A Flange is considered as unsung heroes in the industrial world. It is the main component helpful in connecting pipes, pumps, valves and other types of equipment together. A reliable connection and sealing of the flange demands to choose a perfectly size of components. Here you can explore a detailed step-by-step guide to learn measuring of flange size accurately for industrial application. A proper and precise measurement of flange can ensure efficiency, safety, compatibility for the piping system. Also, understand the significance of measuring flange size and more. Let’s together break down this process further in a blog.
Flanges are the most vital component which is used to connect the components together offering durability, flexibility etc at point of installation. These allow an easy and quick assembly and disassembly of connected pipes. Thus, it is typically applicable for setting a reliable and strong sealing in the piping system. There is a wide sector of industries which prefers the use of flanges in their area to ensure safety, minimize downtime of system and more. It includes industries like power generation, oil and gas, water treatment, chemical processing and more.
Flanges mainly serve as a connector for the pipe having different diameters. Thus, it is helpful in joining pipes with tight and secure sealing.
Flanges imparts the surface for attachment of gasket which ultimately works together to set up a tight seal for minimizing leaks in operating conditions.
Bolts are mainly used for joining two flanges together. Therefore, it gets detached easily providing in hand maintenance or convenience for modification of the system.
There are mainly six types of flanges available in the market to connect different sorts of piping systems in one frame.
Slip on flanges: It easily slid over the pipe and then welded together. Slip on flanges are used for low pressure areas.
Weld neck flanges: The design contains a long tapered hub or neck which is then welded together with pipe. It is preferably used in high pressure conditions.
Blind flanges: It is used when a system needs complete seal off or closing of a particular end of pipe. Mainly it is used for isolation of particular sections for maintenance, repair, inspection, testing etc.
Socket weld flange: The pipe is inserted down into the recessed area of socket and then welded together. It is typically used to connect pipes with different diameters and facing high pressure environments.
Threaded flange: Threaded flanges are screwed with pipe with help of external threads. It is installed in low pressure areas.
Lap joint flange: Lap joint flanges work with stub end type of pipes. It is installed in an area which demands frequent assembly and disassembly of set up.
The selected type of flange is bolted together with a gasket placed in between in order to set up a reliable seal. The bolts are tightened applying pressure on gasket. This process ensures a tight fit in between connected pipes which prevent leaks in the system. The selection of particular size and dimension is preferred on the basis of industrial standards. It is crucial to select flange size and dimension according to standards for maintaining safety, compatibility, low cost, easy availability etc after installation. These standards as follows:
Follow these steps as mentioned in sequence to accurately measure the flange size and minimize chances of leaks.
You need at least the following essential tools to start measuring of flanges:
Before you sit to measure the flange size, it is important to understand each of its components. These are listed below:
Outer diameter: It is considered as total width stated across the flange.
Inner Diameter :- it is considered as the total width of the center hole where the pipe will get welded.
Bolt circle diameter: It is the diameter of the circle which eventually passes through the center of all bolt holes.
Bolt hole diameter: The diameter of each particular bolt hole.
Number of bolt holes: It is the counting of holes where bolts could fit in place.
Hub diameter: Some of the flange designs possess a hub section which demands separate measurement.
Face type: Most of the flanges possess a specific type of flange face. It includes raised face [RF], flat face[FF], ring type joint [RTJ] etc. These faces impart great influence when measuring size of the flange.
Pick up the caliper or measuring tape and measure the flange from edge to edge. Record this measurement as OD. Remember to perfectly align the tape while measuring for getting accurate results. This measurement is further useful while matching the flange size with standard charts.
Measure from the center part of one bolt hole directly to the center of the flange further till the opposite bolt hole. Tag this measurement as bolt circle diameter. Increase your accuracy of measurement with placing ruler on the exact center of each hole. If your flange plant has an even number of bolt holes then try measuring each as a pair of opposite holes. However, odd numbered bolt holes on plates need measurement of two closest ones.
Make use of the caliper or scale for measuring the diameter of one particular bolt hole. Remember to measure the inside portion of diameter in an accurate way. Countdown total number of bolt holes present on surface of flange plate. Record the diameter along with the number of bolts.
Some of the flanges possess the hub or thickened section in design around the neck of flanges. You need to measure the diameter of the hub if present in your selected flange. Additionally, measure the thickness of the hub from the thickest part of the flange.
Thickness of the flange is measured from one side/face to another. The measurement of thickness is important for determination of flange ratings in a certain way from standard charts. It is because thickness of the flange reflects the pressure handling of the flange.
Check for the flange face types. It mainly includes raised face, ring type joint or flat face. The type of face helps in determination of compatibility of flange with piping and gaskets.
Take all your measurements in hand and sit to compare these against the standard flange specification chart. Preferably use the standard chart of ANSI, DIN or ASME for easy comparison.
Once you finish to match the flange with standard chart, double check all your measurements to avoid further mess. Document all of these measurements securely. Preserve it for future reference because these measurements will help in replacements, repairs or maintenance etc.
Follow this systematic approach to measure your flange size with precise accuracy for industrial applications.
There are several reasons which prove beneficial for measuring flange size.
Correct size of the flange is important for ensuring compatibility when connected in the piping system. Misalignment or incompatible size of flange can lead to costly downtime of the system, high risk of leaks and potential failure in operation conditions. Flanges come in a variety of sizes in the market. You can select one after precisely measuring it according to the standardization chart.
Proper and precise size of the flange helps in creation of tighter seals which can pause hazardous situations in systems which need to deal with toxic and high pressurized areas. Inaccuracy in measurement of flange size can lead to poor connection of seal. Ultimately it invites the chances of dangerous leaks in the system which is harmful for workers, environment and equipment too.
Misfit after installation of the flange could lead to frequent downtime in the system and unknowingly increase the maintenance expenses. Measurement of the accurate size of flange ensures proper replacement, repairs and maintenance with efficiency. It could lead to smooth, uninterrupted operations after rework in operating conditions.
A well fitted flange can help a smooth flow of the fluid which ultimately reduces the risk of any sort of blockage. Also, these features help in operating the system to its optimum level without any worries of failure. Systems which constantly have to face high pressure and temperature need an installment of the proper size of flange. It will give stability and efficiency for getting optimal performance in hand.
Industrial standards prevail with strict standards which dictate flange pressure ratings, materials, dimensions and more. Accurate measurement of the flange size can ensure quality control, safety certifications for manufacturers on each component. Non-compliance with flange size might encounter legal issues, reputational damage, fines and more.
In applications involving a high pressure or temperature environment, flange size measuring is essential for getting structural integrity. Accurately sized flanges could handle stressful environments, avoid risk of joint failure etc. in industrial plants.
Flange in incredible option for connection of the piping system. Measuring the accurate flange size is vital to ensure safe performance, compatibility, regulatory compliance, minimizing cost and more. It will make for foundational practice in the industrial system to set up a perfect size of flange. Understand the significance of selecting appropriate flange size before you actually install in the set up.
1. Which are the industrial standardization charts useful in measuring flange size?
Industrial standards like ANSI, ASME, DIN , EN1092 , BS 10 Table D , Table E etc are mostly used for matching the size of flange size.
2. What is the main use of the flange in industries?
In industries, flange is applied for connection of the pipe together having same or different diameters.
3. What is the nominal pipe size helpful in connecting the flange size together?
The common nominal pipe size which is connected through the flange includes ½, ¾, 1, ¼, 1, 2, 3, 4, 6, 8, 10, 12 and more.
4. What are the materials used for composition of flange?
Commonly materials like mild steel , stainless steel, carbon steel, alloy steel, cast iron etc are used for composition of flange.
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.
