Feb. 21,
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Ductile iron pipes are essential components in various water and wastewater systems, offering durability and strength. If you are considering purchasing ductile iron pipes for your infrastructure project, here's a comprehensive guide to help you make an informed decision.
Ductile iron pipes are made from a type of cast iron that undergoes a special treatment, resulting in a more flexible and resilient material compared to traditional cast iron. The ductile iron composition includes iron, carbon, silicon, and small amounts of other alloying elements.
Ensure that the ductile iron pipes you are considering comply with relevant industry standards. Common standards include ISO for water applications and EN 545 for sewerage applications. Checking compliance ensures that the pipes meet the necessary quality and performance criteria.
EN598 Ductile Iron Pipe
Clearly define the application and usage requirements for the ductile iron pipes. Consider factors such as the intended use (water supply, sewerage, etc.), the operating pressure, and the environmental conditions. Different projects may have specific requirements that impact the choice of ductile iron pipes.
Select ductile iron pipes with sizes and dimensions that match your project specifications. Consider the required diameter, length, and wall thickness based on the flow capacity and pressure requirements of your system.
Ductile iron pipes are susceptible to corrosion over time. Choose pipes with appropriate coatings and linings to enhance their corrosion resistance. Common coatings include cement mortar lining and polyethylene encasement, providing a protective barrier against aggressive environments.
Ductile Iron Pipe
Ductile iron pipes come with various joint types, including push-on joints, mechanical joints, and restrained joints. Consider the ease of installation and the desired level of joint restraint for your project. Leak-free joints are crucial for the long-term integrity of the pipeline.
Choose Reliable ManufacturersOpt for ductile iron pipes from reputable manufacturers with a proven track record in the industry. Check for relevant certifications and quality management systems to ensure that the pipes meet the required standards.
While upfront costs are important, consider the total cost of ownership. Assess factors such as installation ease, maintenance requirements, and expected lifespan to determine the long-term cost-effectiveness of the ductile iron pipes.
Check and adhere to local regulations and approvals governing the use of ductile iron pipes. This ensures that your project meets the necessary legal and safety requirements.
In conclusion, buying ductile iron pipes requires a thorough evaluation of project needs, standards compliance, coatings, joints, and other crucial factors. By carefully considering these aspects, you can select ductile iron pipes that not only meet your immediate requirements but also ensure the longevity and reliability of your water or wastewater infrastructure.
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A flange is the protruding rim that enable pipes, valves and other equipment to form a connection. Flanges also increase strength at the joint. They enable you to create a piping system while also allowing for fast disassembly. By providing access points, inspections or modifications can be carried out with relative ease.
How you make a pipe-flange connection varies. It depends on the type and the requirements of your piping system. Some are weld-on pipe flange, while others can be screwed on. The type of flange you choose will also depend on issues such as pressure capacity and application. But first, lets look at Common Flange types.
While specialty pipe flanges are available, there are six main types. Here they are, along with how to secure the flange on a pipe.
Theyre used in low-pressure systems on smaller pipes with thick walls. They also make it easy to connect and disconnect pipe systems without disrupting the entire system for maintenance or to make adjustments. To attach the flange on a pipe, the bores female thread is screwed onto the pipes external threads. These flanges are not welded on.
Typical use:
Flammable, hazardous or explosive applications where welding is dangerous
Ideal in restricted spaces where welding flange to pipe cant be carried out
The simple design is intended for small-size and high-pressure piping that do not transfer highly corrosive fluids. Socket weld flanges are attached by inserting the pipe into the socket and applying one fillet weld around the outside of the flange. First, the pipe is inserted in the socket of the flange. When it reaches the
bottom of the flange, the pipe is lifted out slightly by 1/16" (1.5mm) and welded. This gap allows for thermal expansion created by welding, minimizing the probability that the weld will crack. Not suitable for highly erosive or corrosive applications, as the gap is vulnerable to corrosion between the pipe end and the sockets shoulder.
Typical use:
Hydraulic pipes
Slides over the pipe and used with a stub end. Also known as loose-ring flanges, and back-up flanges. These flanges are used on piping fitted with lapped pipe or with lap joint stub ends. With the stub end, the lap joint flange is typically used in systems requiring frequent dismantling for inspection and cleaning. Another advantage is its ability to swivel and align with bolt holes. As the flange never comes into contact with the fluid, the flange is highly durable and can be re-used.
Not recommended in extreme or high-pressure temperature applications.
Typical use:
Low-pressure applications
When flange needs frequent dismantling for maintenance
These low-pressure flanges are thinner than most other flanges. With an inside diameter slightly larger than the pipes outside diameter, the flange slips onto the pipe. A fillet weld is applied at the top of the flange and at the bottom. The welds enhance strength and prevent leakage. Also known as hubbed flanges. Installation of slip-on pipe flanges is easy and therefore low cost.
The speed at placing the flange on the pipe saves costs, but those savings are reduced with the additional costs of two fillet welds which are needed for proper installation.
Typical use:
Cooling and firefighting water lines
Process lines for oil, gas and steam
The lack of an inner hole enables blind flanges to seal off the end of pipe systems, preventing flow. This makes it easier and more cost efficient to carry out pressure tests. The blind flange connection is also an ideal pipeline flange. You can stop the flow of fluid and safely add new pipes or new lines to the pipeline.
Without blind flanges, shutdowns and repairs would be incredibly difficult to handle. While shutoff valves solve the problem of stopping flow, the location of the valve can be a problem. For example, if the valves are a mile or two away, then youre looking at a significant amount of wasted fluid.
Blind flanges are installed with bolts, so theyre also easy to remove.
Typical use:
Testing pipe pressure
Creating access points to piping systems
Seal a piping system temporarily to make repairs, or permanently
Also known as weld bend flanges. Their long necks are butt welded to a pipe. The flanges bore matches that of the pipe, reducing turbulence and erosion. This flanged connection relocates stress to the pipes, ensuring a decrease in high-stress concentration at the bottom of the flange. When installing, weld neck pipe flanges must be positioned parallel at the time of fitting. Flanges at opposite ends of a pipe should typically have the same bolt-hole direction too.
Typical use:
Piping systems with repeating bends
In conditions with wide fluctuations in temperature and pressure
Volatile and hazardous fluids
Type
Pressure capacity
Pipe sizes
Use for
Threaded
Low
Small
Attaching without welding
Lap joint
Low
All
Systems that need frequent disassembly
Slip on
Low
All
Low installation cost; easy assembly
Blind
Very high
All
Flow pressure testing; closing pipes
Welded neck
High
All
High-pressure systems; extreme temperatures
The flange face is the area on the head where your gasket will go. The three most common types are:
Raised face (RF)
Ring type joint (RTJ)
Flat face (FF)
Flanges with different faces should not be mated. For example, a raised face to flat-face flange connection will result in leakage from the joint, per ASME code B31.3.
The Most Common type is the raised face flange. Its name comes from the raised gasket surface, above the bolting circle face. The raised face concentrates more pressure on a smaller gasket area. In turn, this increases the joints pressure containment capability.
The height of the raised face is determined by the flanges pressure rating. Likewise, the higher the pressure rating, the bigger the flange diameter, the more bolts needed and the thicker the flange.
Raised face vs. flat face flange, also called full face flange, isnt an issue. They play different roles. Instead of a raised face, this is a flat surface. Consequently, the gasket surface is the same plane as the bolt frame, covering the flange from its inside diameter to outside diameter.
Full face is designed to avoid the bending that flanges undergo as bolts are torqued.
Cast iron can break during this process, which is why this material is often used to make flat face flanges. The design prevents this problem from happening.
High temperature, high-pressure flanges or rather, flanges used in extreme environments, utilize a ring-type-joint face. These flanges often have a raised face with a ring groove machined into it. They can also have grooves cut into their faces with steel ring gaskets. The flanges seal when the bolts are torqued, compressing the gasket between the flanges into the grooves.
The purpose behind a raised face flange is to concentrate more pressure on a smaller gasket area, increasing the joints ability to contain the pressure. Ring-type-joint face flanges dont use gaskets. The groove within the flange enables the ring to center itself when the bolts are torqued. As the process pressure increases, so, too, does the sealing pressure.
Typically used:
Raised face flange
Flat face flange
Ring-type- joint face
Process plants (chemical, etc.)
l
Oil & gas
l
Goto MIDAS to know more.
l
Valves
l
Cast-iron equipment
l
Low-pressure water pipe systems
l
Severe applications: high pressure and high temperature (up to 1,382F/ 750C)
l
The pipe flange face is vulnerable to damage during handling and transport, so you need to think about flange covers. This flange cover shown here is made of durable and flexible polyethylene. It protects both raised and flat face flanges, along with full-face gaskets.
Flange protectors are also critical. The studded full face flange protector here is also made of polyethylene and provides full coverage by inserting the lugs firmly into the bolt holes.
Understand more about flange covers in our guide, Why Flange Covers are Essential.
The raised face flange protector shown here has an adhesive backing for fast application.
You can learn more about flange protection in Pipe & flange protection: a quick buyers guide.
Whether steel pipe flanges or a plastic flange, you should base the material you choose on its application. Typically, the materials should match your pipe material, but again, it depends on your application. For example, if your piping system is used for air or other non-corrosive applications, then your flanges and pipes may not need to be of the same corrosion-resistant material as acidic or caustic liquids.
Otherwise, if youre interested in say, carbon steel slip-on flanges, you need to match the grade steel you choose to the pipe. Common flange materials include:
Carbon-steel flanges are alloyed primarily with carbon. Carbon steel has a high hardness and strength that increases with carbon content but lowers ductility and melting point. Carbon steels range from mild and low, with 0.160.29% carbon to ultra-high carbon steel, with around 12% carbon. Steels with carbon content above 2% are considered cast iron.
Just as you can enhance properties in plastics with additives, you can alloy steels with other elements to enhance the properties of your chose steel. Common alloys include molybdenum and chromium. Through different elements, you can increase a steels strength, ductility, corrosion resistance, and machinability.
Stainless steel is alloyed with chromium in amounts above 10%. Its chromium that gives stainless steel a higher corrosion resistance than carbon steel, which easily oxidizes from air and moisture exposure. Stainless steel is ideal for corrosive applications that also require high strength. Different grades of stainless steels yield different outcomes. You can learn more in our guide, Understanding stainless-steel grades.
When iron is alloyed with carbon, silicon, and other alloyants, the result is cast iron. Cast irons have good fluidity, castability, machinability, and wear resistance. They tend to be brittle to a degree with low melting points.
This is a low-density metal with medium strength. Malleable and ductile, its more corrosion resistant than typical carbon and alloy steels. Aluminum is suitable for flanges that need both strength and low weight, such as for irrigation applications.
A PVC flange is low cost and durable. PVC pipe flanges also have the advantage of being both chemical and corrosion resistant. Additives can make PVC more flexible and softer. PVC flange connections can provide extra protection to underlying pipes. Theyre also popular for water-treatment processes, favored by the agricultural industry and used in domestic plumbing. Lightweight and easy to install, PVC flanges are perfect for PVC pipe systems.
For all flange types excluding ring-type-joint faces, youll need gaskets. Choose them based on factors such as operating temperature, the fluid being conveyed by the pipeline, flange type, size, pressure class or rating and other specifications. First, however, you need to know material properties, which can be enhanced with additives.
Suitable for
EPDM
Natural rubber/SBR
Neoprene
Nitrile
Butyl
Silicone
Keytones
Hot oils
Ozone
Weather resistance
Abrasion resistance
Low-moisture permeability
Low-gas permeability
Seawater applications
High temperatures
Low temperatures
Vibration suppression
General chemical resistance
Animal fats
Flange dimensions are determined by the nominal pipe size (NPS) and the pressure class that your application requires. The higher the pressure rating of the class, the higher the size and dimensions of the flange. Typically, a 1/2" pipe flange will belong to the 150-pound pressure class. For threaded flange, a 4" pipe flange is the largest size available.
Large diameter flanges are in higher pressure classes. Below are the different classes:
150 lbs
300 lbs
400 lbs
600 lbs
900 lbs
lbs
lbs
Flange types and sizes vary, but theyre manufactured according to the standards set by organizations. For example, a long weld neck flange ASME B16.5 conforms to ASME standards, and might differ slightly from another standard. ASME B16.5 swivel flange dimensions a type of weld neck flange have equivalents in EN and MSS standards.
(If you see, for example, ANSI 150 swivel flange dimensions, this is incorrect. ANSI at one time published standards and started working with ASME in . At the time standards appeared as ANSI/ASME, but by , ASME had taken over standards.)
So your first task is determining the standard youll work to, which will likely follow whats commonly used in your area.
Size standards are set according for each pressure class.
Flanges are integral to the oil and gas industry, but theyre still a bit of a mystery to the average consumer. The piping systems that we rely upon today cannot function properly without flanges, yet they often are poorly maintained or bought in the wrong form. The more that is known about flanges, the less risk there will be that consumers invest in parts that dont really work for them.
Below are some of the facts that you may not know about flanges. These key pieces of equipment can be challenging, but they are necessary for the continuing function of the pipeline industry.
There are two different methods used for the creation of flanges. One is casting, while the other is forging. Both forged and cast flanges can work well, but each of the production method has advantages and disadvantages.
Cast products are essentially created when molten metal is poured into a mold or vessel in order to create the desired shape. Forged products are created when steel ingots or billets are exposed to mechanical and thermal pressures, which manipulate them into different shapes.
The main issue with cast flanges is that they are more prone to internal defects. This means that they cannot be used in extremely high-pressure situations, as they may fail suddenly with no warning. Due to their risk of internal flaws, cast flanges are also more likely to be heavily affected by corrosion.
In contrast, forged flanges are not only more reliable, but ultimately able to withstand more pressure. Forged parts actually have 37% higher fatigue strength, which means that they last longer. Therefore, its better to invest in high-strength forged products as they are usually better long term investments when used within high-pressure applications.
Typically, flange distributors will offer many different types of flanges. There is no single type of flange that is right for every situation. Rather, they need to be selected carefully. If the wrong flange is used in a project, it will fail. Some of the popular types of pipe flanges include blind, weld neck, slip-on, lap joint, threaded, socket, and orifice flanges. Each of these serves a different purpose.
An orifice flange, for example, is meant to house an orifice meter that can track the flow speed within a pipe. This makes it one of the more complex forged parts on the market. On the other hand, a blind flange is considered one of the simplest flange designs. Its little more than a disk used to block the opening of a pipe, with its main difference being that it lacks an opening in the center through which fluid can flow.
If multiple types of products are needed for one project, its wise to work with a single distributor for all of them. This helps avoid sourcing issues and ensures that all of the products are made with the exact same quality standards.
Lots of materials are used to create this product, including carbon steel and stainless steel, as well as aluminum, cast iron, bronze, and even plastic. At times, different materials may be used to create the same single flange. This is because such products are known as lined flanges, and are essentially built on internal layers of different lining materials. The performance of a product can be affected by the materials used, but the production process is just as important.
Its important to know that the product youre buying is of the correct material grade. Otherwise, it can be far too easy for you to buy a flange that is not suitable for your project. The material grade comes in a combination of numbers and letters and is indicative of the use, mechanical properties, and chemical composition of a product. Study material grades carefully before making a purchase decision.
Without the correct flanges in place, a project can fail spectacularly, resulting in injury or even loss of life. Pay careful attention to the types of flanges being bought for a product, as well as where they came from and how they were made.
Flanges are an integral component in many industrial applications, especially in the construction, petrochemical, and oilfield industries. They are used to connect pipes, valves, pumps, and other equipment in a piping system. A flange provides a secure and leak-proof joint, which is critical in applications where fluids or gases are transported at high pressures or temperatures. In this blog post, we will discuss the seven most common types of flanges used in industrial settings.
A blind flange is a flat plate with bolt holes that is used to close the end of a piping system. It is commonly used in applications where future expansion or maintenance may be required. Blind flanges are also used to cap off pipes or valves that are not in use. They are available in a range of sizes and materials to suit different applications.
A weldneck flange is a type of flange that has a long tapered hub and a neck that is welded to the pipe. The neck provides reinforcement to the pipe and allows for easy alignment during installation. Weldneck flanges are commonly used in high-pressure applications or in pipelines that carry corrosive fluids. They are available in various sizes and materials.
A slip-on flange is a flat plate with a bore that slips over the end of a pipe. The flange is then welded to the pipe, creating a secure and leak-proof joint. Slip-on flanges are commonly used in low-pressure applications or in pipelines that carry non-corrosive fluids. They are available in a range of sizes and materials.
A socket weld flange is a type of flange that is welded to the pipe using a socket weld connection. The socket weld connection provides a high-strength joint and allows for easy alignment during installation. Socket weld flanges are commonly used in high-pressure applications or in pipelines that carry corrosive fluids. They are available in various sizes and materials.
A threaded flange is a type of flange that has threads on the inside bore and outside diameter. The flange is screwed onto the pipe, creating a secure and leak-proof joint. Threaded flanges are commonly used in low-pressure applications or in pipelines that carry non-corrosive fluids. They are available in a range of sizes and materials.
A lap joint flange is a type of flange that is used with a stub end. The stub end is welded to the pipe, and the lap joint flange is bolted to the stub end. Lap joint flanges are commonly used in applications where frequent disassembly is required. They are available in various sizes and materials.
A long weldneck flange is similar to a weldneck flange, but it has a longer neck. The longer neck provides additional reinforcement to the pipe and allows for easy alignment during installation. Long weldneck flanges are commonly used in high-pressure applications or in pipelines that carry corrosive fluids. They are available in various sizes and materials.
In conclusion, flanges are a critical component in industrial piping systems. Choosing the right type of flange for your application can ensure a secure and leak-proof joint, which is essential for maintaining the safety and efficiency of your operation. Whether you need a blind flange, weldneck flange, slip on flange, socket weld flange, threaded flange, lap joint flange, or long weldneck flange, Trupply has you covered with a wide range of options in different sizes and materials. Contact us today to learn more about our flange collections and how we can help you find the right solution for your needs.
Trupply is the leading Pipes, Flange & Fittings industrial supplier for construction, petrochemical, and oilfield customers because we offer competitive prices, exceptional customer service, and reliable delivery times. Visit us at www.trupply.com to learn more.
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