Common problems and countermeasures of pipe flanges

In the pipeline system, pipe flanges are important connecting components, and their performance directly affects the stability and safety of the system. However, flanges may encounter problems such as loose connection, poor sealing, easy rust, and wear of the connection surface during use. The following is a detailed introduction to the problems that flange fittings are prone to encounter during use and the corresponding solutions.

Common problems of pipe flanges mainly include the following:

1. Loose connection
In some harsh application environments, the flange connection may not be strong enough, resulting in pipeline leakage, loosening and other problems. This may be caused by mismatched flange materials, insufficient fasteners or improper installation.

Countermeasures: Select high-quality, compliant flanges, use correct installation methods, strengthen inspection and maintenance, and avoid connection failure.

2. Poor sealing
Due to the large flange connection surface, the sealing is easily affected by environmental factors such as temperature, pressure, vibration, etc., resulting in loose sealing and leakage problems.
Countermeasures: Fully consider environmental factors during design, select suitable sealing materials and sealing methods, and pay attention to maintaining and inspecting the finish of the flange connection surface.

3. Rust
The flange connection surface is often exposed to the air and is susceptible to factors such as oxidation corrosion, resulting in surface rust.
Countermeasures: When selecting pipe flanges, choose anti-corrosion materials, strengthen maintenance and care, and use anti-rust methods to treat the flange connection surface.

4. Wear
During long-term use, the flange connection surface may be worn, causing leakage and connection failure.
Countermeasures: Reasonably select flanges and sealing materials, strengthen maintenance and inspection, and regularly replace flanges and sealing gaskets at the connection parts.

5. Misalignment
The pipeline and flange are vertical but the two flanges are not concentric, resulting in the surrounding bolts being unable to freely penetrate the bolt holes, affecting the sealing effect. ‌
Countermeasures: Ensure that the two flanges are concentric to avoid misalignment.

6. The end face is not perpendicular to the pipeline axis. ‌
The flange end face is not perpendicular to the pipeline axis, which will affect the overall appearance and use function of the pipeline and may cause medium leakage. ‌

Countermeasures: Ensure that the flange end face is perpendicular to the pipeline centerline and the deviation value is within the allowable range. ‌

‌7. Sealing surface damage ‌
The flange sealing surface has obvious signs of damage, resulting in reduced sealing performance. ‌

Countermeasures‌: Perform an appearance inspection before installation to ensure that the flange sealing surface is flat, smooth and undamaged. ‌

‌8. Eccentric installation of gasket ‌
The gasket and flange are not concentric, resulting in reduced sealing performance. ‌

Countermeasures‌: Ensure that the flange gasket matches the flange sealing surface and is installed correctly. ‌

‌9. Rust prevention ‌
During the rust prevention process, you may encounter problems such as difficulty in removing grease and dirt, adhesion of dust and foreign metal particles, and incomplete cleaning and drying. ‌

Countermeasures‌: Thoroughly clean the flange surface, select appropriate anti-rust oil or anti-rust agent, regularly test the use standard of anti-rust oil, and select appropriate packaging materials. ‌

Conclusion:

The role of pipe flanges in the pipeline system is very important, but there are also some shortcomings during use, and we need to take a series of preventive measures to avoid these problems. Regular inspection and maintenance are key measures to ensure the good condition of flange connections.

Read more: Pipe flange size type and selection or How to choose pipe flange material?