Prepared and presented by: Akram Megdad / Sr. Mech.

Inspector

Pipe Flanged joints are considered to be weak joints in the piping system and many considerations should be taken to avoid failure.
Lack of proper installation and inspection could result in a little leakage

OR

In this presentation I will talk about ?

Methods of connecting flanged joints.

Types of flanged joints.

Forces acting on the flanged joints.

Flanged joints installation and inspection. Summary.

Methods of Connecting Pipe Flanges

A flange is used to connect a pipe section to a piece of equipment, valve, or another pipe in a way that will permit relatively simple disassembly. Such disassembly may be required for maintenance, inspection or operational reasons.

Methods of Connecting Pipe Flanges

There are three general methods used to join or connect lengths of pressure piping,

these are:

1 By the use of threaded pipes and screwed

connections.

By the use of welded joints.

3 By the use of flanges.

Typical flange Joint Assembly

Flange assembly consist of :

Two flanges.

Bolting to keep the assembly together.

A gasket to provide a seal between the flanges.

Flange Types
There are several standard types of pipe flanges. Two items must be specified to completely define a flange type. Flange Type Attachment Method

Face Type

A flange type is specified by stating the type of attachment and face. For example, "A weld neck flat-faced flange" The type of attachment defines how the flange is connected to a pipe section or piece of equipment (such as a pressure-vessel nozzle). The type of flange face or facing defines the geometry of the flange surface that contacts the gasket.

Flange Attachment Types

Threaded Flanges
A threaded flange has pipe threads machined into its bore as the flange is screwed to matching threads on the pipe end. Threaded flanges are used only for small-diameter piping systems, up to 50 mm (2 in.) NPS (nominal pipe size) at locations where pipe disassembly may be required for maintenance, field modifications, or to match specialty fittings and valves. For hazardous services, a threaded flange may only be used up to 38 mm (1-1/2 in.) NPS. However, based on SAES-L009, Metallic Flanges, Gaskets, and Bolts, welded slipon-type flanges are preferred over threaded flanges in screwed piping systems.

Flange Attachment Types

Threaded Flanges

Flange Attachment Types

Slip-on Flanges
A Slip-on Flange has an oversized bore, it is slipped over the pipe OD and projects slightly beyond the pipe end, the flange is then fillet welded to the pipe OD, and also between the flange bore and the pipe end.

Based on SAES-L-009, Saudi Aramco requires that an ASME Code Section VIII, Division 1, flange analysis to be performed if a Slip-on Flange is used for any of the following cases: 1 - Severe cyclic conditions. 2 - Design temperature greater than 230C (450F). 3 - ANSI Class 400 or higher rating. 4 - Pipe size over 600 mm (24 in.).

Flange Attachment Types

Slip-on Flanges

Flange Attachment Types

Socket-Welded Flanges
A socket-welded flange is similar to a slip-on flange except it has an oversized bore that is partially machined into the end opposite the face, the pipe is inserted into the "socket" and the flange fillet is welded to the pipe OD, the diameter of the smaller bore is the as the I.D. of the matching pipe. This type of flange is often used with high pressure systems that use smaller diameter pipes (< 4 inches). Based on SAES-L-010, Limitations on Piping Joints, the maximum size of socket-welded joints in hazardous services shall be 38 mm (1-1/2 in.) NPS for new construction. However, as with threaded piping systems, SAES-L-009 indicates that welded slip-on-type flanges are preferred over socket-welded flanges in socket-welded piping systems.

Flange Attachment Types

Socket-Welded Flanges

Flange Attachment Types

Blind Flanges

A blind flange is a flat metal plate without an opening or bore that is used to block flow in a piping system. It is used when a pipe end or equipment nozzle must be blocked from flow.

Flange Attachment Types

Lapped Flange
A lapped flange is not physically connected to the pipe, it is slipped over a pipe stub that has a flared end and the pipe stub is welded to the major pipe section, the flared pipe end has a machined face where the gasket is seated, the bolting holds the flanges and gasket joint together. Based on SAES-L-009, Saudi Aramco prohibits the use of lapjoint flanges in severe cyclic conditions. Their use is also limited to special applications such as :
To avoid welding dissimilar materials.

To facilitate lining up the bolt holes in underwater flanged joints. The use of lap joint flanges is the exception rather than the rule, the main advantage of a lapped flange is cost and then only in high-alloy piping systems.

Flange Attachment Types

Lapped Flange

Flange Attachment Types

Welded-Neck Flanges
A welding-neck flange is normally referred to as the high hub flange and it is the strongest of the standard flange attachment types, it is designed to transfer stress concentration at the base of flange, the end of the flange is butt-welded to the end of the pipe, the flange bore is sized to match the pipe bore. A welding-neck flange is the most widely used in refinery services because of its greater strength and ability to be used at high temperature and in cyclic service. Based on SAES-L-009, this is the preferred flange type in metallic piping systems, 50 mm (2 in.) NPS and above.

Flange Attachment Types

Welded-Neck Flanges

Forces Acting on the Flanged Joints

PRESSURE

THERMAL

DYNAMIC

Forces Acting on the Flanged Joints

PRESSURE

The flange rating should be adequate for the required pressure and temperature range to avoid over pressure on the flanged joints.

Forces Acting on the Flanged Joints

THERMAL

Thermal expansion will cause high bending moment and could lead to alignment difficulties, leaks and fires.

Forces Acting on the Flanged Joints

DYNAMIC
Dynamic forces should be taken in consideration to assure the flanged joints integrity such as: Processes related. Controlled and unpredicted forces. Piping lay out and configuration. Modification to piping lay out.

Flanged joints Installation and Inspection

Alignment

Surface finish

Gasket centering

Bolting procedure

Flanged joints Installation and Inspection

Alignment
Flanged Joint misalignment caused by:
Low quality fabrication. Field measurements mistakes.

And this will lead to:

Uneven load distribution.

Gasket damage.

Flanged joints Installation and Inspection

Surface finish

The

surface finish should be the right one for the right gasket type.

No

scratches, specially in radial direction. from foreign objects.

Clean

Flanged joints Installation and Inspection

Gasket centering

Check

gasket dimensions for precision.

Gasket

should be exactly centered.

Avoid

touching the bolts.

Flanged joints Installation and Inspection

Bolting procedure
Use

the proper equipment.

Follow

the right bolting sequence to provide even load distribution.

Apply

the required torque, No more No less.

W hat happens when bolts are over torqued ?

Squeezed

gaskets. Cracked flanges.

Flanged joints Installation and Inspection

Over torque cracked flange.

Summary
Recognize that flanged joints are a critical and potential hazard.

Proper design, material selection, proper installation, careful inspection shall lead to the highest quality and save pipe flanged joints.

Prepared and presented by: Akram Megdad / Sr. Mech. Inspector