Flat face flanges are ideally used in piping system for joining pipes, valves, pump and other equipments. Although they are less complex and more affordable in implementation to make direct connections between components, their use for high-pressure applications has drawn some questions. Specifically, this article will discuss the general use of flat face flange, their general uses, and how they might be modified for use in high-pressure systems. The complete absence of any taper on the face of the flange characterizes it. Flat face flanges are manufactured using carbon steel materials, stainless steel, or ductile iron in their typical applications.
Challenges of using flat face flanges in high-pressure systems
A gasket blowout is the main problem with flat face flanges in high-pressure systems. First of all, no high surface area contains or forms a cavity to hold the gasket in place, which results in slipping out especially when subjected to higher pressure. This lack of confinement is an issue that can jeopardize or cause the seal to leak and can be risky regarding applications that need an extreme level of containment. Potential problems with flat face flanges under high pressure include: If pressures go above the design limits of the flange, gaskets tend to move or even burst. This is due to the lack of reinforcement of the end-flange design, and thus, it is tough to seal the joint with high pressure. Unlike the conical face flange, which can only sustain a specific amount of bolt torque before deformation, it is inadequate for high pressures.
Enhancing flat face flanges for high-pressure use
Indeed, flat face flanges are mainly employed in low-pressure operations, but some measures could be adopted to enhance their suitability in higher-pressure applications. However, this approach has limitations and must be measured to avoid flange deformation. This gasket is also helpful in maintaining the flange in a protective status against deformation where a high bolt is present. Using high-thickness material for the flange enhances its capability for long service life. Stainless steel applications can improve the long-term durability of such products.
Alternatives to flat face flanges in high-pressure applications
The raised face flange and other types are the RTJ and tongue-and-groove flanges. They are used for high-pressure designs with grooves, raised faces, and metal-to-metal contact. Such designs provide good gasket support and a more reliable seal in high-pressure systems, where flat face flanges alone cannot take it.
Cost effectiveWhile flat flange facing is versatile and relatively less expensive, it is hardly designed for high-pressure operations due to the dangers of gasket blowout and leakage. Moderate high-pressure applications are helped in performance with high-strength bolts, a full-face gasket, and proper material selection for a flat flange facing; however, in systems involving extreme pressure, another flange, such as a raised face or RTJ, is more appropriate. It is essential to understand the limitations and strengths of flat face flanges to ensure piping systems are safe and serviceable for an extended period in all pressure environments.
