A flange is a mechanical device that looks like a circular disk with bolt holes around the parameter. It helps connect different equipment of the piping system. Flanges come in different shapes and sizes. They are chosen based on their pressure and temperature rating to make sure they can work in certain environmental conditions.
Flanges help companies connect multiple pipelines together. So there is no leakage and the system keeps working seamlessly. They play an important role in high risk industries like oil, gas and petrochemicals. They ensure worker safety and low machine downtime, saving companies reduce their cost and increase the product output.
Bolts and Nuts: It helps connect the flanges together and create a tight seal.
Gaskets: It is placed between flanges and makes sure there is no leakage of fluid.
Flange Faces: Different faces are designed based on pressure and temperature requirements. Different faces can make difference in choosing bolts and gaskets.
Flanges do look like a simple piece of metal but they play a vital role in ensuring safety of workers and maintaining smooth operations.
There are many types of flanges, they come in various shapes and sizes. Each and every flange is designed for specific application to work under certain conditions. Here, we are listing some of the most common flange types available in the industry.
 These flanges are welded to the pipe and are an ideal choice for pipelines operating in high pressure environments. Weld neck flanges include a long tapered hub which increases its strength. They’re mostly used in the petrochemical industry, to prevent any leakage. |
 These flanges slide over the pipe and are then welded in place. They’re easier to align than weld neck flanges, making them popular for lower-pressure applications. Their main advantages include lower cost and less precision cutting the pipe to length. |
 Blind flanges are essentially plates that seal the end of piping systems or pressure vessel openings. They’re ideal for piping systems or vessels that need regular inspection or access. |
 Threaded flanges use thread to connect threaded pipes. You can use these flanges in conditions where welding can cause damage. These are mostly used in low-pressure environments where human safety is not at risk |
 If your company uses smaller, and high pressure piping systems, you can use socket weld flanges. They flangesa are usually inserted into the pipe before welding. They are the best choice if you want to pass fluid or gas with high pressure in pipelines. |
 Comprising two pieces, the lap joint flange works with a stub end that interfaces with the pipe and the flange, which can rotate around the stub end. They’re best for systems requiring frequent dismantling for inspection and cleaning. |
 It is used with a lap joint flange to provide an effectively sealed joint in non-critical applications. This allows free rotation of the outer flange and easy bolt-hole alignment. |
 an aid in connecting different-sized pipes. It ensures the critical transition of pipe size changes without compromising the piping system’s structural integrity for a smooth flow transition. |
 This is the design of a flange manufactured for particular applications, mainly in high-stress areas, where they support the piping system. Because of its strength and durability, it mainly finds applications in the oil and petrochemical industries. |
 The RTJ (Ring Type Joint) flange handles, as a rule, very high-pressure values and very high temperatures, where a metal serves as the gasket ring. It is commonly used in gasket sealing where effectiveness is needed, such as in the oil, gas, and petrochemical industries. |
 This is a flange used with orifice plates to measure the flow rates of liquids and gases in pipelines. The design has pairs of pressure taps for differential pressure measurements, making it a must for flow quantity monitoring. |
 This category includes orifice, expander, and reducing flanges, which are designed for specific functions such as measuring fluid flow, connecting pipes of different sizes, and changing pipe diameters. These are less common but crucial for their specialised applications. |
Selecting the correct flange for your piping system ensures efficiency, safety, and longevity. Here are the factors to consider when choosing a flange:
The flange you choose must withstand the system’s maximum pressure and temperature. High-pressure systems often require weld neck flanges for strength and durability, while lower-pressure systems might use slip-on or threaded flanges.
Different types of fluid require different flange types to ensure that there is no leakage. If you are passing corrosive fluids through pipes, consider using corrosion resistant flanges made from stainless steel or aluminum.
Diameter and thickness of your pipe will play an important role in choosing a flange. For example,
If a larger pipe is carrying high pressure fluids, it will require stronger flange
If the same pipe is carrying low pressure fluids, you might need a flange with lower strength.
What are you going to use your flange for? What will be its application? How often do you want to access it? These questions will help you determine the type of flange you want. If your piping system needs frequent cleaning, you can use lap joints or threaded flanges.
Check for the pipes, gaskets, and bolts used in your company. Share details with the manufacturer. They will make sure that the flanges you get are compatible with your existing pipeline.
Flanges you choose must adhere to industry standards like ANSI/ASME, ISO, and others. It ensures that the flanges meet minimum safety and performance requirements. These standards include dimensions, tolerance capacity, material and more.
By considering these factors, you can choose the right type of flange for your business, ensuring performance and safety of your piping system.
Once you have selected the type of flange, its time to install them. But you are done yet, you have to maintain them and check them regularly to ensure that there is no leakage.
Here are some guidelines to help you with flange installation and maintenance.
Inspect Before Installation: Once you get the delivery of flanges, check them for any
defects. Make sure that they are exactly the same dimensions that you asked for. Otherwise, it won’t fit with your existing pipeline systems.
Clean Flange Faces: Before installing, clean flange faces and make sure there is no rust or oil on them.
Correct Gasket Placement: Always use the appropriate gaskets for different type of flanges. Make sure it’s aligned properly to prevent any leakage.
Align Flanges Properly: Misalignment can lead to uneven pressure and potential leaks. Make sure flanges are aligned correctly before bolting them together.
Even Bolt Tightening: Always follow a star pattern to tighten bolts. It ensures that even pressure is distributed across gaskets.
Use the Right Tools: Use proper tools to tighten bolts. Only apply recommended torque settings, and avoid over tightening, as it can result in damage.
Regular Inspections: Make visual inspections in specific time intervals and look if there is any leakage, corrosion or any kind of damage to flanges.
Gasket Replacement: Replace gaskets between flanges regularly. If there is any leak or if you reassembled anything, consider replacing gaskets.
Bolt Integrity: Check bolt integrity and tightness periodically. Loosened bolts can lead to leaks; however, be cautious not to over-tighten during adjustments.
Corrosion Control: If flanges are exposed to corrosive environment, there is risk of them being rusty. So, make sure to take corrosion protection measures. It ensures longevity of the equipment.
Record Keeping: Always keep a record of maintenance and take notes of what maintenance is done. It will help you figure out issues earlier before they turn into a disaster.
Use these guidelines to increase the lifetime of your pipeline and ensure worker safety.
The flange industry is always changing with technological advances and introduction of new materials and designs in the market. It is because the industry is continuously trying to address existing challenges and increase output for the companies.
Here we have listed some trends that are shaping the future of flange manufacturing.
Flanges that can operate under extreme temperature and pressures are in high demand. Companies are looking for super alloys that can offer corrosion resistance properties along with the ability to operate in extreme conditions. These super alloys are helping companies achieve extended lifespan of their equipment.
Along with these advanced materials, manufacturers are also looking forward towards a sustainable future, manufacturers are exploring innovative ways to produce flanges using recyclable and eco-friendly materials. It will help them reduce their carbon footprint and meet the UN Sustainable Development Goals
With advancement in IoT technologies and AI, manufacturers are now designing flanges that are smart. These smart flanges can detect pressure, temperature and any leaks in real time. These automation will help companies reduce downtime and improve predictive maintenance.
There is one more concept gaining market traction. Manufacturing flanges that doesn’t require any welding. It will help companies to do maintenance more efficiently.
Manufacturers are using 3D printing methodology to improve their output of complex designs. There is a little room for error when flange production is done using machines. But 3D printing can help companies develop flanges accurately based on requirements, with no room for error. It can also help company save cost on waste materials, and logistics cost for returned items.
Along this, companies are also embracing AI and automation. AI tools are helping them improve precisions, reduce errors and lower production costs.
Reducing emission and lifecycle analysis is something that companies have been looking for years now. They are focusing on innovative ways to reduce emissions and waste. Also more and more companies are now conducting life cycle analysis. It is helping them understand how often they have to replace a part, and what measures should be taken, so they can reduce its impact on the environment.
As these trends continue to gain traction, the flange manufacturing industry is seeing significant improvements in performance and environmental impact.
We, at KMS Multi Engineers, are committed to manufacture flanges that meet the quality standards while adhering to the UN Sustainable Development Goals (SDG). We have the latest technologies and skilled workforce in place to develop flanges that meet your requirements. We have various types of flanges available in different material ranges.
Drop an email or call us to share your requirements for flanges. Find our contact details here.
A seasoned Electronics and Communications engineer, Amitkumar Miyani brings over 12 years of experience in Pipe Fitting Manufacturing to KMS. He plays a pivotal role in overseeing the Purchase, Sales, and Finance departments, ensuring operational efficiency and financial stability.
