Flange leaks are a common problem in petrochemical plants. It can cause great harm to factory operations as well as to the surrounding environment. In this article, Bao Tin Steel will mention the causes of flange leaks as well as how to solve this problem.
In just 10 minutes, you will know the factors that affect flange leaks and how to solve them. We invite you to follow along.
Overview of flanges
Flange is an important accessory in piping systems, equipment, machinery, etc. It is used to connect two pipes, equipment, or industrial valves. Flanges can be made of many types of materials, including steel, cast iron, stainless steel, copper, aluminum, plastic, etc.
Image of the flange at Bao Tin Steel Company Limited
Flanges are usually attached with flange gaskets and bolts. Therefore, installing and tightening bolts is very important to ensure the safety and efficiency of the system.
Are you experiencing a flange leak but don’t know the cause? If you haven’t found an article about this issue yet, reading the article will help you relieve some of the headaches and confusion.
What is the cause of flange leaks?
Many factors cause flange leaks. However, the most common cause of flange leaks is incorrect selection of flange gaskets, damaged bolts and nuts, incorrect installation of flanges, etc. In addition to the causes just mentioned, there are some other causes, such as:
Flange leaks – Internet
Flange damaged
The following flange-related causes can lead to flange leaks.
Flange is dirty
The flange is scratched, rusted, or corroded
Flange is deformed
The flange is broken, broken, or damaged
The flange is not the right size or type.
The flange is loose or not tightened enough.
The flange is rusted (damaged) causing flange leakage
Improper flange installation
The cause of flange leaks can also be due to improper flange installation. When you do not align the flange correctly, do not position it correctly, or do not align the concentricity of the flange, it will cause unevenly distributed compression force.
If the bolts or screws are installed incorrectly, or installed too close to the flange, the pressure on the flange will not be evenly distributed. This can result in the flange not being properly compacted to prevent leaks.
Normally, uneven screw driving will occur when the person performing the screw driving by hand does not use a force measuring tool or to measure the helix angle.
-> These can cause leaks. In particular, in high-temperature applications, the heavier the bolt is, the greater the risk of the flange leaking.
Improper installation of flange gaskets
The process of installing the flange gasket is equally important. Below are some situations that can cause flange leaks due to improper gasket installation:
The gasket is not positioned correctly.
The gasket was not compressed tightly enough.
The gasket is damaged, or not suitable for the application.
The flange surface is not properly maintained.
Choosing the wrong flange gasket can cause flange leaks
Change the temperature in the system
Maybe you don’t know, that if the temperature changes rapidly, it can cause the flange to deform temporarily. Temperature changes during pumping are inevitable and unpredictable.
Factors that cause rapid temperature changes: rain, storms, heat, etc. can cause the temperature to spread across the flange unevenly, and cause leaks.
-> Therefore, in cases related to temperature, users often install additional shields and heat sinks to effectively protect the system.
The pressure is too great
Excessive pressure and bends in the pipe can loosen bolts or deform flanges. These can cause leaks in the system.
Pipes do not have enough ductility, or flexibility, or use cold springs to align flanges, etc. These factors can lead to a lack of flexibility in pipes and flanges. As the pressure in the system increases, bolts and flanges can loosen or become deformed.
In addition, incorrect installation can also cause pipes and flanges to not be properly aligned, causing loss of tightness and leading to leaks.
The mattress size or material is not suitable
–Mattress size is too large, or small compared to requirements. It may not meet its intended purpose or cause flange leakage problems.
For example. In mechanical applications, a spacer that is too small can result in excessive concentrated loads and damage to the contact surfaces. On the contrary, a pad that is too large may not fit the design and cause uneven pressure on the contact surface, causing wear and tear.
– Inappropriate mattress material is also an important issue. If the material does not meet the requirements of the application, it can lead to failure or damage. For example, in industrial applications, rubber gaskets may not be suitable for environments with high temperatures or exposure to chemicals. Meanwhile, metal pads can cause noise or damage the contact surface.
How to solve flange leaks
At this point, you already know the cause of flange leaks. So how to solve the flange leak problem? Below, Bao Tin Steel will introduce to you some common solutions:
Many factors can cause a flange joint to leak. Such as incorrect gasket selection, broken bolts, and nuts, misaligned flanges, or too far apart… Most of the problems that cause flange leaks are from the material selection and installation process. initial set. See also materials for flange fabrication
Some solutions to address factors affecting flange leaks could be:
Some ways to fix flange leaks
Install the flange properly
As mentioned above, damaged flanges and improper flange installation can lead to leaks. So to fix this situation you can follow these steps:
(1) Before installation, you need to prepare the necessary parts including flanges, bolts, and gaskets.
(2) Clean the flange. Make sure the flange has no dirt, grease, or other impurities in the middle of the flange.
(3) Place the gasket on the flange of either part. Place the remaining part on top of the gasket. Pay attention to ensure that the bolt holes on the two flanges are arranged correctly.
(4) Place the bolts into the holes on the flange, and tighten them evenly. Bolts should be tightened in diagonal order to ensure even pressure distribution.
(5) Check whether the bolts are tightened sufficiently. You can use a pressure tester to ensure the correct pressure on the flange.
Install flange gasket properly
As mentioned above, improper gasket installation is one of the causes of flange leaks. So how can we overcome this situation? Please continue reading to get the answer!
Choose the appropriate gasket or grout. Gaskets must be selected by the design and operating environment of the system.
Check the durability and hardness of the grout. Ron must have durability and hardness suitable for the operating environment. This is to ensure it does not crack or lose elasticity.
Install the gasket properly. The gasket must be properly positioned and aligned so that it is not twisted or too tight. Make sure that the gasket is level and not misaligned.
Check again. After fastening bolts or screws, recheck the tension of the bolts or screws and the compression of the gasket or gasket to ensure the pressure is evenly distributed and there are no leaks.
Tighten the bolts
When tightening flange bolts, you need to follow the steps to ensure consistency and safety during use.
1. Use the correct type of bolt tightening tool. If you use the wrong type or size bolt tightening tool, you could cause damage to the bolt or other parts.
2. Tighten the bolts in diagonal order. You should tighten the bolts in a diagonal order, to ensure the pressure is evenly distributed across the flange.
3. Tighten bolts in stages. Start by tightening the bolt to half-tight, then tighten it to full-tight until the required level of tightness is achieved.
For the pumping process to be effective and safe, each connection step must be appropriate. Flange leaks cause a lot of impact on user time and costs. However, most of the causes of flange leaks are due to incorrect installation from the beginning.
Bao Tin Steel hopes that through this article you will know the cause of flange leaks and how to properly solve the problem. If you need our support, please contact our hotline: 0932 059 176.
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