What Are the Benefits of Using Long Weld Neck Flanges

What Are the Benefits of Using Long Weld Neck Flanges?

Long weld neck flanges are common specialized connections used in the energy, oil, and petrochemical industries among others. They are typically found in complex pipeline systems serving multi-level buildings and refineries. But why are they considered to be the perfect pressure vessel connections for these pipeline systems? Here are a few of the reasons:

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Extremely Strong and Reliable

Long weld neck flanges use a long, tapered hub that gradually increases the thickness of the pipe from the weld all the way to the face of the flange. This design assures that the stress created internally by the flow of high-pressure liquid is transferred to the pipe, thus reducing the stress on the flange itself.

Handles High Pressure and Temperature Fluctuations Well

Due to the nature of the oil, gas, and petrochemical industries, the piping systems used within them must transfer large quantities of liquid across great distances. This requires the system to use a great deal of pressure to force the liquid along the pipe. In addition, these pipes often are constructed in very unforgiving hot and cold environments. The design of the long weld neck flange can help mitigate the constant changes in pressure and temperature that piping systems encounter as they flow through the twists, turns and changes in elevation that the average pipeline system encounters.

Assures the Smooth Flow of the Liquid Passing Through Them

Because long weld neck flanges are bored to match the inside diameter of the pipe itself, the flow of high-pressure liquid is not impeded. This design assures that there is little “turbulence” within the pipe, a common cause of erosion, resulting in stronger more durable pressure vessel connections.

Easier to Align, Install and Test

The design of the long weld neck flange makes it easy to align to the pipe network in which it is installed and results in a stronger weld. Another benefit of the design is that it is very accessible when checking the integrity of the weld via radiography testing.

FCI is the Premier Manufacturer of Long Weld Necks

Forged Components Inc. (FCI) is the leading ASME pressure vessel connections manufacturer with over 45 years of experience in Long Weld Neck manufacturing. FCI maintains the largest inventory of Long Weld Necks in North America, as well as a vast inventory of raw material on the ground. For more information, please call us at (281) 441- or contact us online to get a quote from our sales staff.

Understanding the Types and Uses of Weld Neck Flanges

The weld neck flange is a common feature in industrial operations, helping to reduce stress concentrations at the bottom of the flange by distributing stress from the pipes. It comes in two types, one suitable for gaskets and the other longed version suitable for operative industrial plants but not for pipes.

The flange includes a circular component that extends beyond the rim’s circumference, produced by forging and welding to the pipes. The rim has several holes allowing bolted attachment, thus making it more structurally sound.

Uses of Weld Neck Flanges in Various Applications

The weld neck flange is widespread in industrial environments due to its versatility, reliability, and simplicity of installation and replacement. This piece will concentrate on the slip weld neck flanges, disclosing their potential applications in different industries, the welding technique used, and the numerous options provided.

The weld neck flanges are commonly used in pipe fittings to connect pipes. These flanges create a dependable connection between two pipes or tubes and link various valves and parts in a piping system. Slip-weld neck flanges are effective in chemical plants, oil rigs, and water pipelines.

How is Welding Done for Weld Neck Flanges?

To securely attach slip weld neck flanges, two options are available. First, use a welding machine or manually use an oxy-acetylene torch. Careful connecting of all parts is crucial to prevent leakage or gaps. Moreover, it is necessary to utilize the appropriate welding filler material to achieve a robust bond among the merged parts.

What Are the Different Types of Weld Neck Flanges?

Many types of slip-weld neck flanges can be bought from manufacturers. You get choices like the raised face, blind, lap joint, socket weld, and threaded varieties. The most appropriate option for your specific project will be determined by your requirements, along with the flange specifications of your particular application.

Blind Flange

Blind flanges are utilized when the space is limited or restricted for a threaded or lap joint connection. Socket welds have higher pressure ratings as they sink deeper into the end of the pipe. Lap joints are great for situations that require frequent dismantling as they fit loosely.

Threaded connections are effortless to install and remove. Furthermore, raised face slips help prevent leaks by providing a robust seal between two pipes when fastened with bolts or screws.

Long weld neck Flange

The Long Welding Neck Flange is an enlarged version of the commonly used welding neck flange. It is frequently used as a nozzle for columns and barrels and comes in two types: the LWN Heavy Barrel and the Equal LWN Barrel. Both versions have a robust wall structure and unique shapes.

Reducing Weld Neck Flange

A “Reducing Weld Neck Flange” is not a distinct kind of flange. The term “reducing” generally indicates a flange that links pipes or fittings of varying sizes and is made to transform from a bigger pipe size to a smaller one. A “reducing flange” with a larger outer diameter (OD) on one side and a smaller OD on the other is used to connect pipes with different diameters.

Standard Weld Neck Flange

A standard weld neck flange is a flange variety with a lengthy, conical neck that joins pipes via butt weld strengthening the joint and spreading the stress onto the pipe.

NW Long Weld Neck Flanges

The NW LWN flanges, also known as NW Long Weld Neck Flanges, are a flange type frequently used for vacuum systems. These flanges are defined by their elongated, tapering necks and are typically composed of high-quality materials like stainless steel.

Their lengthy neck adds durability and stiffening, making them appropriate for high-vacuum applications. These flanges are designed to be directly welded onto the vacuum chamber or other vacuum system elements to ensure an airtight and secure connection that maintains the vacuum system’s integrity.

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The NW Long Weld Neck Flanges follow industry standards, such as DIN or ISO , and come in different sizes ranging from NW10 to NW50, each with a different outer diameter and bolt-hole pattern.

Materials used in Weld Neck Flanges

Various materials are appropriate for Welding neck flanges, as specified by standards, with the highest level of quality regulated by ASTM and ASME rules. The flange thickness and internal diameter of the flange should match the intended pipe size. Due to its exceptional resistance to extreme temperatures, carbon alloy is a highly desirable material for flange production.

Clients and professionals can benefit from different flange weights and grades, like the ASME B16 47 ‘A’ Series and ‘B’ Series. Additionally, stainless steel welding neck flanges made from ASTM A182, F304, 316L, 347H, 310S, and ASME B16 5 are available and finished with duplex steel.

Several materials are used in creating welding neck flanges, including stainless steel, carbon alloy, nickel alloy, and others, such as UNS S Duplex Steel. Nickel Alloy materials such as Inconel 600 and 625, Hastelloy C22, and C276 are among the many options available.

Weld Neck Flange Dimensions

Various sizes of Class 150 ASME B16.5 weld neck flanges are available, ranging from 1/2″ to 24″. Each size has a different outside and inside diameter, raised face thickness, and several bolt holes. The smallest size has an outer diameter of 3.50″ and four bolt holes, while the largest has an outer diameter of 32.00″ and a raised face thickness of 5.69″.

Conclusion

If you need a dependable method for joining two pipes or linking valves and other parts in your system, slip-weld neck flanges are the answer. They can be of different types, including blind slips for compact areas and raised faces for added leak protection, and they’re affordable and easy to set up.

You can use an automated welding machine or a manual oxy-acetylene torch. However, it will depend on what your requirements are. As long as you maintain and install them, these sturdy components can last many years, even in challenging environments.

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Pros & Cons of Using a Weld Neck Flange

            There are over a dozen different types of flanges commonly used in industrial piping systems, the Most Common Flange being used today is known as a weld neck flange. A weld neck flange is a type of flange which “features a long tapered hub that can be welded with a pipe.”1 This is done to ensure that none of the product flow is lost or restricted. Among the many versatile uses for a welding flange, its Most Common application is in piping systems which have great fluctuations in temperature and/or pressure, as well as in piping systems which transport hazardous fluids. In short, a weld neck flange is ideal for extreme conditions in piping systems. However, there are some major drawbacks to the weld neck flange, namely the price tag on a weld neck flange compared to the potential use of another flange, such as a slip-on flange. Let’s dive right in and explore the advantages of using weld neck flanges.

            Weld neck flanges are able to withstand great extremes in pH, temperature and pressure fluctuations. “The resilience of this type of flange is achieved by sharing the environmental stress with the pipe with which it is welded.”2 Some weld neck flanges have “been used successfully at pressures up to 5,000 psi.”3 And while weld neck flanges can be used exclusively in such piping systems, it is advised to consult an engineer regarding where weld neck flanges should be applied.

            Another major advantage to weld neck flanges is their ease of installation. Though a skilled welder is required for the installation of a weld neck flange, there are not many variables required to take into consideration. “When using the butt flanges it is easier to determine pipe length applications because the calculations do not have to account for the space taken up by threads on bolt-on applications. Slip-on flanges also require calculation using the insertion amount.”4 Because of this welded connection, the weld neck flange is quite durable– though there are disadvantages, mainly in regard to the price of a weld neck flange.

            Weld neck flanges can run up a check! Yes, despite their size and simple construction, weld neck flanges can be more expensive than an alternative, similar type of flange. The increased cost is mostly due to the additional material in the construction of the flange: “The production of these flanges is more expensive because of the long necks that are present.”5 Besides the (typically) more favorable price for similar, cheaper flanges such as slip-on flanges, the weld neck flange, the next most common disadvantage for weld neck flanges is their potential to leak: “each connection has to pass a radiography test. When the tests are complete and the weld is sufficient there could still be air bubbles in the weld that the test did not detect. Over time these bubbles will develop leaks. Regardless of the welder’s skill set these bubbles occur and leaks will develop over time. These leaks can be repaired without replacing the entire flange.”6 It should be noted that pipe flange radiography is a relatively easy process.

            All in all, there aren’t many disadvantages to using a weld neck flange: They’re easy to install, remarkably resilient and definitely durable. Still, the main disadvantages for these weld neck flanges, though sometimes negligible, are the cost for weld neck flanges, and the fact that a weld neck flange can sometimes leak if not radiographed properly, which can practically negate the entire purpose of a flange if the leaking is excessive and (though rare) unable to be mitigated and requiring replacement. Again, EMC is not making a definitive recommendation to any of its customers to always use a weld neck flange whenever applicable based on the information in this article alone: for a recommendation into which flange to go with for your own unique application, please contact EMC today! We recommend emailing us at and our team of industry experts with over 45 years of experience will get back to you as soon as possible with a recommendation.

1          https://blog.projectmaterials.com/flanges/flange-types-piping/ 

2          https://www.weldflange.com/application-and-advantage-of-weld-neck-flange.html

3          Same as 2

4          http://weldneckflange.weebly.com/benefits-of-using-weld-neck-flanges.html

5          Same as 4

6          Same as 4