Definition and Details of Flanges - Types of Flanges

Weld Neck Flanges:

Weld Neck Flanges are distinguished from other flange types by their long tapered hub
and gentle transition of thickness in the region of the butt weld that joins them to pipe or
a fitting. A weld-neck flange is attached to a pipe or a fitting with a single full
penetration, "V" bevel weld. The long tapered hub provides an important reinforcement
of the flange proper from the standpoint of strength and resistance to dishing. The
smooth transition from the flange thickness to the pipe wall thickness by the taper is
extremely beneficial under conditions of repeated bending caused by line expansion or
other variable forces, and produces an endurance strength of welding neck flanged
assemblies equivalent to that of a butt-welded joint. This type of flange is preferred for
severe service conditions, whether loading conditions are substantially constant or
fluctuate between wide limits.

The weld neck flange is used in each of the seven flange ratings and has the advantage
of requiring only one weld to attach it to the adjacent pipe or fitting.
The key dimension for a weld neck flange is the length through the hub from the
beveled end to the contact face of the flange. This "length" includes the bevel, the
tapered hub, and the thickness of the plate part of the flange and the raised face. To
obtain the correct dimension you must look at a correctly constructed flange dimension
chart (see the "Tools" button on this website) or a flange manufacturers catalog.
Electronic piping design software will normally already have the correct dimension built-
in.

It is important to understand and remember that the (1/16") raised face on the Class 150
raised face and on the Class 300 raised face flanges is normally included in the length
dimension. However, the ¼" raised face is not included in the chart or catalog length
dimension for the Class 400 and higher pressure rated flanges. The raised face
dimension for Class 400 flanges (and up) normally must be added to the chart or
catalog length to arrive at the true total length of these higher-pressure flanges.

Slip-on Flanges:
Slip-On (SO) Flanges are preferred by some contractors, over the Weld-neck, because
of the lower initial cost. However, this may be offset by the added cost of the two fillet
welds required for proper installation. The strength of the slip-on flange is ample for it's
rating, but its life under fatigue conditions is considered to be only one-third that of the
weld-neck flange.

The slip-on flange may be attached to the end of a piece of pipe or to one or more ends
of a pipe fitting. The slip-on flange is positioned so the inserted end of the pipe or fitting
is set back or short of the flange face by the thickness of the pipe wall plus 1/8 of an
inch. This allows for a fillet weld inside the SO flange equal to the thickness of the pipe
wall without doing any damage to the flange face. The back or outside of the flange is
also welded with a fillet weld.

A variation of the Slip-On flange also exists. This is the Slip-On Reducing Flange. This
is simply a larger (say a 14") Slip-On flange blank that, instead of the Center (pipe) hole
being cut out (or drilled out) for 14" pipe it is cut out for a 6" (or some other size) pipe.
The SO Reducing flange is basically used for reducing the line size where space
limitations will not allow the length of a weld neck flange and reducer combination. The
use of the Slip-On Reducing Flange should only be used where the flow direction is
from the smaller size into the larger size.

Lap Joint Flanges:

A Lap Joint Flange is a two piece device that is much like a weld-neck flange but also
like a loose slip-on flange. One piece is a sleeve called a 'Stub-end" and is shaped like
a short piece of pipe with a weld bevel on one end and a narrow shoulder on the other
end called the hub. The hub is the same outside diameter as the raised face (gasket
contact surface) of a weld neck flange. The thickness of the hub is normally about ¼" to
3/8". The back face of the hub has a rounded transition (or inside fillet) that joins the hub
to the sleeve.

The other piece of a Lap Joint Flange is the backing flange. This flange has all the same
common dimensions (O.D., bolt circle, bolt hole size, etc.) as any other flange however
it does not have a raised face. One side, the backside, has a slight shoulder that is
square cut at the center or pipe hole. The front side has flat face and at the center hole
an outside fillet to match the fillet of the "Stub-end" piece. The flange part of the Lap-
joint flange assembly is slipped on to the stub-end prior to the sleeve being welded to
the adjoining pipe or fitting. The flange itself is not welded or fixed in any way. It is free
to spin for proper alignment with what ever it is joining to.

The "Stub-end" can normally be purchased in two lengths. There is a short version,
about 3" long and a long version of about 6" long. It is prudent for the piping designer to
know which version is in the piping specification.

Because of it's two piece configuration, the Lap Joint Flange offers a way to cut cost or
simplify work. The cost saving comes when the piping system requires a high cost alloy
for all "wetted" parts to reduce corrosion. The sleeve or Stub-end can be the required
higher cost alloy but the flange can be the lower cost forged carbon steel.

The work simplification comes into the picture where there are cases that require
frequent and rapid disassemble and assembly during the operation of a plant. The
ability to spin that backing flange compensates for misalignment of the bolt holes during
reassembly.
Flange types
As already described before, the most used flange types acc. to ASME B16.5 are:
Welding Neck, Slip On, Socket Weld, Lap Joint, Threaded and Blind flange. Below you
will find a short description and definition of each type, completed with an detailed
image.

MOST COMMON FLANGE TYPES

Welding Neck flange

Welding Neck Flanges are easy to recognize at the long tapered hub, that goes
gradually over to the wall thickness from a pipe or fitting.

The long tapered hub provides an important reinforcement for use in several
applications involving high pressure, sub-zero and / or elevated temperatures. The
smooth transition from flange thickness to pipe or fitting wall thickness effected by the
taper is extremely beneficial, under conditions of repeated bending, caused by line
expansion or other variable forces.

These flanges are bored to match the inside diameter of the mating pipe or fitting so
there will be no restriction of product flow. This prevents turbulence at the joint and
reduces erosion. They also provide excellent stress distribution through the tapered hub
and are easily radiographed for flaw detection.

This flange type will be welded to a pipe or fitting with a single full penetration, V weld
(Buttweld).

DETAILS OF WELDING NECK FLANGE

 1. Weld Neck flange 2. Butt Weld
3. Pipe or Fitting

Slip On flange
The calculated strength from a Slip On flange under internal pressure is of the order of
two-thirds that of Welding Neck flanges, and their life under fatigue is about one-third
that of the latter.

The connection with the pipe is done with 2 fillet welds, as well at the outside as also at
the inside of the flange.

The X measure on the image, are approximately:

Wall thickness of pipe + 3 mm.

This space is necessary, to do not damage the flange face, during the welding process.

A disadvantage of the flange is, that principle always firstly a pipe must be welded and
then just a fitting. A combination of flange and elbow or flange and tee is not possible,
because named fittings have not a straight end, that complete slid in the Slip On flange.

DETAILS OF SLIP ON FLANGE

 1. Slip On flange 2. Filled weld outside
3. Filled weld inside 4. Pipe

Socket Weld flange

Socket Weld flanges were initially developed for use on small-size high pressure piping.
Their static strength is equal to Slip On flanges, but their fatigue strength 50% greater
than double-welded Slip On flanges.

The connection with the pipe is done with 1 fillet weld, at the outside of the flange. But
before welding, a space must be created between flange or fitting and pipe.

ASME B31.1 1998 127.3 Preparation for Welding (E) Socket Weld Assembly says:
In assembly of the joint before welding, the pipe or tube shall be inserted into the
socket to the maximum depth and then withdrawn approximately 1/16" (1.6 mm) away
from contact between the end of the pipe and the shoulder of the socket.

The purpose for the bottoming clearance in a Socket Weld is usually to reduce the
residual stress at the root of the weld that could occur during solidification of the weld
metal. The image shows you the X measure for the expansion gap.

The disadvantage of this flange is right the gap, that must be made. By corrosive
products, and mainly in stainless steel pipe systems, the crack between pipe and flange
can give corrosion problems. In some processes this flange is also not allowed. I am not
an expert in this matter, but on the internet, you will find a lot of information about
forms of corrosion.

Also for this flange counts, that principle always firstly a pipe must be welded and then
just a fitting.
 DETAILS OF SOCKET WELD FLANGE

1. Socket Weld flange 2. Filled weld 3. Pipe

X = Expansion gap

Lap Joint flange

Lap Joint Flanges have all the same common dimensions as any other flange named on
this page however it does not have a raised face, they used in conjunction with a "Lap
Joint Stub End".

These flanges are nearly identical to a Slip On flange with the exception of a radius at
the intersection of the flange face and the bore to accommodate the flanged portion of
the Stub End.

Their pressure-holding ability is little, if any, better than that of Slip On flanges and the
fatigue life for the assembly is only one tenth that of Welding Neck flanges.

They may be used at all pressures and are available in a full size range. These flanges
slip over the pipe, and are not welded or otherwise fastened to it. Bolting pressure is
transmitted to the gasket by the pressure of the flange against the back of the pipe lap
(Stub End).

Lap Joint flanges have certain special advantages:

 Freedom to swivel around the pipe facilitates the lining up of opposing flange
bolt holes.
 Lack of contact with the fluid in the pipe often permits the use of inexpensive
carbon steel flanges with corrosion resistant pipe.
 In systems which erode or corrode quickly, the flanges may be salvaged for
re-use.
 DETAILS OF LAP JOINT FLANGE

1. Lap Joint flange 2. Stub End

3. Butt weld 4. Pipe or Fitting

Stub End
A Stub End always will be used with a Lap Joint flange, as a backing flange.

This flange connections are applied, in low-pressure and non critical applications, and is
a cheap method of flanging.
In a stainless steel pipe system, for example, a carbon steel flange can be applied,
because they are not come in contact with the product in the pipe.

Stub Ends are available in almost all pipe diameters. Dimensions and dimensional
tolerances are defined in the ASME B.16.9 standard. Light-weight corrosion resistant
Stub Ends (fittings) are defined in MSS SP43.

LAP JOINT FLANGE WITH A STUB END

Threaded flange
Threaded Flanges are used for special circumstances with their main advantage being
that they can be attached to the pipe without welding. Sometimes a seal weld is also
used in conjunction with the threaded connection.

Although still available in most sizes and pressure ratings, screwed fittings today are
used almost exclusively in smaller pipe sizes.

A threaded flange or fitting is not suitable for a pipe system with thin wall thickness,
because cutting thread on a pipe is not possible. Thus, thicker wall thickness must be
chosen...what is thicker ?

ASME B31.3 Piping Guide says:

Where steel pipe is threaded and used for steam service above 250 psi or for water
service above 100 psi with water temperatures above 220° F, the pipe shall be
seamless and have a thickness at least equal to schedule 80 of ASME B36.10.

DETAILS OF THREADED FLANGE

1. Threaded flange 2. Thread 3. Pipe or Fitting

Blind flange
Blind Flanges are manufactured without a bore and used to blank off the ends of piping,
Valves and pressure vessel openings.

From the standpoint of internal pressure and bolt loading, blind flanges, particularly in
the larger sizes, are the most highly stressed flange types.

However, most of these stresses are bending types near the center, and since there is
no standard inside diameter, these flanges are suitable for higher pressure temperature
applications.
 DETAILS OF BLIND FLANGE

1. Blind flange 2. Stud Bolt 3. Gasket 4. Other flange

REMARK(S) OF THE AUTHOR...

A SIMPLE MANNER TO MAKE A 1/16" GAP...

 Have you ever seen a Socket Weld contraction ring ?.

It is a split ring that is engineered and designed to give a pre-measured 1/16"
minimum gap for socket welds. Made from a certified stainless steel, and resists
corrosion from chemicals, radioactive materials and water. Once inserted into the
fitting the ring becomes a permanent part of the joint. It will not rattle or vibrate
even under extreme pressure.
Another manner is the applying of in water-soluble board. Make rings with a hole
punch with outside and inside diameter of the pipe. Insert the ring into the
flange or fitting and after hydrotesting there is no ring anymore.
For both solutions, ask your customer for permission.

HOLD THEM ON ITS PLACE...

  If a Lap Joint flanged connection must be disassembled, for example to replace a
gasket, it is not always possible to do that on the conventional manner. The
conventional manner is the use of a flange spreader or crowbar that pushed off
the two flanges.
By Lap Joint flanges that is not possible, because these slide back over the pipe,
while the Stub Ends stay together. To prevent that, often are on 3 places, single
millimeters behind the flange, on the Stub End, short pieces flat steel, will be
welded.
There is no general rule how a Lap Joint flange must be hold on its place, and
therefore it can deviate per customer specification.

YOU KNEW THAT...?

 At the smallest sizes, the amount of wall lost during threading actually equals
approximately 55% of the original pipe wall.

BUTT WELDS VS FILLET WELDS

 In systems with relatively high pressures and temperatures, we need to avoid

the use of fillet welds. Butt welds, in such systems must be used. The strength of
a butt weld is at least the strength of the base material. The strength of fillet
welds related to the strength of the butt weld, is about one third.
At higher pressures and temperatures, the expansion and contraction caused
fast for serious cracks in fillet welds and therefore the use of butt welds is
essential.
For conduits to critical machinery such as pumps, compressors and turbines,
which are exposed to vibration (in addition to the expansion and contraction), we
should avoid the use of fillet welds or threaded connections.
Fillet welds have a higher sensitivity to cracks due to stress concentration, while
butt welds are characterized by smooth exchange of tensions.
So, for critical situations, we have to use flanges connected by butt welding like
as weld neck and ring type joint, and avoid using flanges connected by fillet
welds like Slip On or Socket Weld.