Plate Flanges Manufacturers Mumbai India
Plate Flanges Manufacturers Mumbai India. Best Price Exporter Supplier of Customize Flange for Europe, US, UK & Gulf. Call +91-9769996991
Plate flanges are essential components in pipeline systems, offering a cost-effective and reliable method to connect pipes, valves, and equipment. These flat, circular metal discs are widely used in industries like oil & gas, petrochemicals, water treatment, and power plants. This article provides an in-depth look at plate flanges, their types, benefits, applications, and key considerations for selection.
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What is a Plate Flange?
A plate flange is a flat, circular metal plate with holes around its circumference, used to connect piping systems. It is typically welded or bolted to the pipeline, allowing for secure and leak-proof connections.
Unlike raised face or slip-on flanges, plate flanges by Falcon offer a simple and economical solution, making them ideal for low-pressure applications.
Key Features of Plate Flanges:
- Made from stainless steel, carbon steel, or alloy steel.
- Available in various pressure ratings (150, 300, 600, etc.).
- Ideal for low to moderate pressure applications.
- Designed with standard or custom hole patterns.
Types of Plate Flanges
Understanding the different types of plate flanges is essential for selecting the right one for your application.
1. Standard Plate Flange
- A simple flat disc with bolt holes.
- Commonly used in water pipelines and low-pressure systems.
2. Welded Plate Flange
- Welded directly to the pipe for a strong and durable connection.
- Used in industrial applications requiring high strength.
3. Threaded Plate Flange
- Has internal threads that allow pipes to be screwed into the flange.
- Ideal for applications where welding is not feasible.
4. Blind Plate Flange
- A solid plate used to seal pipe ends.
- Helps in system maintenance and modifications.
Benefits of Using Plate Flanges
Plate flanges offer numerous advantages, making them a preferred choice in various industries.
✔️ Cost-Effective
Compared to other flange types, plate flanges are more affordable due to their simple design and manufacturing process.
✔️ Easy Installation
They can be easily installed, removed, or replaced, reducing downtime and maintenance costs.
✔️ Versatile Applications
Suitable for different industries, including oil & gas, chemical processing, and wastewater treatment.
✔️ High Durability
When made from high-quality materials, plate flanges can withstand harsh environments and extreme temperatures.
Applications of Plate Flanges
Plate flanges are widely used in various industries due to their versatility and reliability.
🏭 Oil & Gas Industry
- Used in pipelines transporting crude oil and natural gas.
- Ensures leak-proof connections in processing plants.
🚰 Water Treatment Plants
- Helps in joining pipes for efficient water distribution.
- Corrosion-resistant plate flanges ensure longevity.
⚡ Power Plants
- Used in steam and gas turbine systems.
- Provides secure connections in high-temperature environments.
🏗️ Construction Industry
- Utilized in HVAC systems and structural piping.
- Offers a strong and stable connection for piping networks.
How to Select the Right Plate Flange?
Choosing the correct plate flange depends on several factors. Here’s what to consider:
🔹 Material Selection
- Carbon Steel Plate Flange – Ideal for high-temperature applications.
- Stainless Steel Plate Flange – Resistant to corrosion and ideal for water systems.
- Alloy Steel Plate Flange – Provides extra strength and durability.
🔹 Pressure Rating
- Ensure the flange meets the required pressure rating (e.g., ANSI 150, ANSI 300).
- Higher ratings are needed for high-pressure applications.
🔹 Flange Size & Thickness
- Select the correct diameter and thickness based on the pipe dimensions.
- Incorrect sizing can lead to leaks and failures.
🔹 Bolt Hole Pattern
- Check compatibility with existing piping systems.
- Ensure proper alignment for easy installation.
Maintenance & Care Tips for Plate Flanges
Regular maintenance can extend the lifespan of plate flanges and prevent failures.
🛠️ Inspection Routine
- Check for corrosion, cracks, or deformations.
- Ensure bolts are tightly secured to avoid leaks.
🛠️ Cleaning & Lubrication
- Remove dirt and debris from flange surfaces.
- Apply anti-corrosion coatings for long-term protection.
🛠️ Replacement Guidelines
- Replace worn-out or damaged flanges immediately.
- Use high-quality gaskets and seals for a secure fit.
Plate Flange Standard Specifications
Plate flanges are manufactured according to various international standards to ensure compatibility and reliability in industrial applications.
1. Common Standards for Plate Flanges
Plate flanges must meet industry standards to ensure durability and safety. Below are the widely recognized standards:
- ASME/ANSI B16.5 – American standard for pipe flanges and fittings (sizes up to 24 inches).
- ASME/ANSI B16.47 – Covers larger pipe flanges (above 24 inches).
- EN 1092-1 – European standard for steel flanges.
- DIN 2576 – German standard for slip-on and plate flanges.
- BS 4504 – British standard for circular flanges.
- JIS B2220 – Japanese standard for steel flanges.
2. Material Specifications
Plate flanges are available in various materials to suit different environmental conditions and pressure requirements.
| Material Type | Description & Applications |
|---|---|
| Carbon Steel | Used in high-temperature and high-pressure applications. |
| Stainless Steel | Ideal for corrosive environments like chemical and water industries. |
| Alloy Steel | Offers enhanced strength and durability for heavy-duty applications. |
| Mild Steel | Cost-effective and suitable for low-pressure applications. |
| Galvanized Steel | Provides corrosion resistance for outdoor or underground piping. |
3. Size & Dimensions
Plate flanges come in various sizes based on pipe diameter and industry standards.
Common Plate Flange Dimensions (ANSI B16.5 Standard)
| Nominal Pipe Size (NPS) | Outer Diameter (OD) mm | Bolt Circle Diameter (BCD) mm | Bolt Hole Diameter mm | Number of Bolts |
|---|---|---|---|---|
| ½” | 90 | 60 | 16 | 4 |
| 1″ | 125 | 90 | 19 | 4 |
| 2″ | 150 | 120 | 19 | 4 |
| 4″ | 230 | 190 | 19 | 8 |
| 6″ | 280 | 241 | 22 | 8 |
| 8″ | 345 | 298 | 22 | 8 |
| 10″ | 405 | 362 | 25 | 12 |
| 12″ | 485 | 432 | 25 | 12 |
(Note: Dimensions vary based on pressure ratings and specific standards.)
4. Pressure Ratings
Plate flanges are categorized based on pressure ratings, which indicate the maximum pressure the flange can withstand.
| Class (ANSI/ASME B16.5) | Pressure Rating (PSI) |
|---|---|
| Class 150 | Up to 285 PSI |
| Class 300 | Up to 740 PSI |
| Class 600 | Up to 1,480 PSI |
| Class 900 | Up to 2,220 PSI |
| Class 1500 | Up to 3,700 PSI |
| Class 2500 | Up to 6,170 PSI |
Higher class ratings indicate increased strength and pressure tolerance.
5. Manufacturing Process
Plate flanges undergo various manufacturing processes to ensure quality and durability.
Manufacturing Steps:
- Material Selection – Choosing the right steel grade.
- Cutting & Shaping – Using plasma cutting or laser cutting.
- Drilling Bolt Holes – Precision drilling for accurate fitting.
- Surface Treatment – Anti-corrosion coating (galvanizing, painting, or electroplating).
- Testing & Quality Control – Includes hydrostatic testing, ultrasonic inspection, and dimensional checks.
6. Surface Finish & Coating Options
Plate flanges can have different finishes to improve performance and lifespan.
| Finish Type | Description |
|---|---|
| Machined | Smooth finish for precise sealing. |
| Galvanized | Zinc-coated for corrosion resistance. |
| Black Oxide | Increases wear resistance. |
| Epoxy Coating | Ideal for marine and chemical applications. |
7. Bolt Hole Configuration
- The number and size of bolt holes depend on the flange size and pressure rating.
- Holes are evenly spaced around the flange for uniform pressure distribution.
8. Applications of Plate Flanges
Plate flanges are widely used in industries such as:
✔ Oil & Gas Pipelines – Connecting transport pipelines.
✔ Water Treatment Plants – Secure water flow systems.
✔ Power Plants – Steam piping applications.
✔ Chemical Processing – Corrosion-resistant piping solutions.
✔ Marine & Shipbuilding – Saltwater-resistant piping connections.
(FAQs)
1. What is the difference between a plate flange and a slip-on flange?
A plate flange is a simple flat disc used for bolted connections, while a slip-on flange has a slightly larger inner diameter, allowing it to slide over the pipe before welding. Slip-on flanges are used in higher-pressure applications compared to plate flanges.
2. Can plate flanges handle high-pressure applications?
Plate flanges are typically used for low to moderate pressure systems. For high-pressure applications, reinforced or higher-rated flanges like weld neck flanges are recommended.
3. How do I choose the right material for a plate flange?
The material choice depends on temperature, pressure, and environmental conditions.
- Carbon steel for high-temperature applications.
- Stainless steel for corrosion resistance.
- Alloy steel for enhanced durability.
4. What are the common standards for plate flanges?
Plate flanges follow industry standards such as:
- ANSI/ASME B16.5 – American standard for pipe flanges.
- DIN Standard – European standard for plate flanges.
- BS 4504 – British standard specifications.
5. Are plate flanges suitable for underground piping?
Yes, but it is essential to use corrosion-resistant coatings or galvanized plate flanges to protect against soil moisture and rust.