Piping systems need connections that are secure and leak-proof. That’s where flanges come in.
Flanges are connection points in piping systems, joining pipes, valves, pumps, and other pieces of equipment together. They’re a mechanical means of creating a sealed connection.
A companion flange has a specialized role. It’s especially important when you need precise alignment in your piping system.
Understanding flanges: The foundation
Before we dive into companion flanges, let’s cover the basics of flanges in general. Flanges are connecting devices used to connect sections of pipe or to connect a pipe to a pressure vessel, valve, or other piece of equipment. They’re usually circular, but they can also be square or rectangular.
When bolted together, flanges create a secure and leak-tight seal. They make it easy to assemble and disassemble piping systems when they need to be maintained or modified.
Here are a few of the most common types of flanges:
- Weld neck flanges: These are designed for butt welding to a pipe and provide high-integrity joints.
- Slip-on flanges: These slip over the pipe and are fillet welded. They’re generally easier to install than weld neck flanges.
- Blind flanges: These are used to close off the end of a pipe or vessel opening, allowing access for inspection or future expansion.
Companion Flanges: A Closer Look
Let’s zoom in on companion flanges and what makes them special.
What are they?
A companion flange is a type of flange made to connect to another, identical flange. They’re often sold in pairs to make the connection easier.
What do they do?
Companion flanges are designed to create a leak-free connection and ensure precise alignment, particularly in situations where even a tiny misalignment could cause big problems.
What are the unique features of companion flanges?
- Precision bolt holes. The bolt holes are drilled according to exact specifications to ensure proper alignment and even distribution of pressure.
- Raised face. The raised face creates a concentrated sealing surface to enhance the leak-tightness of the joint.
- Material compatibility. Companion flanges are available in a variety of materials to match piping requirements and ensure corrosion resistance and a long service life.
Companion flanges vs. standard flanges
So, what sets a companion flange apart from a standard flange?
Design Differences
Companion flanges are typically manufactured with greater precision than standard flanges. This is particularly true for the bolt holes and sealing surfaces, which are machined to very tight tolerances.
Companion flanges are often sold and used in matched pairs, which ensures an optimal fit and seal.
Application Differences
Standard flanges are fine for most general piping systems, including applications where alignment isn’t critical.
Companion flanges, on the other hand, are preferred in situations where precise alignment and leak-free performance are essential, such as in high-pressure or hazardous fluid systems.
Applications Across Industries
Standard flanges and companion flanges play important roles in a wide range of industries.
Standard Flanges in Diverse Sectors
- Oil and Gas: You’ll find standard flanges in pipelines, refineries, and processing plants, connecting pipes, valves, and pumps.
- Chemical Processing: In chemical processing, standard flanges safely and reliably connect pipes and equipment that handle corrosive and hazardous materials.
- Water Treatment: Standard flanges join pipes and equipment in water and wastewater treatment facilities, helping to maintain water quality and system integrity.
Companion Flanges in Precision Applications
- Aerospace: Companion flanges are critical components in aircraft hydraulic and fuel systems, ensuring leak-free and reliable operation under demanding conditions.
- Automotive: Companion flanges are used in high-performance vehicles and racing applications where precise alignment and secure connections are essential.
- High-Performance Machinery: You’ll also find companion flanges in industrial equipment requiring tight seals to prevent leaks and maintain optimal performance.
Maintenance and long-term reliability
Like any piece of equipment, both standard flanges and companion flanges require maintenance for reliable, long-term performance.
Standard flange maintenance
With standard flanges, it’s important to look for signs of corrosion, wear, or damage on a regular basis. Spotting and fixing small problems early can prevent bigger, more expensive problems later on.
It’s also important to replace the gaskets when needed to keep the seal leak-tight. Be sure to use the right gasket material for the specific application.
Companion flange considerations
Proper alignment during installation is key for companion flanges. Alignment tools can help with this. It’s also important to tighten the bolts to the torque values recommended by the manufacturer, and to avoid overtightening or undertightening.
Be sure the materials you choose are compatible with the substances being transported. This can help prevent corrosion and degradation of the flange.
Putting It All Together
Flanges and companion flanges are important parts of any piping system. They each have a specific purpose, depending on the application.
Choosing the right flange, installing it correctly, and maintaining it well will help you ensure long-term reliability and, above all, safety.