BTO 3153

STATIC EQUIPMENT

CHAPTER 3
PIPING & FLANGE LECTURER: DR AGI AUGUSTINE
FLANGES

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 FLANGES
❑Flanges

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TYPES OF FLANGES

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TYPES OF FLANGES

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TYPES OF FLANGES

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TYPES OF FLANGES

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TYPES OF FLANGES

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TYPES OF FLANGES

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TYPES OF FLANGES

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 FLANGE SIZE & RATING
❑Temperature Rating: Piping materials such as carbon steel, stainless steel,
and alloy steel have different mechanical and chemical properties. The
same material can handle different amounts of stress at different
temperatures.
oBased on the ability of a material to handle the stresses at a given
temperature, ASME B31.3 has devolved the maximum allowable stress
value of the material at a specific temperature
❑Pressure Rating: The pressure rating is safe working or maximum operating
pressure with respect to the working temperature. It depends on the
materials’ Stress-Strain characteristics. It is available in different Codes and
Standards.
❑Pressure-Temperature Rating: Pressure- temperature rating is the
maximum allowable non-shock gauge pressure at the specific temperature
for a given material.
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 FLANGE SIZE & RATING
❑Flange Rating: As per ASME B31.3, ratings are the maximum allowable
working gauge pressure at the given temperature and pressure class for
applicable material.
oASME B16.5 has listed the Pressure-Temperature ratings for flanges.
These ratings are established based on the prime factor of hydro testing
of the flanged fittings to the bursting and by adding a factor of safety of
3.0 at the rated working pressure and ambient temperature.
oASME/ANSI B16.5 has established these temperature-pressure ratings by
using the formula given below and listed in the tabular form for all
materials at different flange ratings.

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 FLANGE SIZE & RATING
Flanges pressure rating in psig for common carbon steel ASME flanges
( A105 / A350 LF2 / A350 LF3 / A350 LF6)

Temperat 150# 300# 400# 600# 900# 1500# 2500#

ure (F°)

-20 to 100 285 740 985 1480 2220 3705 6170

200 260 680 905 1360 2035 3395 5655

300 230 655 870 1310 1965 3270 5450

400 200 635 845 1265 1900 3170 5280

500 170 605 805 1205 1810 3015 5025

600 140 570 755 1135 1705 2840 4730

650 125 550 730 1100 1650 2745 4575

700 110 530 710 1060 1590 2655 4425

750 95 505 675 1015 1520 2535 4230

800 80 410 550 825 1235 2055 3430

850 65 320 425 640 955 1595 2655

900 50 230 305 460 690 1150 1915

950 35 135 185 275 410 685 1145

1000 20 85 115 170 255 430 715

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FLANGE SIZE & RATING

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 FLANGE SIZE & RATING
oFrom the above table, the following important points can be noted:
▪ With an increase in temperature, the pressure-withstanding capability
of the same material decreases.
▪ With an increase in pressure class rating, pressure capability
increases.
▪ With a change in flange material pressure-temperature table and
pressure

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 FLANGE SIZE & RATING
❑Examples: The above table shows that in a 150 lb carbon steel
flange,
oThe allowable pressure is 285 psi at 100°F,
o170 psi at 500°F, and
o20 psi at 1000°F.
oThe only temperature at which the flange is rated for 150 psi is near
500°F.
oHigher class flanges are rated at their nominal pressure rating only at
near 850°F. See the cells in yellows.

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 FLANGE SIZE & RATING
❑Type of Flange Pressure-Temperature Rating: Normally two types of
pressure-temperature ratings are used for piping/pipeline flanges. They
are:
▪ Pressure-Temperature rating for API flanges and
▪ Pressure-Temperature rating for ASME or ANSI Flanges.
oFor oil drilling and wellhead system applications, API flanges are used
which are based on the API 6A standard.
o The pressure-temperature rating for API flanges ranges from 2000 psi to
20,000 psi.
oFor all other applications, ASME or ANSI flanges are used which are based
on ASME
oB16.5 for sizes up to 24″ and ASME B16.47 for larger sizes.

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 FLANGE SIZE & RATING
❑Flange Class: ASME has developed a flange Class considering
temperature and pressure rating. There are seven:
oClass 150#, 300#, 400#, 600#, 900#, 1500#, and 2500#.
oThe higher the flange ratings, the heavier the flange and can withstand
higher pressure and temperature. So, when the temperature goes up for
a given material, the maximum allowable pressure goes down, and vice
versa.

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FLANGE SIZE & RATING

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 FLANGE SIZE & RATING
oThe higher the flange rating, the higher the pressure it can withstand at
temperatures.
oFlanges with higher ratings have more thickness and more weight and are
stronger as compared to flanges with lower ratings.
oWith the change in pressure rating class, flange dimensions vary, and
hence, the flange of one pressure class may not fit with its higher or lower
class flange.
oWith the increase in pressure rating, the number of bolts increases which
increases the bolt area. The increase in bolt area reduces flange leakage
tendency by increasing force and moment-carrying capability

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 FLANGE SIZE & RATING
❑Calculation for Determining Flange Rating
Assuming an ASME B16.5 flange for a Carbon Steel pipe carrying
fluid at 300°C design temperature and 50 bar design pressure. To select the proper
flange.
❑Solutions
▪ From the Figure, We can see that the Maximum Pressure that the A-105 flange
with 150 pressure class can withstand at 300 Deg C Temperature is 10.2 bar
which is lower than our design pressure (50 bar). So not suitable.
▪ Next, we will move to the next higher class i. e, pressure class 300. Here the
maximum pressure capability is 39.8 bar which is also less than 50 bar. So rating
class 300 is also not suitable.
▪ Now e will move to the next higher class i. e, pressure class 400. Here the
maximum pressure capability is 53.1 bar which is more than our design pressure.
▪ So Selected flange class is 400.
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 FLANGE SIZE & RATING
❑Calculating Rated Flange Pressure
o The pressure-temperature ratings for Class 300 and higher can be derived by the
following equation:

oHere,
▪ C1 = 10 when S1 is expressed in MPa units and the resultant pt will be in
bar units
▪ C1 = 1 when S1 is expressed in psi units and the resultant pt will be in psi
units)
▪ Pr = pressure rating class index. For all designations, Class 300 and
above, Pr is equal to the class designation (e.g., for Class 300, Pr = 300).
▪ pt = rated working pressure, bar (psi), for the specified material at
temperature T
▪ S1 = selected stress, MPa (psi) for the specified material at temperature
T.

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 FLANGE SIZE & RATING
oNow if we apply the above equation for the above-mentioned sample
problem, we will get the following output.

oGiven,
▪ Pt=50 bar
▪ S1=133 Mpa
▪ C1=10

oHence
▪ Pr=(8750*50)/10*133= 329.
oAs the calculated Rated working pressure is more than 300, we will select
class 400 for the flange

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 BOLT & SPANNER SIZE
Metric

Thread Size Spanner Size A/F DIN (mm) Spanner Size A/F ISO (mm)

M1.6 3.2 3.2

M2 4 4

M2.5 5 5

M3 5.5 5.5

M3.5 6 6

M4 7 7

M5 8 8

M6 10 10

M7 11 -

M8 13 13

M10 17 16

M12 19 18

M14 22 21

M16 24 24

M18 27 27

M20 30 30

M22 32 34

M24 36 36

M27 41 41

M30 46 46

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 BOLT & SPANNER SIZE
M33 50 50

M36 55 55

M39 60 60

M42 65 65

M45 70 70

M48 75 75

M52 80 80

M56 85 85

M60 90 90

M64 95 95

M68 100 -

M72 105 -

M76 110 -

M80 115 -

M90 130 -

M100 145 -

M110 155 -

M125 180 -

M140 200 -

M160 230

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 BOLT & SPANNER SIZE
Inch

Thread Size Spanner Size A/F ASME (inch) Spanner Size A/F BS (inch)

1/4 0.438 0.445

5/16 0.500 0.525

3/8 0.562 0.600

7/16 0.625 0.710

1/2 0.750 0.820

9/16 0.812 0.920

5/8 0.938 1.010

3/4 1.125 1.200

7/8 1.312 1.300

1 1.500 1.480

1.1/8 1.688 1.670

1.1/4 1.875 1.860

1.3/8 2.062 2.050

1.1/2 2.250 2.220

1.3/4 2.625 2.580

2 3.000 2.760

2.1/4 3.375 -

2.1/2 3.750 -

2.3/4 4.125 -

3 4.500

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 BOLT TIGHTENING SEQUENCE/TECHNIQUE OF TIGHTENING
BOLTS
oThe correct placement of the gasket and proper tightening of bolts in a
flanged joint will ensure a leak-free joint. Proper bolt tightening will
ensure uniform load distribution in all bolts without damaging the
gaskets. The following procedure describes how to tighten flange bolts.

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 BOLT TIGHTENING SEQUENCE/TECHNIQUE OF TIGHTENING
BOLTS
oCheck the following points prior to flange bolting.
▪ Before inserting the gasket in between the pipe flanges, check the flanges
are parallel and co-axial (When none of the bolts is installed in the
flange).
▪ As per ANSI B31.3 clause no. 335-C, permitted tolerances are as follows:
Flange faces shall be aligned to the design plane within 1 mm in 200
mm(1/16 in. /ft) measured across any diameter; flange bolts holes shall
be aligned within 3 mm (1/8 inch) maximum offset.
▪ If pipe flanges are not meeting the ANSI B31.3 requirement, the piping
shall be rectified.
▪ All gasket seating areas shall be cleaned properly before gasket insertion.
If serration is damaged, re-serration must be done.

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 BOLT TIGHTENING SEQUENCE/TECHNIQUE OF TIGHTENING
BOLTS
oCheckpoints for Gasket prior to tightening flange bolts

▪ Ensure the gasket of the correct dimension and of specified material is used.
▪ The gasket shall be located correctly to ensure full sealing as indicated in the
drawing. For example – a gasket on the tube sheet of an exchanger needs to
be located so that the outer periphery of the gasket matches the OD of the
tube sheet at all points.
oExamine the gasket in advance and ensure that it is free from defects.

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 BOLT TIGHTENING SEQUENCE/TECHNIQUE OF TIGHTENING
BOLTS
oFlange Bolt Tightening Procedure: It is important that all bolted joints are
tightened uniformly and in a diametrically staggered pattern.

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 BOLT TIGHTENING SEQUENCE/TECHNIQUE OF TIGHTENING
BOLTS
▪ In the case of pipe flanges 8″ NB & up to 12″NB and having a pipe with a
spacer piece and a minimum of two gaskets (which are getting compressed
simultaneously during tightening) the distance between two flanges should be
measured at four locations like 12’o clock, 3’o clock’ 6’o clock and 9’on clock
positions and maintained equal for even tightening.
▪ The tightening shall be gradual and uniform.
▪ In case of flanges above 12” NB distance between the flanges shall be
measured in 8 locations for uniform tightening.
▪ All stud bolts of 7/8″ and above shall be tightened using a torque wrench.
▪ While tightening the bolt with torque wrenches (for pipe / Manway flanges)
ensure that the tightening load to each bolt is applied as uniformly as possible.
▪ The tightening shall be carried out in three or four stages in steps of 30, 50 &
70 percent of the final torque value
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BOLT TIGHTENING SEQUENCE/TECHNIQUE OF TIGHTENING
BOLTS

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 BOLT TIGHTENING SEQUENCE/TECHNIQUE OF TIGHTENING
BOLTS
❑ Wrong Practices during Flange Bolt Tightening
oMany a time, plant operators use wrong practices while flange bolt tightening
as follows:
▪ Improper sequence of bolt tightening.
▪ Reuse of old gasket.
▪ Procurement of un-specified material.
▪ Improper storage of gaskets.
▪ Use of many gaskets to fill a large gap between flanges.
▪ Use of ordinary fasteners instead of high-tensile fasteners
▪ Use of dirty/rusted fasteners without lubrication.

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 FLANGES ALIGNMENT

oFlange alignment tools are mechanical or hydraulic devices that are used to
align or re-align flange joints during pipework construction, maintenance,
commissioning, or shut-down activities. During initial bolting or after opening
the bolting for maintenance and repair work, the flanges are, in general,
misaligned. For proper fit-up of the flanges and smooth working, the flanges
are required to be properly aligned. The flange alignment tools are very
useful in such activities.
oVarious industries like chemical, petrochemical, pipeline, water, wastewater,
refinery, oil and gas, power, food processing, etc. Use flange alignment tools
to ensure that pipes and other fittings are perfectly aligned. Flange alignment
tools are very cost-effective solutions for alignment and they make the
alignment job easier.

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 FLANGES ALIGNMENT
❑Working of Flange Alignment Tool: At the location of the greatest
misalignment, the flange alignment tool is attached to the flange joint.
The tool then pushes and pulls the flanges to bring them in the correct
alignment. Depending on the sizes of the flanges, a range of flange
alignment tools is available. The working steps of a typical flange
alignment tool can be explained as follows:
▪ Step 1: Determine the location of the greatest misalignment.
▪ Step 2: Attach the Flange Alignment tool at the location of the greatest
misalignment.
▪ Step 3: Adjust and secure the tool to the pipe using the strap.
▪ Step 4: Rotate the Screw handle until contact is made with the flange
circumference.
▪ Step 5: Continue to rotate the handle till the flanges are pushed and
pulled and aligned

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FLANGES ALIGNMENT

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 FLANGES ALIGNMENT
❑Types of Flange Alignment: Depending on the working mechanism,
there are two types of flange alignment tools that are used for
industrial flange alignment purposes.
▪ Mechanical Flange Alignment Tools and
▪ Hydraulic Flange Alignment Tools
oMechanical flange alignment tools generate the pulling force by
mechanical action whereas hydraulic flange alignment tools use the
hydraulic action of a fluid to generate forces for alignment. The load-
carrying capability of hydraulic flange alignment tools is usually more
and they are more suited for very large-diameter piping and pipeline
flanges. Mechanical flange alignment tools are preferred for small
diameter lower pressure flange applications.
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 FLANGE FACE INSPECTION
oBased on the usage, design parameters, and used material, various
international, American, European,… standards have been issued to
control the mandatory parameters and meet the requirements during the
production.
oThird-Party inspection agency “TPIA” as an independent side, controls
these points through the inspection and surveillance of needful tests and
reports the observation against the Inspection and Test Plan “ITP” or
Quality Control Plan “QCP” and related acceptance criteria to the
customer.

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FLANGE FACE INSPECTION

Produced pipe flanges

ready for final inspection
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 FLANGE FACE INSPECTION
❑Identity Check in Flange Inspection: First of all the flanges should be
checked against the Purchase Order (PO), bill of material (BOM),… to
identify the offered items are complied with the requested items to be
inspected or not. The inspector controls the identification number of the
items.
❑Material Inspection
▪ Material Test Certificates: The technical inspector controls the quality
certificates of used material to produce the flange. The chemical
requirement composition and mechanical properties should comply with
specified standards in the ITP/QCP or data sheet as an approved
document.
oAs a step of “Flange inspection” the material test certificates should be
reviewed and stamped by the third-party representative.

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 FLANGE FACE INSPECTION
▪ Flange Inspection- Visual control: A visual inspection should be
performed on the flanges to check the appearance of the surfaces, holes,
welding (for welded type). It should be free from any defect, surface
flaws, slag, crack, burn through, spatter, etc. Also, for forged flanges, no
forging scars and cracks are allowed. Machined surfaces must be checked
for any burrs, hazardous scratches, and other defects that reduce flange
strength and connection reliability.
❑Dimension Inspection: A dimensional check should be performed by a
calibrated caliper, ruler, or tape measure under the presence of the TPI
inspector on Inner diameter, outside diameter, thickness, sealing surface
diameter, flange neck, neck diameter, bolt hole center circle diameter,
bolt hole, the width of the sealing surface and other parameters.

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FLANGE FACE INSPECTION

Flange inspection- Dimensional

check

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 FLANGE FACE INSPECTION
❑Flange Face Control: The inspector should consider the flange face types
i.e., Flat Face (FF), Raised Face (RF), Male and Female (M&F), Tongue and
groove (T&G), Ring Type Joint (RTJ), requirements according to the relevant
standards and general arrangement drawing.

Raised face flange under inspection

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 FLANGE FACE INSPECTION
❑Flange Inspection-Paint Control
▪ Visual Inspection:The painted items should be checked visually for any
paint defects e.g. pinhole, blistering, touch up, delamination, etc

Paint imperfection on the

flange to be repaired

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 FLANGE FACE INSPECTION
▪ Dry Film Thickness Check: The thickness of the coating should be
measured and compared with the specified minimum and maximum
allowed thickness which has been specified in the painting procedure.

Measuring dry film

thickness by an elcometer

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 FLANGE FACE INSPECTION
▪ RAL color code check: Applied paint color coding will be considered against the
ordered RAL code.
❑Flange Final Inspection-Marking Check: The marking must include the
mandatory information specified in the standard. Usually, the below
information is engraved on the produced flange:
▪ Manufacturer’s Name or Trademark
▪ Rating Designation
▪ Material Designation
▪ Melt Designation – as required by the specification
▪ Valve Trim Identification – valves only when required
▪ Size Designation
▪ Identification of Threaded Ends
▪ Ring-Joint Facing Identification
▪ Permissible Omission of Markings

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 PIPING INSULATION
❑Piping Insulation: Pipe Insulations are materials or combinations of
materials wrapped around the pipe which retard the flow of heat energy.
oPipe insulation reduces energy losses to a great extent and thereby reduce
energy cost.
❑Functions of Pipe Insulation: A piping insulation system serves three
principal purposes:
▪ The significant reduction in heat transfer of thermal energy to and from
the surface of the piping system (Heat Conservation). So, piping insulation
conserves energy.
▪ The prevention of moisture formation and collection on the surface of the
piping system due to condensation on cold surfaces (Cold Insulation).
▪ The prevention of potentially injurious personnel contact with the surface
of the exposed piping system (Personal Protection).

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 PIPING INSULATION
oHowever, there are various other benefits of piping insulation as listed below

▪ Piping insulation facilitates temperature control of the process.

▪ Prevent vapor flow and water condensation on cold surfaces.
▪ Increase the operating efficiency of heating/cooling, power, and process
systems.
▪ Reduce major damages in the piping during fire or accidents.
▪ Prevent pollutant emissions to the atmosphere to a great extent.
▪ Sometimes Steam traced/Electric traced insulation, Regeneration insulation,
jacketing, etc. are used as per process/licensor requirements.
▪ Fireproofing, fire protection, and acoustic insulation (to control noise and
absorb vibration) are provided based on project specifications/ ITB
requirements.

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 PIPING INSULATION

❑Piping Insulation Types: Piping insulation can be classified based on

various parameters like:
oBased on the Pipe Insulation Function
▪ Hot Insulation
▪ Cold Insulation
▪ Personal Protection Insulation
▪ Acoustic Insulation
oBased on Insulation Material Types
▪ Fibrous Insulation
▪ Cellular Insulation
▪ Granular Insulation
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 PIPING INSULATION
❑Piping Insulation Types Based on the Function of Pipe Insulation
▪ Hot Insulation: Hot insulation is applied on the hot surfaces of the piping
system to prevent the energy flow from flowing fluid. So, the main aim of
hot piping insulation is heat conservation. Mineral Wool, Glass Wool,
Calcium Silicate, etc. are normally used as Hot insulating material. Hot
Piping Insulation is typically applied for process temperatures above 60°C.

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 PIPING INSULATION
▪ Cold Insulation: Cold Insulation is the insulation used on cold surfaces of
the piping system to avoid heat gain from outside (Cold Conservation) or
to avoid Condensation. Polyurethane Foam, Expanded Perlite Foam,
Expanded Polystyrene Foam, etc. are the widely used cold insulating
materials.

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 PIPING INSULATION
▪ Personal Protection Insulation: Personal Protection insulation is provided
to avoid personal heat injury. All exposed piping surfaces that exceed 60
degrees C are provided with personal protection insulation. The areas that
are not accessible by construction or operating personnel can be left
exposed. An open mesh metal guard, mineral wool, etc. are used as
personal protection insulation material.

Personal Protection Insulation in Operating

Plant
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 PIPING INSULATION
▪ Acoustic insulation: Acoustic Insulation is provided for all piping that is
considered a potential sound source. The main purpose is to reduce the
noise (vibration) to an acceptable limit. The minimum thickness for
acoustic insulation is normally 75 mm. Acoustic Foam, fiberglass,
polyester/polyurethane foams, rock wool, Mass Loaded Vinyl, etc. are
used as Acoustic Insulating material.

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 PIPING INSULATION
❑Piping Insulation Types based on insulation material types
▪ Fibrous Insulation: Fibrous insulation consists of small diameter fibers
which finely divide the air space. The fibers may be perpendicular or
parallel to the surface being insulated, and they may or may not be
bonded together.
oCommon fibers used in piping insulation are Silica, slag wool, rock wool,
and alumina-silica. Among these, Glass fiber and Mineral Wool are the
two most widely used piping insulations of this type. Their fibers are
normally bonded with organic binders for structural integrity.

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 PIPING INSULATION
▪ Cellular Insulation: Cellular pipe insulation material comprises small
individual cells separated from each other. Common cellular material used
as pipe insulation is glass or foamed plastics such as cellular glass,
phenolic foam, or nitrile rubber.

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 PIPING INSULATION
▪ Granular Insulation: Small nodules containing voids or hollow spaces
constitute granular insulation. As gas can be transferred between the
individual spaces, It is not considered a true cellular material. This type is
manufactured as loose or pourable material or combined with a binder
and fibers. Sometimes they undergo a chemical reaction to form rigid
insulation. Calcium silicate and vermiculite are examples of these types of
insulations.

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 PIPING INSULATION MATERIAL
▪ Low-temperature insulation is frequently made of expanded cellular
plastic or foam rubber material.
▪ Moderate temperature insulations are made from grass fiber
products.
▪ High-temperature insulation is made of preformed cementations or
refractory materials or blankets made from ceramic fibers.
▪ Insulation and accessory materials have to be 100% asbestos-free.
▪ Normally mineral fiber, cellular glass, ceramic fiber, glass fiber,
polyisocyanurate, polyurethane foam, Rockwool, Glass Wool,
Expanded Perlite, Flexible Elastomeric Foam (FEF), Flexible aerogel
blanket, Calcium magnesium silicate wool (CMS), Alkaline earth
silicate wool (AES), Calcium Silicate, etc. are used as pipe insulation
material.

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 PIPING INSULATION MATERIAL
Pipe Insulation Material Density (kg/m3) Temperature Limitation

Mineral Glass Fibre up to 535°C

Mineral Wool 140 up to 700°C

Rock Wool 140 up to 550°C

Glass Wool 80 up to 450°C

Calcium Silicate 200-280 up to 815°C

Expanded Perlite 192 up to 550°C

Expanded Silica up to 535°C

Refractory Fiber 150 up to 1750°C

Polyurethane Foam 40 from -150°C to 110°C

Polyisocyanurate 40-64 from -150°C to 125°C

Cellular Glass 147 up to 350°C

Ceramic Fibre 250 up to 760°C

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PIPING INSULATION MATERIAL

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 PIPING SYMBOL & DRAWINGS
❑Pipe Symbols: Pipe Drawings are much different from specific weld
symbols but they do have a similar relationship from part to symbol.
Some individuals will not see these in their line of work but it is
important to be aware of them.
oAs with weld symbols, pipe symbols are a reflection of what that part
would look like in theory. For example if a 90 degree elbow is to be
placed in service the drawing will reflect a 90 degree angle. There
may be multiple symbols for one fitting or part depending on the
fashion it is to be installed (Butt weld, Socket Weld, Threaded.)

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 PIPING SYMBOL & DRAWINGS
❑Coordination System Symbols for Isometrics: Below is a breakdown of
almost every type of fitting and connection.

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PIPING SYMBOL & DRAWINGS

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PIPING SYMBOL & DRAWINGS

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PIPING SYMBOL & DRAWINGS

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THANK YOU

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