Flanges are common tools in the oil and gas industry. However, the average individual may struggle to understand how they work. Different piping systems need flanges to function properly.
Flanges must be of standard quality and form. If they’re poorly maintained or overused, the risks could be catastrophic, making them a significant part of the piping industry.
The more we know about flanges, the less risk involved in buying them. We know that these pieces of equipment pose many challenges. But they are necessary to keep complex piping systems functioning.
So, we will discuss the facts you need to know about choosing flanges.
What is a Flange?
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A flange is a protruding rim created to allow equipment like pipes to form a connection. This increases strength at the joint as you create a piping system. With such access points, inspections or modifications are easy to perform.
There are different ways to make a pipe-flange connection. Oftentimes, it depends on the type and requirements of your piping system. For example, some flanges require welding while others are screwed on.
The type of flange you settle for depends on several factors. These include material, application, and accessories that complete the job. However, these factors are not exhaustive. We will discuss more to help you choose the best options.
What Are the Common Flange Accessories?
Common flange accessories include the following:
1) Bolts and Nuts
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Bolts and nuts are high-strength, heavy hex that provides extra durability. This heavy hex gives the installer more socket area, allowing for easy tightening. You have to get the bolt and nuts right. Do that by ordering for the correct length and diameter per mating flanges.
The nuts are fasteners, often carrying a wide bottom circular flange. Along with the mating bolt, nuts help to fasten many parts together. Additionally, they have a ‘washer-like’ base. This helps to spread load pressure uniformly over large surfaces.
Depending on the requirements, bolts, and nuts are crucial for maximum torque and grip.
2) Gaskets
Gaskets are significant components in industrial applications. They’re used to seal joints between two flanges. This helps to prevent liquids and gases from escaping piping systems. Flange gaskets guarantee the integrity of piping systems.
You’ll find flange gaskets in many industries, including petrochemicals and energy. Gaskets can withstand pressure levels and temperature conditions.
3) Stud Bolts
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These are fastener bolts used to tighten flange joint connections in pipelines. Their threaded bodies and chamfered ends come in metric and imperial sizes. As for applications, their length is calculated based on flange size. Pressure-temperature ratings are also considered during application.
Further, bolt holes in the flange determine the number of stud bolts needed. Several factors lead to the increase of bolt holes. This includes the flange’s size, working pressure, temperature, and material.
4) Spacers and Plugs
A quality, solid connection is not complete without spacers and plugs. The spacer flanges add or fill space between flanges. There may be short anticipated or unanticipated gaps between equipment flanges. Since these gaps must connect, spacer flanges solve this problem.
Plugs are fittings that block the flow of gas or liquid in a pipe. They do this by closing off the end of a flanged pipe or fitting. Plugs lack a center hole but they’re bolted to standard mating flanges. Materials for plugs include carbon steel and aluminum.
How to Choose the Right Flange for Your Application
You must choose the right flanges for your application. This will help your piping system function optimally. Here are some ways to help you choose the right flanges:
1) Understand System Requirements
Understanding system requirements is crucial to meeting the required standards. According to the ASTM, flange and pipe materials must meet similar standards. For example, ASTM A36 is a low-carbon steel favored for its welding properties. It is suitable for machining, making it a common material for steel flanges.
ASTM A105 is another option. It’s a standard for carbon steel piping components. Also, it’s particularly useful for high-temperature applications.
2) Work on Material Selection
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What kind of materials do you want? Flange uses often depends on the application. Installers must match the materials with that of the pipe.
If your piping system is aluminum, you need similar materials. Besides, aluminum is more corrosive-resistant than most steels. Whatever you do, select the right materials that match the flange application.
3) Ensure Compatibility with Pipe Dimensions and Standards
This is another crucial part of the process. Consider the material, dimensions, standards, and temperature ratings. These factors will lead you to the ideal flange material. What’s more, ANSI ratings give you information on pressure and heat tolerances.
Some fittings need welding while others do not. Flanges must adhere to standards because they provide necessary guidelines. Common standards include ASME B16.5, covering pipe flanges and flanged fittings. It comes in sizes NPS 1/2 through NPS 24.
ASME B16.47 is another option. It addresses large-diameter steel flanges in sizes NPS 26 through NPS 60. There are others to consider. However, the primary thing is compatibility with pipe dimensions and standards.
4) Evaluate the Operating Environment
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You must choose flange material based on its intended use and operating environment. Some operating environments are hazardous, so quality is essential. For example, environments with high temperatures and pressure need more resistant flanges. You wouldn’t want a situation with poor mechanical performance and corrosion.
5) Focus on Proper Sizing and Alignment
Flanges’ sizes and other physical dimensions are critical to ensure the best fit. Proper sizing and alignment promote flange usability on the piping system. Your measurements must be based on pipes, gasket size, and flange interface. Standard dimensions of pipe fitting flanges include nominal bore size and thickness.
What to Look for in a Reliable Flange Supplier
Are you looking for a reliable flange supplier? Ensure that they have these qualities:
1) Product Quality
A reliable flange supplier must show commitment to delivering quality. As you search for manufacturers, shortlist those who stick to internationally recognized standards. There are some significant standards to watch out for. They include ISO, AST, and ANSI.
The products suppliers provide must pass various quality checks. Focus on manufacturers that deliver quality products.
2) Manufacturing Capabilities
What’s their manufacturing strength? Do they stick to standard flanges and nothing else? Learn what they’re capable of manufacturing, the quality, and the time frame.
Some suppliers have what it takes to meet huge demands. They can meet your needs and flange requirements without compromising on quality. Use a supplier that can provide all your pipe fittings.
3) Industry Experience
Experience is something you must check. You want a manufacturer that understands project requirements and workings. Experienced flange suppliers can help you with custom fabrications. They can also provide engineering assistance with the design.
Industry experience translates to high-level customer service and quickly executed orders.
4) Logistics and Support
A dedicated flange manufacturer has comprehensive logistics and support. They provide these qualities to give you the best products and experience. From pre-sales inquiries to after-sales service, their support team must be knowledgeable. Search for a responsive manufacturer that helps you navigate potential issues.
5) Cost Transparency
Cost transparency is essential. The prices offered by the manufacturer must be reasonable and competitive. Depending on what you need, it is crucial to compare prices with similar products. Additionally, check for gaps between each flange type and their categories.
How to Save Costs When Sourcing Flanges and Accessories
Before you bring out your checkbook, consider these tips to save costs:
1) Bulk Purchasing
Prices of flanges may fluctuate. You can buy the equipment and accessories you need in bulk. But, ensure the products are genuine, without compromising on quality.
When you partner with a reliable supplier, making bulk purchases is beneficial. You’ll save money, boost efficiency, and increase profitability.
2) Choose the Right Materials to Get a Better Cost and Performance
Choosing materials is crucial to the engineering process. The materials are the bedrock of the design process. It is where the product’s capabilities are determined. Besides, your choice of materials also determines strength and density.
The right materials determine electrical conductivity and responses to environmental conditions. Inadequate materials will lead to compromised structures and increased corrosion.
3) Compare Different Suppliers
The flange market has many players. Before committing to one manufacturer or supplier, compare products and prices. Comparing suppliers leads to cost savings, quality improvement, and reduced risks.
Further, you’ll enjoy different approaches and innovative solutions. The best part? You get greater bargaining power. This means you can negotiate favorable terms, including pricing and payment conditions.
4) Assess Total Cost of Ownership (TCO), Including Shipping and Maintenance
The total cost of ownership (TCO) is the buy price of an asset and the costs of operation. It also includes shipping, maintenance, and possible long-term expenses. Assessing these factors will help you observe the products and their value.
This value covers the product’s useful life and ultimate disposal. The flange with the lowest total cost of ownership can present a better value in the long run.
5) Build Long-Term Relationships with Suppliers for Better Terms
Conduct business with suppliers you’ve built relationships with. Improved communication can lead to better deliveries and reduced costs. Also, it means less chance of products getting compromised. It’s all about building trust that leads to better terms for you and the supplier.
Final Thoughts!
Flanges are critical components in industrial piping systems. Choosing the right products promotes the safety and efficiency of operations. Getting a reputable flange and accessories supplier is a possibility.
When you know how to approach the market, you can guarantee quality. Always consider the materials, sizes, dimensions, and durability. You need products that ensure safe piping and prolonged application. With this information, you can buy precision-manufactured flanges.
You’ll get a perfect fit and reliable performance in demanding environments. Follow cost-cutting measures and steps to build lasting business relationships. Reach out to us now!
