Titanium Grade 2 Grade 5 Weld Neck Flange ASME B16.5 Class 150 WNRF Flanges for Industrial Applications

1. Introduction of ASME Class 150 Weld Neck Flange:

The ASME B16.5 Class 150 Weld Neck Flange is a type of flange that is defined by the ASME B16.5 standard, which covers the dimensions, tolerances, materials, and other specifications for flanges and flanged fittings used in piping systems. Specifically, Class 150 refers to the pressure rating of the flange, indicating that it is designed to withstand pressures of up to 150 psi at a specified temperature.

2. Details of Products:

Design: The weld neck flange has a long tapered hub that is welded to the pipe, providing a strong and leak-resistant joint. The flange’s neck helps to distribute stress evenly at the pipe’s connection.

Pressure Class: The Class 150 designation indicates a pressure rating of 150 pounds per square inch (psi) at ambient temperature. The pressure rating will vary with temperature, meaning the flange can handle different pressures depending on the operating temperature.

Material: The materials commonly used for ASME B16.5 Class 150 flanges are carbon steel, stainless steel, and alloy steels, although other materials are also available based on project requirements.

Size Range: The size range for Class 150 Weld Neck Flanges typically spans from ½ inch to 24 inches in diameter, though larger sizes may be available depending on the specific application.

Applications: These flanges are widely used in piping systems in industries like oil and gas, chemical, power generation, and water treatment, among others. They provide a robust solution for high-pressure applications, particularly in environments where strong and reliable pipe connections are essential.

Connection Type: A weld neck flange is designed to be welded to a pipe. Its long, tapered neck provides a smooth transition from the pipe to the flange, which helps reduce stress concentration and increase the strength of the overall connection.

Standards Compliance: The ASME B16.5 standard defines the dimensions and requirements for flanges used in pressure applications. The flanges conform to specific tolerances for bolt hole patterns, bolt circle diameters, flange thicknesses, and other critical factors.

3. Titanium Weck Neck Flanges Certicifates:

EN 10204/3.1B Certificate:

This is a standard certificate that confirms compliance with the material specification and provides chemical composition and mechanical properties of the titanium alloy used in manufacturing the flanges. It is issued by the manufacturer and verifies that the material meets the required standards.

Raw Materials Certificate:

This certificate provides details about the raw materials used in the production of the titanium flanges. It includes information such as the origin of the raw materials, their composition, and any applicable material testing results. This ensures traceability and quality control from the initial material procurement stage.

100% Ultrasonic Flaw Detection:

Ultrasonic testing (UT) is a non-destructive testing method used to detect internal and surface defects in the titanium flanges. A 100% UT coverage means that all flanges undergo thorough testing to ensure there are no defects that could compromise their structural integrity or performance.

Hydrostatic Test:

This test involves pressurizing the titanium flange with water or another liquid to a predetermined pressure level. It assesses the flange's ability to withstand pressure without leakage or deformation, ensuring it meets the specified pressure ratings and safety requirements.

Third Party Inspection Report:

This report is conducted by an independent third-party inspection agency or authority. It provides an unbiased assessment of the titanium flanges' quality, confirming compliance with applicable standards, specifications, and customer requirements. It adds credibility to the manufacturer's quality assurance processes.

4. Grades of Titanium:

5. Specification of ANSI B16.5 Class 150 Titanium Weld Neck Flange:

6. Manufacturing Process of Weld Neck Flanges:

The manufacturing process of welding neck flanges involves multiple steps aimed at transforming raw materials into high-strength connectors suitable for pipeline systems. Welding neck flanges are commonly used to connect pipes to other equipment or pipelines, providing a secure joint. Here is a detailed description of the manufacturing process for welding neck flanges:

Material Selection

The first step in manufacturing a welding neck flange is selecting the appropriate material. Common materials include carbon steel, stainless steel, alloy steel, nickel alloys, and titanium alloys. The choice of material depends on the application's requirements, such as strength, corrosion resistance, and high-temperature performance.

Cutting and Forming the Blank

After selecting the material, the metal ingot or steel plate is cut into the required size and shape of a circular blank. The size and thickness of the blank depend on the flange design specifications. Cutting methods typically include shearing, sawing, or laser cutting.

Turning and Machining

The blank is then sent to a lathe or CNC machine for processing to form the basic shape of the flange. During this process, the outer diameter (OD) and thickness of the flange are processed, with turning, milling, and grinding operations to ensure precision and symmetry.

Forging (Optional)

For larger sizes or flanges requiring higher strength, a forging process may be used. The hot forging process involves heating the metal to a high temperature and using hammers or pressure to form it into the shape of the flange. Forging can improve the mechanical properties of the flange, allowing it to withstand higher pressures.

Neck Forming

A distinctive feature of welding neck flanges is their long, tapered neck, which is designed to be welded to a pipe. The forming of the neck is typically done through extrusion, forging, or casting. The central hole for the pipe connection is also created at this stage, matching the pipe's diameter.

Heat Treatment

After the flange is formed, it typically undergoes heat treatment to achieve the desired mechanical properties, such as hardness and strength. Common heat treatment methods include annealing or normalizing, which help eliminate stress and improve the material's corrosion resistance. Heat treatment also enhances weldability, ensuring a secure weld with the pipe.

Surface Treatment

Once the flange has been processed, surface treatments are applied to improve its surface quality, appearance, and durability. Common surface treatments include sandblasting (to clean the surface and remove impurities), polishing (to improve appearance and reduce roughness), and passivation (especially for stainless steel, to remove iron filings and other contaminants to enhance corrosion resistance).

Drilling

Next, the flange needs to have holes drilled around its perimeter for connecting to other flanges or equipment. The number and size of the holes depend on the flange standards and pressure rating requirements. The uniformity and precision of the drilling are crucial to ensure proper alignment with matching flanges during installation.

Inspection and Testing

Once the flange is complete, it undergoes a series of quality control checks to ensure it meets design specifications. Inspection items include dimension checks, appearance checks, and non-destructive testing (such as ultrasonic or X-ray testing) to ensure there are no internal defects. The flange is also subjected to pressure testing to confirm it can handle the specified pressure rating.

Final Cleaning

After passing all inspections, the flange is thoroughly cleaned to remove any oil, debris, or other contaminants from the manufacturing process. Cleaning methods may include water washing, acid cleaning, or chemical solutions.

Packaging and Shipping

All inspected and approved welding neck flanges are packaged and prepared for shipment to customers, distributors, or processing plants. These flanges are used for connecting various components in pipeline systems.