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What is a Steel Flange? - eeww0824 - 10-08-2021
What is a Steel Flange?
THE BASICS OF STEEL FLANGES
Stainless steel flanges provide an easy access for cleaning, inspection or modification. They usually come in round shapes but they can also come in square and rectangular forms. The flanges are joined to each other by bolting and joined to the piping system by welding or threading and are designed to the specific pressure ratings; 150lb, 300lb, 400lb, 600lb, 900lb, 1500lb and 2500lb.
A flange can be a plate for covering or closing the end of a pipe. This is called a blind flange. Thus, flanges are considered to be internal components which are used to support mechanical parts.
MATERIALS
Each flange material is to be considered for its application prior to ordering, this is due to the structural integrity of the application that the flange will be used on.
Currently, the most common materials for flanges are:
Carbon steel
? ASTM A105/A266 Gr.2 (high temperature carbon steel flanges)
? ASTM A350 LF1 to LF3 (low temperature carbon steel flanges)
? ASTM A694 Gr. F42/F52/F56/F60/F65 (high yield carbon steel flanges to match API 5L linepipes)
Alloy Steel
? ASTM A182 Gr. F1/F2/F5/F9/F11 Cl.2/F12 Cl.2/F22 Cl.3/F91 (alloy steel flanges)
Stainless / Duplex Steel
? ASTM A182 F304/304L, 316/316L, 321, 347, 348 (stainless steel flanges), 904/904L
? ASTM A182 F51 (duplex flanges)/F53-F55 (superduplex flanges)
Nickel Alloys / Superalloys
? ASTM B166 UNS NO6600 (Inconel 600)
? ASTM B564 UNS N06625 (Inconel 625)
? ASTM B425 UNS-NO8800 (Incoloy 800)
? ASTM B564 UNS N08825 (Incoloy 825)
? ASTM B160 UNS N0200 (Nickel 200)
? ASTM B564 UNS N04400 (Monel 400)
? ASTM B564 UNS N10276 (Hastelloy C-276)
Titanium
? ASTM B381 Gr.2 (Titanium)
In industry, flanges, including stainless steel flate flanges, stainless steel slip on flanges, and stainless steel weld neck flanges, form a vital connecting link for piping, valves and other equipment. They provide an easy point of access for cleaning, inspection, modification, and for necessary repairs. A flanged joint provides a strong seal in a closed system, and is made by bolting together a gasket flanked by two flanges.
In heavy industry, these flanges need to be especially resilient or they can prove to be the weak point in a system. It is important therefore, to ensure that the flanges you are choosing are up to the task.
Why are stainless steel flanges preferred for industrial use?
In all metal applications, corrosion is a constant consideration. Rust, chemicals and other environmental factors all take their toll on metals. Therefore, the choice of flange would need to be resistant to these factors. Stainless steel outperforms other metal flanges – including carbon steel – due to its high resistance to corrosion.
Stainless steel is incredibly strong and durable, capable of withstanding immense pressures. By comparison, aluminium may be a cheaper option but it is softer and not as reliable under heavy stress.
Any system or piece of equipment is only as strong as its weakest part. Joins and welds are traditionally a weak point, so it would be wise to make sure that your choice of metal is correct for the application.
Depending its use, a flange may need to withstand high very temperatures. The correct grade of stainless steel flange would ensure that there is no warping or deformation which would compromise the system.
Cheaper, lower grade metal flanges may be fine for certain applications, but if you want your system or equipment to work at maximum capacity, then you should consider spending a little more on stainless steel flanges.
WHAT ARE PIPE FLANGES AND HOW DO THEY WORK?
Offering a reliable way to connect pipe systems with the various equipment, valves, and other components of virtually any processing system, flanges are the second most used joining method after welding.
Using flanges adds flexibility when maintaining piping systems by allowing for easier disassembly and improved access to system components.
A typical flanged connection is comprised of three parts:
Pipe Flanges
Gasket
Bolting
In most cases, there are specific gasket and bolting materials made from the same, or approved materials as the piping components you wish to connect. Stainless Steel flanges are some of the most common, and mostly stainless steel threaded flanges. However, flanges are available in a wide range of materials so matching them with your needs is essential.
Other common flange materials include Monel, Inconel, Chrome Moly, and many others depending on the application.
The best option for your needs will depend on both the system in which you intend to use the flange and your specific requirements.
COMMON FLANGE TYPES AND CHARACTERISTICS
Flanges are not a one-type-fits-all sort of solution. Sizing aside, matching the ideal flange design to your piping system and intended usage will help to ensure reliable operation, a long service life, and optimal pricing.
MAKING THE CONNECTION: FLANGE FACING TYPES
Flange design is only the start when considering the ideal flange for your piping system. Face types are another characteristic that will have a major impact on the final performance and service life of your flanges.
Facing types determine both the gaskets needed to install the flange and characteristics related to the seal created.
Common face types include:
Flat Face (FF): As the name suggests, flat face flanges feature a flat, even surface combined with a full face gasket that contacts most of the flange surface.
Raised Face (RF): These flanges feature a small raised section around the bore with an inside bore circle gasket.
Ring Joint Face (RTJ): Used in high-pressure and high-temperature processes, this face type features a groove in which a metal gasket sits to maintain the seal.
Tongue and Groove (T&G): These stainless steel blind flanges feature matching grooves and raised sections. This aids in installation as the design helps the flanges to self-align and provides a reservoir for gasket adhesive.
Male & Female (M&F): Similar to tongue and groove flanges, these flanges use a matching pair of grooves and raised sections to secure the gasket. However, unlike tongue and groove flanges, these retain the gasket on the female face, providing more accurate placement and increased gasket material options.
Many face types also offer one of two finishes: serrated or smooth.
Choosing between the options is important as they will determine the optimal gasket for a reliable seal.
In general, smooth faces work best with metallic gaskets while serrated faces help to create stronger seals with soft material gaskets.
Duplex alloys were originally created to counter the corrosion problems caused by chloride-bearing cooling waters and other aggressive chemical process fluids. They are known to be Duplex because of its mixed microstructure with about equal proportions of ferrite and austenite, duplex stainless steels are a family of grades, which range in corrosion performance depending on their alloy content. The term “Super-Duplex” is used to denote highly alloyed, high-performance Duplex steel with a pitting resistance equivalent of >40 (based on Cr % + 3.3Mo % + 16N %).
With a high level of chromium, Duplex steel plate flange provides outstanding resistance to acids, acid chlorides, caustic solutions and other environments in the chemical/petrochemical, pulp, and paper industries.
Super Duplex contains 25% chromium, 7% nickel, 3.6% molybdenum as well as copper, tungsten, and nitrogen, they are highly alloyed steel with high PREN for use in aggressive environments.
The alloy consists of around 40-50 percent ferrite in the annealed condition. The super duplex microstructure has the high strength of the ferritic grades in spite of retaining the corrosion resistance of the austenitic grades. It is common to see Super Duplex Steel being used as a practical solution to chloride-induced stress cracking. It also has outstanding resistance against sulfide-stress corrosion cracking in sour-gas environments.
Super Duplex UNS S32750 Flanges help the material withstand pitting and crevice corrosion. These duplex steel blind flanges are also resistant to chloride stress corrosion cracking, to erosion-corrosion, to corrosion fatigue, to general corrosion in acids. They have good weldability and very high mechanical strength.
Benefits of Super Duplex Flanges
High strength,
High resistance to pitting, crevice corrosion.
High resistance to stress corrosion cracking, corrosion fatigue, and erosion,
Excellent resistance to chloride stress- corrosion cracking
High thermal conductivity
Good sulfide stress corrosion resistance,
Low thermal expansion and higher heat conductivity than austenitic steels,
Good workability and weldability,
High energy absorption.
Applications of Super Duplex Steel Flanges
Heat exchangers, tubes and pipes for production and handling of gas and oil,
Heat exchangers and pipes in desalination plants,
Mechanical and structural components,
Power industry FGD systems,
Pipes handling solutions containing chlorides,
Utility and industrial systems, rotors, fans, shafts and press rolls where the high corrosion fatigue strength can be utilized,
Cargo tanks, vessels, piping and welding consumables for chemical tankers.
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Right, that’s enough of the techy stuff, lets take a look at how the LED came to be.
The LED appeared as early on 1962, and were used as practical components in electric items, such as warning lights. The early LEDs were limited to low-intensity infrared light such as those still used in remote controls, and do you remember those first LED watches with a black screen and red numbers appeared when you pressed a button? The first visible light LEDs were also low intensity and limited to red, but modern LEDs are now available across the visible, ultraviolet and infrared wavelengths and can be extremely bright.
SO WHAT IS LED LINEAR
LED Linear Lighting is simply the use of many ‘Light emitting diodes’ packaged together in a long, narrow housing to create a strip of light. This simple concept revolutionised the way we light spaces.
Before the conception of LED Linear, lighting long commercial spaces such as offices, warehouses and retail situations was notoriously tricky. Such spaces were lit with large, industrial incandescent bulbs. Linear lighting started evolving in the 1950s with fluorescent tubes, mainly used in industrial spaces. By the 1970s this technology was being used in homes, garages and workshops, and retail spaces. This further created a need for lower cost, better-looking fittings. Creating a continuous uninterrupted line of light wasn’t possible before LED because the fluorescent tubes had to stop and start leaving a black or dark spot.
The improved looks didn’t happen until the early 2000’s when the early version of commercial LED Linear as we know it was made. The demand for LED Linear lighting is now huge and continues to grow. The difference now is that linear architectural lighting and LED technology has broadened the applications of commercial LED linear fixtures. The industry continues to evolve with improvements in aesthetics and performance, moving away from the old, traditional housings, utilising materials in a better way and incorporating more advanced technology.
LED LINEAR REGULATIONS AND STANDARDS
There’s a couple of key things that Synergy’s clients like to know about standards and regulations around commercial lighting, particularly for use in public and work spaces; just ask and we can advise!
One of the main regulations is regarding glare from commercial lighting. Excessive glare from lights, such as LED highbay light can cause eyestrain and headaches, so it’s important to reduce direct glare and reflected glare within an office environment. Unified Glare Rating (UGR) is used as a measure of glare and is calculated by the glare from all visible lamps divided by the background lamination of the room. In an office environment, a UGR of less than 19 is considered acceptable for best concentration. Want to find out more about UGR19?
Lux levels are important too. This is essentially the light level in a space, usually measured from a specified height (such as desk height in an office). CIBSE (Chartered Institution of Building Services Engineers) specify recommended lux levels for different areas in the commercial building sector.
WHY COMMERCIAL LED LINEAR?
Our clients appreciate a host of benefits boasted by commercial LED Linear lighting, including;
Aesthetics – if looks are important to you, then LED Linear has a pretty strong offering. It provides a massive amount of versatility for creating unique and eye-catching designs. Bespoke angles, curves and customised RAL colour powder coating are just a few of the options available that make LED Linear an easy choice.
Directional light – LEDs are directional, reducing the need for reflectors and diffusers that can trap light.
Colour temperature – LED Linear lights offer a large range of colour temperatures, which affect the way the eye interprets the light. From cool white to warm white, different temperatures can be used to create mood and atmosphere in a space. Neutral white, or 4000 kelvin to use its technical name, is recommended for offices and retail areas which provides the most comfortable environment.
Cost effective – an obvious advantage, LED Linear is extremely efficient to run due to its low energy usage, and also its inherent longevity; an LED will typically last many times longer than a fluorescent tube.
Once you’ve made the decision to use commercial LED Linear lighting for your space, there are a bewildering array of options, so we’ve broken it down into some of the key factors for you to consider:
LED LIGHT TYPE
The three main types of LED Linear are pendant, surface mounted or recessed.
LED Linear Pendant lighting use suspension wires to hang from the ceiling, and are most suited to rooms with generous ceiling height. These are also ideal for creating stunning accent lighting – think about hanging over reception desks, stairways or atriums.
Surface Mounted LED tri proof light are mounted onto the surface of the and are suited to situations where pendant lights could be too low due to ceiling height.
Recessed LED linear are recessed into a surface, be it a ceiling, wall or . This offers clean, uninterrupted lines.
LED LINEAR PROFILE
LED Linear lights with LED lichtband system can be straight or shaped to create dramatic sculptures for ultimate effect.
Straight profiles will typically create a subtler effect, but can also be used to create eye catching geometric style designs.
Curved profiles will typically help to create flow in a space and give a feeling of movement.
Round profiles are often used to help divide space into zones, particularly in open plan spaces. For example LED rings suspended lower than surrounding lighting over collaborative zones creates a sense of focus.
LED LINEAR APPLICATIONS
LED linear is very versatile and can be used for a number of commercial lighting applications, such as LED sport light.
General lighting – this is the high level lighting that provides that background light in a space. Care should be taken that light is distributed evenly and glare is avoided.
Task lighting – this is focused light for specific tasks, such as a low hung LED ring over a collaborative area.
Accent – light used for aesthetic effect, such as to highlight or mirror the shape of a distinctive architectural feature or give a sense of height to a room. Our recessed LED Linear lights are perfect for this. Let your imagination run wild and the results can be stunning!
Here are the top 4 reasons why LED Emergency Lights are better:
Efficiency — LEDs use a process called electroluminescence, meaning that electrons are combined with electron holes when switched on. Incandescent bulbs have a filament that burns to create light, which means energy is being used to create heat. There is no filament used in LEDs, so heat is not a major issue. LEDs are thinner and lighter, which makes them more economical and efficient. Low-temperature performance, ability to be controlled digitally, and the robust nature of the bulbs make LED lights more efficient than others. Overall, LED lights typically produce a 30% energy savings compared to normal bulbs, and solar light might be a more eco-friendly product.
Lifespan — The lifespan of an LED bulb is about 50x longer than standard incandescent bulbs. The burning filament inside of an incandescent bulb wears out very quickly, which results in the bulb needing replaced. LED lights do not have a burning filament, which allow them to last approximately 50,000 more hours than a standard incandescent bulb.
Brightness — Brightness is extremely important when it comes to an emergency light. Emergency lights are used to illuminate the path for evacuation of the building in the event of an emergency. LED lights are some of the brightest types of bulbs available. They are much brighter than incandescent bulbs of the same wattage. LED lights are the best choice for brightness in an emergency light.
Maintenance — Inspections and testing are required for all emergency lights; LEDs are no exception. However, the extended lifespan makes replacement less likely. Constant replacement of non-LED bulbs can get costly. Emergency lights with LED bulbs can save your facility money in the long run.