "lange has &an% di&ensions. The &ost critical is the length o" the "lange. This di&ension $ill var% $ith each t%pe o" "lange and $ill 'e covered in the section 'elo$ covering Flange T%pes. All other di&ensions "or a "lange $ill nor&all% 'e the sa&e across all "lange t%pes 'ut $ill var% $ith each "lange rating. These co&&on di&ensions include4 5 Flange >utside ?ia&eter 5 Flange Thic=ness 5 Bolt 3ircle 5 !u&'er o" Bolts 5 Bolt @ole Si+e 5 Bolt Si+e Bolt .ole /ocation: The ASME B16.5 has a standard "or 'oltholes that in used '% all -AS/ &anu"acturers "or "lange si+es up through 24 For instanceB the nu&'er o" 'oltholes re1uired varies $ith the si+e and rating o" the "lange. But the nu&'er and si+e is the sa&e no &ater the t%pe o" "lange. The 'oltholes are evenl% spaced around the "lange on a concentric 'olt circle. There $ill al$a%s 'e an even nu&'er o" 'oltholes( in graduations o" 4 -i.e.( 4( C( 12( 16( etc./. Anless speci"icall% noted other$ise '% the piping designer -and then onl% i" "or good reason/ all "lange 'oltholes shall straddle the natural centerlines. This is the "lange 'olthole orientation rule. This natural centerline rule "or "lange is =no$n( understood and "ollo$ed '% all responsi'le e1uip&ent &anu"acturers and pipe "a'ricators. The rule is4 5 For a vertical "lange "ace -the "lange "ace in vertical and the line is hori+ontal/ the 'oltholes shall 'e oriented to straddle the vertical and hori+ontal centerlines.

5 For a hori+ontal "lange "ace -the "lange "ace is hori+ontal and the line is vertical up or vertical do$n/ the 'oltholes shall 'e oriented to straddle the -plant/ north:south centerlines. 3are &ust 'e ta=en to chec= all e1uip&ent vendor outlines to identi"% an% "lange orientations that do not &atch this rule. 2hen an eDception is "ound the vendor can 'e re1uested to change his 'olt hole orientation. This is not al$a%s success"ul and i" not then the piping designer &ust insure that the piping "a'rication docu&ents call "or the correct orientation. This rule o" 'oltholes straddling the natural centerlines is so&eti&es re"erred to as T$o0@ole the "lange. This &eans that the t$o o" the holes straddle the centerline. To >ne0@ole a "lange &eans that the "lange has 'een rotated so that one hole is right on the natural centerline. * assure %ou that 88.888E o" the ti&e that to >ne @ole a "lange is a &ista=e and $ill add cost to the "ield. *t also &a=es the piping "ore&an ver% unhapp%.

Flange T#pes:
0eld &eck Flanges: 2eld Face Flanges are distinguished "ro& other "lange t%pes '% their long tapered hu' and gentle transition o" thic=ness in the region o" the 'utt $eld that )oins the& to pipe or a "itting. A $eld0nec= "lange is attached to a pipe or a "itting $ith a single "ull penetration( F 'evel $eld. The long tapered hu' provides an i&portant rein"orce&ent o" the "lange proper "ro& the standpoint o" strength and resistance to dishing. The s&ooth transition "ro& the "lange thic=ness to the pipe $all thic=ness '% the taper is eDtre&el% 'ene"icial under conditions o" repeated 'ending caused '% line eDpansion or other varia'le "orces( and produces an endurance strength o" $elding nec= "langed asse&'lies e1uivalent to that o" a 'utt0$elded )oint. This t%pe o" "lange is pre"erred "or severe service conditions( $hether loading conditions are su'stantiall% constant or "luctuate 'et$een $ide li&its. The $eld nec= "lange is used in each o" the seven "lange ratings and has the advantage o" re1uiring onl% one $eld to attach it to the ad)acent pipe or "itting. The =e% di&ension "or a $eld nec= "lange in the length through the hu' "ro& the 'eveled end to the contact "ace o" the "lange. This length includes the 'evel( the tapered hu'( and the thic=ness o" the plate part o" the "lange and the raised "ace. To o'tain the correct di&ension %ou &ust loo= at a correctl% constructed "lange di&ension chart -see the Tools 'utton on this $e'site/ or a "lange &anu"acturers catalog. Electronic piping design so"t$are $ill nor&all% alread% have the correct di&ension 'uilt0in. *t is i&portant to understand and re&e&'er that the -1:16 / raised "ace on the 1567 raised "ace and on the .667 raised "ace "langes is nor&all% included in the length di&ension. @o$ever( the G raised "ace is not included in the chart or catalog length di&ension "or the 4667 and higher pressure rated "langes. The raised "ace di&ension "or 4667 "langes -and up/ nor&all% &ust 'e added to the chart or catalog length to arrive at the true total length o" these higher0pressure "langes.

Slip-on Flanges: Slip0>n -S>/ Flanges are pre"erred '% so&e contractors( over the 2eld0nec=( 'ecause o" the lo$er initial cost. @o$ever( this &a% 'e o""set '% the added cost o" the t$o "illet $elds re1uired "or proper installation. The strength o" the slip0on "lange is a&ple "or itHs rating( 'ut its li"e under "atigue conditions is considered to 'e onl% one0third that o" the $eld0nec= "lange. The slip0on "lange &a% 'e attached to the end o" a piece o" pipe or to one or &ore ends o" a pipe"itting. The slip0on "lange is positioned so the inserted end o" the pipe or "itting is set 'ac= or short o" the "lange "ace '% the thic=ness o" the pipe $all plus 1:C o" an inch. This allo$s "or a "illet $eld inside the S> "lange e1ual to the thic=ness o" the pipe $ithout doing an% da&age to the "lange "ace. The 'ac= or outside o" the "lange is also $elded $ith a "illet $eld. A variation o" the Slip0>n "lange also eDists. This is the Slip0>n 9educing Flange. This is si&pl% a larger -sa% a 14 / Slip0>n "lange 'lan= that( instead o" the 3enter -pipe/ hole 'eing cut out -or drilled out/ "or 14 pipe it is cut out "or a 6 pipe. The S> 9educing "lange is 'asicall% used "or reducing the line si+e $here space li&itations $ill not allo$ the length o" a $eld nec= "lange and reducer co&'ination. The use o" the Slip0>n 9educing Flange should onl% 'e used $here the "lo$ direction is "ro& the s&aller si+e into the larger si+e. /ap Joint Flanges: A ,ap Ioint Flange is a t$o piece device that is &uch li=e a $eld0nec= "lange 'ut also li=e a loose slip0on "lange. >ne piece is a sleeve called a HStu'0end and is shaped li=e a short piece o" pipe $ith a $eld 'evel on one end and a narro$ shoulder on the other end called the hu'. The hu' is the sa&e outside dia&eter as the raised "ace -gas=et contact sur"ace/ o" a $eld nec= "lange. The thic=ness o" the hu' is nor&all% a'out G to .:C . The 'ac= "ace o" the hu' has a rounded transition -or inside "illet/ that )oins the hu' to the sleeve. The other piece o" a ,ap Ioint Flange is the 'ac=ing "lange. This "lange has all the sa&e co&&on di&ensions ->.?.( 'olt circle( 'olt hole si+e( etc./ as an% other "lange ho$ever it does not have a raised "ace. >ne side( the 'ac=side( has a slight shoulder that is s1uare cut at the center or pipe hole. The "ront side has "lat "ace and at the center hole an outside "illet to &atch the "illet o" the Stu'0end piece. The "lange part o" the ,ap0)oint "lange asse&'l% is slipped on to the stu'0 end prior to the sleeve 'eing $elded to the ad)oining pipe or "itting. The "lange itsel" is not $elded or "iDed in an% $a%. *t is "ree to spin "or proper align&ent $ith $hat ever it is )oining to. The Stu'0end can nor&all% 'e purchased in t$o lengths. There is a short version( a'out . long and a long version o" a'out 6 long. *t is prudent "or the piping designer to =no$ $hich version is in the piping speci"ication. Because o" itHs t$o piece con"iguration( the ,ap Ioint Flange o""ers a $a% to cut cost or si&pli"% $or=. The cost saving co&es $hen the piping s%ste& re1uires a high cost allo% "or all $etted parts to reduce corrosion. The sleeve or Stu'0end can 'e the re1uired higher cost allo% 'ut the "lange can 'e the lo$er cost "orged car'on steel. The $or= si&pli"ication co&es into the picture $here there are cases that re1uire "re1uent and rapid disasse&'l% and asse&'l% during the operation o" a plant. The a'ilit% to spin that 'ac=ing "lange co&pensates "or &isalign&ent o" the 'oltholes during reasse&'l%.

Scre1ed (or T readed" Flanges: Scre$ed "langes loo= ver% &uch li=e a Slip0>n "lange in so&e $a%s. The &ain di""erence is the Scre$ed "lange $as 'ored out initiall% to &atch a speci"ic pipe inside dia&eter. The 'ac=side o" this center opening is then threaded $ith the proper si+ed tapered pipe thread. This "lange is pri&aril% used to &a=e "langed )oints $here re1uired in s&all si+es in threaded pipe specs Socket 0eld Flanges: Soc=et 2eld "langes also loo= ver% &uch li=e a Slip0>n "lange. @ere the &ain di""erence is the Soc=et 2eld "lange $as also 'ored out initiall% to &atch a speci"ic pipe inside dia&eter. @ere ho$ever( the 'ac=side o" this center opening is then counter 'ored to "or& the proper si+e soc=et to ta=e the pipe >.?. This "lange is pri&aril% used to &a=e "langed )oints $here re1uired in s&all si+es in soc=et $elded pipe specs Blind Flanges: Blind "langes are a round plate $ith all the proper 'oltholes 'ut no center hold. This "lange is used to provide positive closer on the ends o" pipes( valves or e1uip&ent no++les.

Flange Faces:
Face T#pes: Flanges "aces co&e in di""erent "or&s. So&e "or&s are &ore co&&on and others are old and out o" date "or&s. These old "or&s &a% 'e ordered 'ut possi'l% onl% to &atch an eDisting piece o" old e1uip&ent. Flange "ace "or&s are4 5 Flat Face -FF/ 0 The Flat Face is pri&aril% used on 3ast *ron "langes. 2ith this "ace the $hole contact "ace o" the "lange is &achined "lat. 5 9aised Face -9F/ 0 The 9aised Face is &ost co&&on o" all "lange "aces. The "lange has a raised area &achined on the "lange "ace e1ual to the contact area o" a gas=et. 5 9ing0t%pe Ioint -9TI/ 0 This is a "or& o" "lange "ace that is 'eco&ing o'solete. This t%pe has a higher raised portion on the "ace into $hich a ring groove is then &achined. 5 Tongue and ;roove -TJ;/ 0 This is also a "or& o" "lange "ace that in 'eco&ing o'solete. 2ith this t%pe the "langes &ust 'e &atched. >ne "lange "ace has a raised ring -Tongue/ &achined onto the "lange "ace $hile the &ating "lange has a &atching depression -;roove/ &achined into itHs "ace. 5 Male0and 0Fe&ale -MJF/ 0 This is another "or& o" "lange "ace that is o'solete. 2ith this t%pe the "langes &ust also 'e &atched. >ne "lange "ace has an area that eDtends 'e%ond the nor&al "lange "ace -Male/. The co&panion "lange or &ating "lange has a &atching depression -Fe&ale/ &achined into itHs "ace. ?issi&ilar "lange "aces such as the 9TI( TJ; and the FJM shall never 'e 'olted together. The pri&ar% reason "or this is that the contact sur"aces do not &atch and there is no gas=et that has one t%pe on one side and another t%pe on the other side. ?onHt even thin= a'out itK Flat "ace "langes are never to 'e 'olted to a raised "ace "lange. *" %ou need to 'olt a Forged steel "lange to cast iron then %ou &ust call "or the "orged steel "lange to 'e &achined o"" to a "lat "ace. For &ore in"or&ation on this see this lin= to ;oulds pu&ps

Flange Face Finis : The part o" a "lange $here the gas=et touches is called the contact sur"ace. This area is the &ost critical area to the prevention o" lea=s. This area o" a "lange &ust 'e protected "ro& the ti&e it is &achined clear through all the various shipping( storage( "a'rication and installation periods. Flange "aces are &achined $ith the "ollo$ing standard "inishes. !o dou't %our piping &aterial engineer could re1uest another special "inish 'ut that $ould onl% add eDtra cost. The &ost co&&on "inish "or the contact "ace o" a "lange is a concentric -or phonographic/ groove. This pattern is &achined into the "lange "ace and provides the grip "or the gas=et. Gaskets: Lou can have 6667 stainless steel "langes and have the 'olts "ull% tight and i" %ou do not have a gas=et -or the proper gas=et/ %ou $ill have a lot o" lea=s. @aving the gas=et and the right gas=et is ver% i&portant. ;as=ets provide the tight seal that retains the pressure and =eeps the gas or li1uid in the pipe. *n a vacuu& s%ste& it =eeps the outside air "ro& getting in. ;as=ets are designed and later chosen considering all the sa&e issues as $ere used to select the pipe. These include pressure( te&perature( and corrosiveness o" the co&&odit%( a&ong others. ;as=ets are &ade o" a $ide range o" &aterials. These include ru''er( elasto&ers and graphite. The Spiral 2ound gas=et has a graphite or te"lon &aterial $ound $ith a &etal strip $hich is then held in shape '% a "lat &etal ring. This &etal retainer ring also acts as a centering tool to insure that the cas=et is not &isaligned or 'loc=s the product "lo$. ;as=ets "or 9ing T%pe Ioint "langes are si&pl% a solid &etal ring. There are t$o 'asic cross0sectional shapes "or the 9TI gas=et. These are >val and @eDagonal. Bolts: Bolting is the "inal ele&ent o" a co&plete "lange )oint asse&'l%. @ere again $e have so&e variations. The &ost co&&on is the Stud Bolt. !eDt is nor&all% the 3ap Scre$. And "inall% $e have the Machine Bolt. Stud Bolts: The Stud Bolt is a long threaded rod -$ith no head on either end/ and t$o nuts. The Stud Bolt is used in all locations $here %ou have t$o nor&al "langes $ith access to the 'ac=side o" 'oth "langes and 'oth ends o" the stud. ,ap Scre1s: The 3ap Scre$ is a "ull% threaded rod $ith a head on one end. !o nut is used $ith the 3ap Scre$. The 3ap Scre$ is nor&all% used in all locations $here a "lange is 'eing attached to a piece o" e1uip&ent $here there are onl% tapped holes -i.e.4 no access to the 'ac=side/. 3ap Scre$s are also used to attach threaded0lug t%pe $a"er valves -Butter"l% Falves/ 'et$een a pair o" "langes. For this application the length o" the 3ap Scre$ selected is critical. T$o 3ap Scre$s are used at each lug position( one "ro& one side and one "ro& the other side. The 3ap Scre$ &ust 'e long enough to go through the "lange( the raised "ace and hal" o" the threaded lug &inus 1:16 o" an inch. This leaves a 1:C inch total gap 'et$een the ends o" the t$o cap scre$s $hen the scre$s are tight. (ac ine Bolts: A Machine Bolt is a rod $ith a heDagon head on one end and threads on so&e o" the length. Machine Bolts are nor&all% &ade o" a lo$er strength &aterial than Stud Bolts and are there"ore considered onl% $here lo$ strength 'olting is re1uired. These applications &ost o"ten include 3ast *ron "langes. For additional in"or&ation a'out "langes( gas=ets and 'olts see the Standards ta' on the pipingdesigners.co& $e'site.