FORGED FLANGES

Super Industries

“Global Manufacturer of Heavy & Custom Engineered Fasteners for Oil & Gas, Power & EPC Contractors.”

1. Industry Context & System Relevance

Forged Flanges are fundamental pressure-boundary components used in engineered piping systems where controlled assembly, disassembly, and inspection access are mandatory. Their application spans across high-integrity industrial environments where pressure containment, leak prevention, and maintenance accessibility must be simultaneously achieved.

Role in Pressure Piping Systems

In pressure piping systems, Forged Flanges function as detachable mechanical joints that connect:

• Pipe-to-pipe interfaces
• Pipe-to-valve connections
• Pipe-to-equipment nozzles
• Pipe-to-instrumentation assemblies

Unlike permanent welded joints, flange assemblies provide a bolted and gasketed interface that allows:

• Controlled compression sealing
• Periodic inspection
• Replacement of internal components
• Isolation for maintenance

Application Across Industrial Sectors

Refinery & Petrochemical Systems

• High-pressure hydrocarbon processing lines
• Crude distillation units
• Catalytic cracking systems
• Hydrogen service lines

Flanged joints are used where frequent inspection or catalyst replacement is required.

Power Generation Plants

• Main steam lines
• Boiler feedwater systems
• Turbine inlet/outlet connections

High-pressure and high-temperature conditions necessitate flanges with controlled metallurgy and predictable sealing performance.

LNG & Cryogenic Systems

• Liquefaction trains
• Cryogenic transfer lines
• Storage tank connections

Forged Flanges in these systems require materials with low-temperature toughness and resistance to brittle fracture.

Offshore Platforms

• Subsea and topside piping
• High-pressure riser systems
• Injection lines

Flanges are selected for their ability to accommodate installation constraints and allow disassembly in constrained offshore environments.

Process & Chemical Plants

• Acidic and corrosive service lines
• Multi-phase flow systems
• Reactor feed and discharge piping

Material selection and gasket compatibility are critical in such environments.

Selection Over Welded and Threaded Systems

Compared to Welded Joints

Parameter	Welded Joint	Forged Flange Joint
Permanence	Permanent	Removable
Inspection Access	Limited	Full access
Maintenance	Requires cutting	Simple disassembly
Leak Control	Dependent on weld integrity	Controlled via gasket compression

Forged Flanges are selected where:

• Periodic maintenance is expected
• Internal inspection is required
• Equipment replacement cycles are defined

Compared to Threaded Systems

Parameter	Threaded Joint	Forged Flange Joint
Pressure Capability	Limited	High pressure capable
Sealing Mechanism	Thread interference	Gasket compression
Leakage Risk	Higher under vibration	Controlled under preload
Size Limitation	Small bore	Full range (NPS ½” to 60”+)

Flanged joints are preferred in:

• High-pressure applications
• High-temperature systems
• Critical service environments

Functional Advantages of Forged Flanges

• Maintainability: Enables repeated assembly/disassembly without material degradation
• Inspection Accessibility: Allows internal pipeline inspection and gasket replacement
• Controlled Sealing: Bolt preload ensures predictable gasket compression
• Alignment Flexibility: Facilitates alignment adjustments during installation
• System Integrity: Supports pressure containment under cyclic and thermal loads

2. Technical Definition of Forged Flanges

Forged Flanges are pressure-retaining mechanical components manufactured through controlled forging processes, designed to connect piping elements via bolted joints and gasket-sealed interfaces.

Core Functional Definition

A Forged Flange is:

• A forged metallic ring with machined sealing surfaces
• Designed to transfer bolt load into gasket compression
• Used to create a leak-tight joint under internal pressure
• Engineered to withstand:
  • Internal pressure
  • External piping loads
  • Thermal expansion stresses

Forging Advantage (Grain Flow Control)

Unlike cast or plate-cut flanges, forged flanges exhibit:

• Directional grain flow aligned with stress paths
• Reduced internal defects (voids, inclusions)
• Improved fatigue resistance
• Enhanced mechanical strength

This makes them suitable for:

• High-pressure systems
• Cyclic loading conditions
• Critical service applications

Primary Types of Forged Flanges

Weld Neck Flange (WN)

• Long tapered hub
• Butt-welded to pipe
• Provides smooth stress transition
• Preferred for high-pressure and cyclic service

Slip-On Flange (SO)

• Slides over pipe
• Fillet welded (inside and outside)
• Used in moderate pressure systems

Blind Flange (BL)

• Solid disc
• Used to close pipeline ends
• Withstands full system pressure

Socket Weld Flange (SW)

• Socket connection for small bore piping
• Internal shoulder for pipe seating
• Used in high-pressure small diameter systems

Threaded Flange (TH)

• Internal threads
• No welding required
• Used in low-pressure or hazardous environments where welding is restricted

Lap Joint Flange (LJ)

• Used with stub end
• Allows rotational alignment
• Suitable for systems requiring frequent dismantling

Long Weld Neck (LWN)

• Extended hub
• Used for pressure vessels and special applications
• Designed for high stress concentration areas

Flange Facing Types

Raised Face (RF)

• Most commonly used
• Concentrates gasket load
• Suitable for soft gasket sealing

Ring Type Joint (RTJ)

• Metal-to-metal sealing
• Uses metallic ring gasket
• Designed for high-pressure, high-temperature service

Flat Face (FF)

• Entire face is flat
• Used with non-metallic piping systems (e.g., cast iron)
• Prevents flange damage due to uneven loading

3. Engineering & Sealing Principle

The sealing performance of Forged Flanges is governed by the interaction between:

• Bolt preload
• Gasket compression
• Flange rigidity
• Internal pressure forces

Bolt Preload Mechanics

Bolts are tensioned during installation to create preload force, which:

• Compresses the gasket
• Generates sealing stress
• Maintains joint integrity under pressure

Key Concept:

Bolt load must exceed the force generated by internal pressure attempting to separate the joint.

Gasket Compression Theory

Gaskets act as deformable elements that:

• Fill surface irregularities
• Create a seal under compressive stress

Two key parameters define gasket behavior:

m Factor (Maintenance Factor)

• Represents gasket’s ability to maintain seal under pressure
• Used in flange design calculations

y Factor (Seating Stress)

• Minimum stress required to seat the gasket initially

Sealing Stress vs Internal Pressure

For leak-tight performance:

• Initial gasket seating stress must exceed y factor
• Operating stress must satisfy m × internal pressure

Failure to maintain this balance leads to:

• Leakage
• Gasket blowout
• Joint separation

Flange Rotation Under Load

Under bolt preload and internal pressure:

• Flange faces tend to rotate outward
• This reduces gasket compression at the inner diameter

Design considerations include:

• Flange thickness
• Hub geometry (in WN flanges)
• Bolt distribution

Bolt Relaxation Behavior

Over time, bolt preload may reduce due to:

• Gasket creep
• Thermal cycling
• Material relaxation

This leads to:

• Reduced sealing stress
• Increased leakage risk

Mitigation:

• Controlled tightening procedures
• Re-torque practices
• Selection of appropriate gasket material

RTJ vs Soft Gasket Sealing

RTJ Sealing (Metallic)

• Metal-to-metal contact
• High seating stress
• Suitable for extreme pressure and temperature

Advantages:

• Minimal creep
• High integrity sealing

Soft Gasket Sealing

• Uses materials like graphite, PTFE
• Requires controlled compression

Advantages:

• Better conformity
• Suitable for lower pressure applications

Surface Finish Requirements

Flange face finish directly affects sealing performance.

Typical roughness:

• 125–250 AARH (3.2–6.3 µm Ra) for RF flanges

Too smooth:

• Reduces gasket grip

Too rough:

• Causes leakage paths

RTJ grooves require:

• Precision machining
• Tight tolerances
• Controlled surface finish

Leakage Prevention Mechanism

Leakage is prevented when:

• Bolt preload ≥ internal separating force
• Gasket stress ≥ minimum required sealing stress
• Flange deformation remains within allowable limits

Engineering control involves:

• Proper flange selection (class & type)
• Correct gasket specification
• Accurate bolt torque application

Summary of Sealing System Behavior

Component	Function
Bolts	Provide preload force
Flange	Transfers load to gasket
Gasket	Creates seal
Internal Pressure	Attempts to separate joint

A stable flange joint is achieved when:

• Load distribution is uniform
• Material properties are within specified limits
• Installation practices follow defined torque procedures

4. Applicable Standards (ASME / ASTM / DIN / EN / ISO)

Forged Flanges are governed by internationally accepted dimensional, material, and inspection standards. Compliance ensures interchangeability, pressure integrity, and acceptance in EPC projects.

ASME Dimensional Standards

ASME B16.5

Covers:

• NPS ½” to 24”
• Pressure Classes: 150 to 2500
• Dimensions:
  • Outside diameter (OD)
  • Bolt circle diameter (BCD)
  • Flange thickness
  • Facing dimensions (RF, RTJ, FF)

Application:

• Oil & Gas piping
• Refineries
• Power plants
• General process piping

ASME B16.47 Series A & B

Covers:

• NPS 26” to 60”

Series A:

• Larger bolt circle
• Higher strength design
• Used in critical services

Series B:

• Smaller bolt circle
• Economical
• Used in less critical applications

ASTM Material Standards

Material standards define:

• Chemical composition
• Mechanical properties
• Heat treatment conditions

Common standards:

• ASTM A105 → Carbon steel forged flanges
• ASTM A350 LF2 → Low-temperature carbon steel
• ASTM A182 → Stainless & alloy steel forged flanges

European Standards (DIN / EN)

DIN EN 1092-1

Defines:

• PN pressure ratings (PN6 to PN100+)
• Metric-based flange dimensions
• Facing types and tolerances

Application:

• European EPC projects
• Chemical and water systems

ISO Flange Systems

ISO standards provide:

• Global harmonization
• Interchangeability between regions
• Standardized pressure-temperature relationships

Standards Mapping

Standard	Coverage	Pressure Range	Typical Application
ASME B16.5	NPS ≤ 24”	Class 150–2500	Oil & Gas, Power
ASME B16.47	NPS 26”–60”	High pressure	Pipelines, offshore
ASTM A105	Material	Moderate temp	General piping
ASTM A350 LF2	Material	Low temp	Cryogenic systems
ASTM A182	Material	High temp/corrosion	Refinery, chemical
EN 1092-1	Metric flanges	PN rated	EU projects
ISO	Global	Varies	International projects

5. Material & Grade Options

Material selection for Forged Flanges is driven by:

• Operating pressure and temperature
• Corrosive environment
• Mechanical loading conditions
• Project specifications

Carbon Steel Forged Flanges

ASTM A105

• Standard carbon steel forging grade
• Suitable for ambient to moderate temperature service

ASTM A350 LF2

• Designed for low-temperature service
• Improved impact toughness
• Used in sub-zero applications

Stainless Steel Forged Flanges

ASTM A182 F304

• Austenitic stainless steel
• General corrosion resistance

ASTM A182 F316

• Contains molybdenum
• Enhanced resistance to chlorides and chemicals

Alloy Steel Forged Flanges

ASTM A182 F11

• Chromium-molybdenum alloy
• Suitable for elevated temperature service

ASTM A182 F22

• Higher strength than F11
• Used in high-pressure and high-temperature systems

Duplex & Super Duplex Grades

ASTM A182 F51 (Duplex)

• Dual-phase microstructure
• High strength and corrosion resistance

ASTM A182 F53 (Super Duplex)

• Superior pitting and crevice corrosion resistance
• Used in offshore and marine environments

Material Property Table

Grade	Yield Strength (MPa)	Tensile Strength (MPa)	Temperature Range	Corrosion Resistance	Typical Use
A105	≥ 250	485–620	-29°C to 425°C	Low	General piping
A350 LF2	≥ 250	485–620	-46°C to 345°C	Low	Low-temperature service
F304	≥ 205	515–720	Up to 870°C	Moderate	Chemical processing
F316	≥ 205	515–720	Up to 870°C	High	Marine, chemical
F11	≥ 275	415–585	Up to 540°C	Moderate	Power plants
F22	≥ 415	585–760	Up to 600°C	Moderate	High-pressure systems
F51	≥ 450	620–880	-50°C to 300°C	High	Offshore
F53	≥ 550	750–950	-50°C to 300°C	Very High	Marine, subsea

6. Heat Treatment of Forged Flanges

Heat treatment is applied to achieve:

• Required mechanical properties
• Grain refinement
• Residual stress reduction
• Improved toughness

Normalizing

• Heating above critical temperature
• Air cooling

Effect:

• Refines grain structure
• Improves uniformity
• Enhances strength

Quenching & Tempering (Q&T)

• Rapid cooling (quenching)
• Followed by reheating (tempering)

Effect:

• Increases strength
• Improves toughness
• Reduces brittleness

Used for:

• Alloy steel grades (F11, F22)

Solution Annealing (Stainless Steel)

• Heating to high temperature
• Rapid quenching

Effect:

• Dissolves carbides
• Restores corrosion resistance
• Improves ductility

Stress Relieving

• Heating below transformation temperature
• Controlled cooling

Effect:

• Reduces residual stresses
• Prevents distortion during machining

Hardness & Microstructure Control

Material	Typical Hardness (HB)	Microstructure
A105	120–180	Ferrite-Pearlite
LF2	120–180	Fine-grained ferrite
F11/F22	150–220	Tempered martensite
SS304/316	150–200	Austenitic
Duplex	200–300	Austenite + Ferrite

Impact Testing (Charpy V-Notch)

Conducted for:

• Low-temperature applications
• Critical service conditions

Ensures:

• Resistance to brittle fracture
• Compliance with project specifications

7. Manufacturing Process of Forged Flanges

Forged Flanges are produced through a controlled sequence ensuring dimensional accuracy and metallurgical integrity.

Raw Material Inspection

• Verification of chemical composition
• Ultrasonic testing for internal defects
• Traceability through heat numbers

Cutting & Heating

• Billets cut to required size
• Heated in controlled furnaces

Temperature control is critical to:

• Avoid overheating
• Maintain metallurgical properties

Closed-Die Forging

• Material shaped using dies under high pressure

Results in:

• Controlled grain flow
• Dense structure
• Improved mechanical strength

Heat Treatment

Applied as per material grade:

• Normalizing
• Q&T
• Solution annealing

Ensures required mechanical properties.

CNC Machining

Precision machining operations include:

• Bore machining
• Hub profiling (WN flanges)
• Facing operations

Achieves:

• Tight tolerances
• Surface finish requirements

Facing & Drilling

• Machining of RF/RTJ/FF faces
• Drilling of bolt holes as per BCD

Accuracy is critical for:

• Proper bolt alignment
• Load distribution

RTJ Groove Machining

For RTJ flanges:

• Precision groove cutting
• Dimensional tolerance control
• Surface finish verification

Surface Finishing

• Removal of scale and burrs
• Application of protective coatings

Marking & Traceability

Each Forged Flange is marked with:

• Material grade
• Heat number
• Size and pressure class
• Manufacturer identification

Ensures:

• Full traceability
• Compliance with inspection requirements

Surface Finish Options

Surface protection and flange face finish are critical for storage, corrosion resistance, and sealing performance.

External Surface Coatings

Anti-Rust Oil Coating

• Temporary protection during storage and transport

Black Paint

• Protection against atmospheric corrosion

Galvanizing

• Zinc coating for corrosion resistance
• Used in water systems

PTFE Coating

• Chemical resistance
• Used in aggressive environments

Passivation (Stainless Steel)

• Enhances corrosion resistance
• Removes surface contaminants

Flange Face Finish

Critical for gasket sealing.

Typical finish:

• 125–250 AARH (3.2–6.3 µm Ra)

Types:

• Spiral serrated finish (standard RF)
• Smooth finish (special applications)

Surface Finish Impact

Condition	Effect
Too Smooth	Poor gasket grip
Too Rough	Leakage paths
Controlled Finish	Optimal sealing

RTJ Groove Finish

• Precision machined
• Low roughness
• Tight dimensional tolerances

Ensures:

• Metal-to-metal sealing integrity

A. Dimensional Reference Table (ASME B16.5 – Representative)

The following table provides indicative dimensions for commonly used Forged Flanges. Final dimensions must always be verified against the latest ASME standards and project specifications.

NPS	Class	OD (mm)	BCD (mm)	Bolt Size	No. of Bolts	Thickness (mm)
2”	150	152	120.7	M16	4	17.5
2”	300	165	127	M16	8	20.6
4”	150	229	190.5	M16	8	23.9
4”	600	292	235	M20	8	47.8
6”	300	318	269.9	M20	12	36.6
8”	600	419	362	M24	12	55.6
10”	900	508	431.8	M30	16	85.9
12”	1500	584	482.6	M33	16	117.3

Engineering Notes:

• Increase in pressure class results in increased thickness and bolt quantity
• Bolt Circle Diameter (BCD) governs load distribution
• Thickness is directly related to flange rigidity and rotation resistance

B. Pressure–Temperature Rating Table (Indicative)

Pressure ratings depend on material and temperature as defined in ASME B16.5.

Class	Pressure (Bar) @ Ambient	Temperature (°C)	Material	Remarks
150	~19	Up to 200	A105	Low-pressure service
300	~51	Up to 200	A105	Moderate pressure
600	~102	Up to 200	A105	Process piping
900	~153	Up to 200	A105	High-pressure systems
1500	~255	Up to 200	A105	Critical service
2500	~425	Up to 200	A105	Extreme pressure

Engineering Consideration:

• Pressure rating decreases as temperature increases
• Material grade selection is critical at elevated temperatures

C. Torque Chart for Bolting (Indicative Values)

Torque values are dependent on bolt size, lubrication condition, and friction coefficient. The following table provides engineering reference values.

Bolt Size	Class	Torque (Nm) – Lubricated	Torque (Nm) – Dry
M16	150	70	100
M16	300	110	150
M20	300	210	280
M20	600	320	420
M24	600	550	720
M24	900	720	950
M30	900	1200	1550
M33	1500	1800	2300

Torque Application Notes

• Lubricated bolts reduce friction → lower torque required
• Dry bolts increase torque variability
• Torque must be applied in controlled increments
• Use calibrated torque wrenches or hydraulic tensioners

D. Preload Calculation Guide

Proper bolt preload is essential to achieve leak-tight sealing.

1. Bolt Load Formula

Bolt preload force:

   

Where:

• ( F ) = Bolt preload force (N)
• ( \sigma_b ) = Bolt stress (MPa)
• ( A_b ) = Bolt tensile stress area (mm²)

2. Gasket Seating Load

Initial seating load:

   

Where:

• ( y ) = Gasket seating stress
• ( A_g ) = Effective gasket area

3. Operating Load Requirement

   

Where:

• ( m ) = Gasket factor
• ( P ) = Internal pressure
• ( A_g ) = Gasket area

4. Design Condition

For safe sealing:

   

5. Sample Calculation

Given:

• Bolt size: M20
• Tensile stress area ( A_b = 245 , mm^2 )
• Bolt stress ( \sigma_b = 200 , MPa )

   

If:

• Gasket seating load = 35,000 N
• Operating load = 42,000 N

Then:

• Required load = 42,000 N
• Available bolt load = 49,000 N

Condition satisfied → Joint is safe

6. Safety Margin

   

Recommended:

• Minimum safety factor: 1.2 to 1.5

E. Mechanical Property Table

Material	Yield Strength (MPa)	Tensile Strength (MPa)	Elongation (%)	Hardness (HB)	Impact (J)
A105	≥ 250	485–620	≥ 20	120–180	Moderate
LF2	≥ 250	485–620	≥ 22	120–180	High (low temp)
F304	≥ 205	515–720	≥ 30	150–200	High
F316	≥ 205	515–720	≥ 30	150–200	High
F11	≥ 275	415–585	≥ 20	150–220	Moderate
F22	≥ 415	585–760	≥ 18	170–220	Moderate
F51	≥ 450	620–880	≥ 25	200–300	High
F53	≥ 550	750–950	≥ 25	250–320	High

F. Corrosion Resistance Comparison Table

Material	Marine	Acidic	High Temperature	Hydrocarbon
Carbon Steel (A105)	Low	Low	Moderate	High
SS304	Moderate	Moderate	High	High
SS316	High	High	High	High
Alloy Steel (F11/F22)	Low	Low	Very High	High
Duplex (F51)	Very High	High	Moderate	High
Super Duplex (F53)	Excellent	Very High	Moderate	High

8. Inspection & Quality Control

Inspection of Forged Flanges ensures compliance with dimensional, material, and performance requirements.

Positive Material Identification (PMI)

• Verifies chemical composition
• Conducted using XRF or OES
• Ensures correct material grade

Ultrasonic Testing (UT)

• Detects internal discontinuities
• Identifies:
  • Voids
  • Inclusions
  • Cracks

Magnetic Particle Inspection (MPI)

• Surface and near-surface defect detection
• Applicable for ferromagnetic materials

Dye Penetrant Testing (DPT)

• Detects surface cracks
• Used for stainless steel and non-magnetic materials

Dimensional Inspection

Verification of:

• OD, ID
• BCD
• Bolt hole alignment
• Thickness
• Facing dimensions

Hardness Testing

• Confirms heat treatment results
• Ensures compliance with material standards

Hydrostatic Testing (Assembly Level)

• Conducted on assembled flange joints
• Validates sealing performance under pressure

Documentation & Certification

EN 10204 Certification

• 3.1 Certificate: Manufacturer test certificate
• 3.2 Certificate: Third-party verified certificate

Includes:

• Chemical composition
• Mechanical properties
• Heat treatment details
• Test results

Third-Party Inspection (TPI)

Inspection agencies may include:

• Independent inspection bodies
• Client-appointed inspectors
• EPC consultant representatives

Scope includes:

• Stage inspection
• Final inspection
• Documentation review

Traceability System

Each Forged Flange is traceable through:

• Heat number
• Batch number
• Material certificate

Ensures:

• Full lifecycle traceability
• Compliance with EPC requirements

9. Industries Served

Forged Flanges are deployed across multiple industries where pressure containment, mechanical integrity, and inspection accessibility are critical.

Oil & Gas Sector

Upstream (Exploration & Production)

• Wellhead connections
• High-pressure injection lines
• Subsea flow systems

Requirements:

• High-pressure ratings (Class 900–2500)
• Corrosion-resistant materials (Duplex / Super Duplex)
• Fatigue resistance under cyclic loads

Midstream (Transportation)

• Pipeline booster stations
• Compressor stations
• Metering skid connections

Requirements:

• Large diameter flanges (ASME B16.47)
• Resistance to external loads and vibration
• Reliable sealing over long operational cycles

Downstream (Refining & Processing)

• Distillation columns
• Reactor piping
• Hydrogen service

Requirements:

• High-temperature alloy steels
• RTJ sealing for critical joints
• Resistance to chemical corrosion

Petrochemical Industry

• Polymer processing units
• Chemical reactors
• Solvent handling systems

Material selection focuses on:

• Stainless steel (F304 / F316)
• Chemical compatibility
• Corrosion resistance

Power Generation

Thermal Power Plants

• Boiler systems
• Main steam pipelines
• Turbine connections

Requirements:

• Alloy steel flanges (F11 / F22)
• Resistance to creep and thermal fatigue

Nuclear Power Systems

• High-integrity piping systems
• Safety-critical connections

Requirements:

• Strict dimensional tolerance
• Full traceability
• Third-party inspection compliance

LNG & Cryogenic Systems

• LNG liquefaction plants
• Storage tanks
• Transfer pipelines

Requirements:

• Low-temperature materials (ASTM A350 LF2, Duplex)
• Charpy impact-tested flanges
• Resistance to brittle fracture

Offshore & Marine

• Offshore platforms
• FPSO systems
• Seawater injection lines

Requirements:

• Super Duplex materials (F53)
• Resistance to chloride-induced corrosion
• High fatigue resistance

Hydrogen & Emerging Energy Systems

• Hydrogen pipelines
• Electrolyzer systems
• Carbon capture systems

Requirements:

• Material compatibility with hydrogen
• Resistance to hydrogen embrittlement
• High-integrity sealing systems

10. Export Capability & Global Supply

Super Industries supports international EPC and industrial projects with structured export and documentation systems.

Export Regions

• United States
• European Union
• Middle East (UAE, Saudi Arabia, Qatar)
• Southeast Asia (Singapore, Indonesia, Malaysia)

Packaging Standards

Forged Flanges are supplied in seaworthy export packaging:

• Wooden crates (fumigated)
• Palletized packaging
• Anti-corrosion wrapping
• Protective flange face covers

Purpose:

• Prevent mechanical damage
• Protect sealing surfaces
• Ensure corrosion resistance during transit

Documentation Package

Each shipment includes:

• Material Test Certificates (MTC – EN 10204 3.1 / 3.2)
• Dimensional inspection reports
• Heat treatment records
• NDT reports (UT, PMI, MPI/DPT)
• Compliance certificates (ASME / ASTM / EN)

Logistics & Project Execution Capability

• Bulk supply for EPC projects
• Lot-wise traceability
• Stage inspection coordination
• Delivery scheduling aligned with project timelines

11. Procurement & Installation View

Forged Flanges require controlled installation practices to ensure sealing integrity and long-term performance.

Gasket Installation

• Verify gasket type and rating
• Ensure clean and undamaged flange faces
• Proper centering of gasket

Bolt Tightening Sequence

Bolts must be tightened in a star (cross) pattern:

1. Initial snug tightening
2. 30% of final torque
3. 60% of final torque
4. 100% of final torque
5. Final pass for uniformity

Purpose:

• Uniform load distribution
• Minimized flange distortion
• Consistent gasket compression

Torque Tightening Practices

• Use calibrated torque tools
• Apply lubrication where specified
• Avoid over-tightening

Re-Torque Practice

• Required after initial pressurization or thermal cycling
• Compensates for gasket creep and bolt relaxation

Inspection Checkpoints

Before commissioning:

• Bolt torque verification
• Alignment check
• Gasket integrity verification
• Leak testing

Storage & Handling

• Store in dry conditions
• Protect flange faces with covers
• Avoid stacking damage

12. Custom Engineering Capabilities

Super Industries supports project-specific requirements for Forged Flanges beyond standard specifications.

Non-Standard Dimensions

• Custom OD, thickness, and bore
• Project-specific dimensional tolerances

High-Thickness / High-Pressure Flanges

• Designed for Class 1500–2500 applications
• Enhanced rigidity and load capacity

Special RTJ Groove Configurations

• Custom groove dimensions
• Compatibility with non-standard ring gaskets

Custom Drilling Patterns

• Modified bolt hole arrangements
• Special BCD configurations

Project Identification & Stamping

• Client-specific marking
• Traceability coding
• EPC documentation alignment

Engineering Conclusion

Forged Flanges are critical pressure-boundary components that integrate mechanical design, material science, and sealing engineering into a single functional unit.

Their performance is governed by:

• Correct selection of pressure class
• Proper material specification
• Controlled manufacturing and heat treatment
• Accurate machining and surface finishing
• Verified inspection and certification
• Proper installation and preload control

From an EPC and consultant evaluation perspective, a compliant Forged Flange must demonstrate:

• Conformance to ASME / ASTM / EN standards
• Verified mechanical and chemical properties
• Dimensional accuracy within specified tolerances
• Traceability from raw material to final product
• Documented inspection and testing records

Super Industries supplies Forged Flanges aligned with these engineering requirements, supporting:

• Pressure system reliability
• Inspection compliance
• Global project execution standards