Everything You Need To Know To Find The Best Custom Flanges

In this introduction to flanges, we&#;ll cover the different types of flange attachment methods, which flanges to choose for a variety of applications, and an overview of pressure and temperature ratings and how they apply to different types of piping systems.

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What Are Flanges and How Do They Work?

A flange is a protruding rim, lip, or rib that is used to increase strength or provide an attachment method to connect pipes, valves, and other equipment to form a piping system and to create an easy access point for cleaning, inspection, or modifications.

Flange Attachment Methods and Purposes

Flanges can be welded or screwed on, depending on the type of flange and piping system requirements. When selecting a flange type, some important aspects include pressure capacity, pipe size, and intended application.

• Ring or slip-on flanges have a center hole, and they slide onto a pipe end. The flange face extends beyond the pipe end to be welded into place.
• Lap-joint flanges are similar to slip-on flanges but are used in conjunction, which means that the flange doesn&#;t have contact with the medium in the pipe. These flanges don&#;t require welding, which allows them to rotate freely to line up with the mating flange.
• Threaded flanges are often used for smaller pipe sizes and do not require welding, which makes them a convenient option&#;however, they are not suitable for piping systems with thin walls.
• Socket weld flanges are used for small, high-pressure applications. The pipe is inserted into one end, then a fillet weld is applied around the outside of the flange. An expansion gap is required between the flange and pipe to reduce weld stress.
• Weld neck flanges feature a long, tapered hub that provides reinforcement and improved distribution of stress for use in high-pressure, sub-zero, or elevated-temperature applications.
• Blind flanges are flat, with no bore, and are used to finish off a piping system.

Common Flange Materials

Flange material can affect everything from connection methods to pressure rating, so it is an important consideration. While there are a variety of options, the best flange material varies by application requirements.

Some common flange materials include:

• Steel &#; The most common flange material, is preferred for strength
• Stainless Steel &#; Preferred for its higher resistance to corrosion and rust
• Aluminum &#; Lightweight material ideal for corrosion resistance
• Ductile Iron &#; A lower-cost option for backing flanges that can be used because the flange doesn&#;t come in contact with the medium

Flanges come in a variety of surface finishes, which determine the roughness or smoothness of the finished flange face. Flange faces may offer a smooth finish or can have serrations&#;small grooves on the flange face. The appropriate finishing technique depends on the intended service use.

The AWWA standard finish is between 24-55 serrations per inch and is suitable for a range of applications. Serrations may be continuous spirals or evenly spaced concentric grooves. Other finishing options include a mill (or rolled) finish and surface flanges that offer no finishing except where machining is required.

Coatings protect the flanges from corrosion or damage through shipping, storage, and use. These coatings include:

• Light oil or other rust-prohibiting material
• Zinc
• Paint
• Epoxy
• Galvanized

Outside of flange material and coatings, it is also important to differentiate between the different flange material sources.

• Import &#; These are popular due to their lower cost, but in some cases, like for government projects, they may not be appropriate.
• Buy America &#; This standard provides a preference for domestically produced materials, but there are provisions that allow for materials to be sourced from a list of approved countries if it is a small enough part of the total contract, domestic product availability is low, or the price is too high.
• Domestic &#; These flanges meet AIS (American Iron & Steel) standards, which allows imported raw components of the metal, but requires that the flange material be melted and manufactured in the United States.

How Are the Most Common Flanges Used?

To determine the correct flange for your application, consider flange size and attachment method, materials used to manufacture the flange, the pressure class rating, bolt hole size and placement, and which standards your flanges must meet. Refer to flange dimensions when selecting your pipe fittings&#;most often listed as outside diameter (OD), inside diameter (ID), bolt hole diameter and spacing, and thickness (T). Refer to flange dimensional tolerances if necessary specifications aren&#;t available, or consider a custom-machined fitting.

Slip-On Flanges

Slip-on or ring flanges are often used for high-temperature, low-pressure piping systems and can be used in applications with higher flow rates. Also called a &#;ring flange,&#; this style flange slides onto a pipe end through a center hole and the flange face extends beyond the pipe. The flange is then welded into place for a secure fit. Ring flanges may be manufactured to ANSI and AWWA standards, are available in Class 150 through , and are available in flat face or raised face styles.

Ring-type joint flanges are similar to ring or slip-on flanges, but are preferred for high-pressure applications as this type is paired with a gasket for improved sealing.

Lap-Joint Flanges

Lap-Joint flanges, also called back-up or backing flanges, are paired with stub ends or angle face rings. The backing flange slides over the pipe end, and welding is not required. This solution is ideal for ensuring flange bolt holes line up correctly as the backing rings are able to rotate to match bolt holes&#;connect the stub end and backing flange, line up the connection points, then align the bolt holes to complete the installation. Lap-Joint flanges are suitable for piping systems that require regular maintenance or that are dismantled often.

Threaded Flanges

Threaded flanges attach to pipes with threaded ends, no welding is required&#;making threaded flanges ideal in small spaces or areas where welding is not possible. This convenient option is often used for smaller diameter pipe sizes and high-pressure applications, but should not be used in a piping system with thin walls. Threaded flanges are available in a variety of materials and dimensions to meet a wide range of specifications.

Blind Flanges

Blind flanges are available with the same thicknesses and bolt hole patterns as other flange types, but are manufactured with no bore. They are used to finish off a piping system and can create an efficient, leak-proof seal when paired with a gasket and properly seated.

Weld-Neck Flanges

Weld-neck flanges feature a long, tapered hub that is welded to the pipe. Weld-neck flanges are used for high-pressure and sub-zero to high-temperature applications to distribute piping system stress and provide reinforcement.

Socket Weld Flanges

Socket weld flanges offer a higher fatigue strength over a slip-on flange when used for small pipe sizes and high-pressure applications. Choose socket weld flanges based on class and pressure rating, as well as pipe schedule. To assemble, the pipe is inserted into one end, then retracted slightly to form an expansion gap to reduce weld stress. Then, a fillet weld is applied around the outside of the flange. This assembly allows smooth fluid flow with no leakage.

Reducing Flanges

Reducing flanges are used in pipe-to-pipe connections when there is a change in pipe size. The bore matches the smaller pipe size so the larger and smaller pipes fit together properly. Reducing flanges are available in weld-neck, slip-on, and threaded styles.

Flanged Pump Connectors

Flanged pump connectors include flanges on either end of a hose&#;generally made of flexible braided steel or stainless steel&#;and are used to absorb pump vibration and reduce stress on the piping system. They&#;re also suitable when adjusting for minor misalignment. Pump connectors are also available with male X male threaded ends.

Overview of Flange Types and Benefits

Type of FlangePressure CapacityBenefits and UsesSlip-On FlangeLowLower-cost option; fits over the pipe for a snug fitLap-Joint FlangeLowEasier bolt hole alignment; good for applications that require frequent dismantlingThreaded FlangeLowNo-weld attachment for small-diameter applicationsBlind FlangeHighestTo seal off piping systems and provide easy accessWeld-Neck FlangeHighReduces pipe stress in high-pressure applicationsSocket Weld FlangeHighSmooth fluid flow, no leakage

Common Piping and Flange Standards

Flange standards cover everything from dimensions, materials, maximum pressure capabilities, temperature ratings, manufacturing technique, and other technical details. These classifications help determine which flange is appropriate for which applications.

There are a variety of piping standards, including these most common standards:

• ANSI/ASME (American National Standards Institute and American Society of Mechanical Engineers) is the industry standard for pipeline flanges in the United States.
• MSS (Manufacturers Standardization Society) is a standard used in steel pipelines.
• API (American Petroleum Institute) covers large diameter carbon steel flanges used in high-pressure oilfield applications.
• AWWA (American Water Works Association) is a set of waterworks industry standards that cover water treatment and supply.
• DIN (&#;Deutsches Institut für Normung&#; German Institute of Standardization) is a European metric standard that is used internationally, often in maritime applications.

ANSI Flange Temperature and Pressure Ratings

Flanges are rated based on the maximum pressure they can withstand at a particular temperature. There are seven main ANSI pressure ratings, from #150 to #. Flange performance is determined by the rating&#;generally, the lower the class number, the lower the pressure capability. This rating may be listed in a number of ways, including pressure rating, #, Lb(s), or class. This means that 300 Lb, 300#, and Class 300 all refer to the same pressure class or rating.

AWWA Flange Standards, Ratings, and Size Range

This table lists flanges by AWWA standard, class and drill pattern, PSI rating, and size to assist in determining the appropriate flange based on these specific requirements.

StandardClass/Drilling PatternPSI RatingRing/Slip-On Size RangeBlind Size RangeHub Size RangeAWWA C207 SteelClass B, # psi4&#; &#; 144&#;4&#; &#; 72&#;N/AAWWA C207 SteelClass D, # psi (4&#; &#; 12&#;), 150 psi (all other sizes)4&#; &#; 144&#;4&#; &#; 72&#;4&#; &#; 96&#;AWWA C207 SteelClass E, # psi4&#; &#; 144&#;4&#; &#; 72&#;4&#; &#; 96&#;AWWA C207 SteelClass F, # psi4&#; &#; 48&#;4&#; &#; 48&#;N/AAWWA C228 Stainless SteelClass SA, # psi (SPFH Series)2&#; &#; 12&#;2&#; &#; 8&#;N/AAWWA C228 Stainless SteelClass SB, # psi2&#; &#; 72&#;2&#; &#; 72&#;N/AAWWA C228 Stainless SteelClass SD, # psi (4&#;&#; 12&#;) 150 psi (all other sizes)2&#; &#; 72&#;2&#; &#; 72&#;N/AAWWA C228 Stainless SteelClass SE, # psi2&#; &#; 72&#;2&#; &#; 72&#;N/AAWWA C228 Stainless SteelClass SF, # psi4&#; &#; 48&#;4&#; &#; 48&#;N/A

The best flange style, material, and rating will ultimately depend on the intended application. We manufacture standard and custom flanges to meet the highest quality standard. Our full line of flanges can be viewed here.

If our standard flanges don&#;t meet your requirements our Custom Machining Shop allows the manufacture of custom parts as well as modifications to stock items, so you can get exactly what you need.

Planning to install a piping system? If yes, having pipe flanges and fittings of high quality and standard dimensions is crucial. It entirely depends on the flange manufacturer you have chosen. Using a better-quality piping system means it will not deteriorate soon and will last long.

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The quality of flanges directly impacts the efficiency and safety of various industrial processes. Therefore, selecting the right flange manufacturers becomes a crucial decision.

To feel assured in your fittings and flanges, read this blog to know what you consider while looking for flange manufacturers.

This blog will explain three things to look out for to help you find the right flange distributor for your projects.

Check supply capacity

One thing that you want to avoid is visiting multiple suppliers for different parts. It not only consumes your time but is also an exhausting process. You also run the risk of miscommunication between suppliers in terms of your project needs. What do you need to do to avoid this tedious work?

When you speak with any manufacturer or master distributor, look at products that a flanges distributor supplies. Do they have flanges or other products like forged steel fittings and long weld necks? The more products they offer, the less research you need to do to look for another supplier. Look for a one-stop solution for your pipe fittings and flanges needs, in particular one with dimensional data!

Customization

It is not necessary that every pipe fitting in the market meet the project&#;s unique needs. Most of the time, your project will have challenging demands, and you might need customization. Looking for flange manufacturers that offer custom flanges and other fitting products is a great idea.

There are various custom products that you might need for the project, including high-yield fittings and flanges, specialty flow nozzles, weld saddles, and finished wellhead components.

A top-notch flange manufacturer should have the capability to provide customization options. Whether it&#;s dimensions, materials, or special coatings, the manufacturer should be willing to tailor their products to your flange specification.

Communication

Communication is the key to success, no matter what kind of business you&#;re doing. It establishes a relationship between a customer and a supplier. If the flange distributor is ready to answer all your questions, it&#;s a green flag for you. One of the best ways to identify how well a shortlisted supplier will communicate with you is to call or them. The manufacturer you&#;re considering must pick up the or respond to emails quickly and efficiently.

Commitment to delivering quality

While looking for manufacturers, shortlist those who stick to internationally recognized quality standards such as ISO, AST, or ANSI. These products should pass the various quality checks. Give priority to that manufacturer that believes in delivering quality products.

Material selection

Flanges come in various materials, each suited for different applications and environments. From carbon steel to stainless steel, ensure the manufacturer offers a wide selection of materials. It will ensure that your chosen flanges can withstand the intended conditions and last for the duration of a project cycle.

Timely delivery

In the fast-paced world of industries, time is money. An efficient flange manufacturer produces quality products and delivers them within the agreed-upon timeframe. Delayed deliveries can disrupt your project schedule and incur unnecessary costs, so choose a manufacturer known for punctuality.

After-sales service system

It is crucial to check whether your chosen manufacturer provides an after-sales service system. It includes the following:

1. Technical services like installation, training, and maintenance.
2. Provides spare parts at a reasonable price or for free.
3. Offer a warranty period for products that involve both quality and performance problems
4. Skilled engineers to solve your problem within no time.

Cost-effective

Check whether the price the manufacturer is offering is reasonable and competitive. Some manufacturers construct stainless steel and alloys, and some focus on carbon, and others still specialty materials like copper or polymers. It is crucial to compare the price with similar products in size, material, and quality.

You must check for gaps between each flange type and its product categories. For instance, the stainless steel flange series price ranges from budget friendly commodity stock, to more cost considerable custom pieces.

Comprehensive Customer Support

A reputable flange manufacturer doesn&#;t just stop at delivering products; they provide excellent customer support, too. From pre-sales inquiries to after-sales service, their support team should be knowledgeable and responsive, helping you navigate any issues

Examine the flange production process

To ensure the quality of the flange, you must check the flange manufacturer&#;s production process. In this process, you can examine whether the production process sticks to the standard and completes following your requirements. You can ask them to improve their work processes if there is any deviation from your needs.

Additionally, verify whether the flange manufacturer&#;s quality control system is sound. You can check if they have access to different test equipment, such as a liquid penetrant testing, hardness testers (HRC), thickness gauges, and other non destructive test methods.

Also, ensure the flange manufacturer has a robust inspection system before shipping out or after finishing processing workpieces if required.

Conclusion

In a landscape where compromise is not an option, prioritizing quality is the foremost consideration. Seek manufacturers who align with esteemed industry standards and deliver products on time.

Flange diversity and customization capabilities are not just amenities but indicators of a manufacturer&#;s versatility. A manufacturer&#;s support team should embody expertise and responsiveness from initial inquiries to troubleshooting after delivery. Remember, the right flange manufacturer isn&#;t just a provider; they are partners in your pursuit of operational excellence.

Texas Flange is the flange distributor you can trust to supply the high-quality pipe fittings and flanges you require to get the job done. Contact us to learn more about our industrial pipe fittings and other products.

FAQ

Q.1  What role does a manufacturer&#;s experience play in this selection process?

A: The experience of a flange manufacturer matters significantly as it reflects their ability to understand industry demands, produce consistent quality, and handle different client specifications.

Q:2 What should we keep in mind during the selection process?

A: Apart from experience, reputation, certifications, customization, and pricing, factors like communication efficiency, after-sales support, and their willingness to provide references for their work can also influence your decision-making process.

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