Carbon Steel Flange Manufacturers, Suppliers, Stockist in India – We Sell the Best Quality Flange at Low Prices!
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- We are India’s leading exporter and manufacturer of carbon steel flanges, with monthly production and sales of over 500 tons. Most of our production of carbon steel flange is exported out of India. In India, we have extensive stock of carbon steel or mild steel flanges, and we can deliver the goods just in time.
- As one of the leading carbon steel flange manufacturer in India we can produce high quality flanges in size range of 1/2″ NB to 60″ NB in ASTM A105 and A350 LF2 grade. In addition to being the lowest cost supplier of carbon steel flanges, buttweld pipe fittings, and forged pipe fittings; we are also one of the biggest carbon steel and stainless steel seamless pipes stockist, dealer and distributor in India.
- We are large volume carbon steel flanges manufacturers in India, and are able to give you the best price and quality just in time. Our objective is to achieve highest volume sales, allowing us to offer maximum discount to our customers.
- All standard size and type in carbon steel flanges are available Ex-stock, and we can offer immediate delivery and inspection for all our goods.
- Various Types of Carbon Steel Flanges – Carbon Steel Slip On Flanges (SORF Flanges), Carbon Steel Weldneck Flanges (WN Flanges), Carbon Steel Blind Flanges (BLRF Flange), Carbon Steel Socket Weld Flanges, Carbon Steel Orifice Flanges, Carbon Steel High Hub Flanges, Carbon Steel Square Flanges, Carbon Steel Lap Joint Flanges, Carbon Steel Loose Flanges, Carbon Steel Flat Flanges/Plate Flanges, Carbon Steel Ring Type Joint Flanges (RTJ Flanges), Carbon Steel Threaded Flanges, Carbon Steel Expander Flanges, Carbon Steel Spectacle Flange.
Features & Information on Carbon Steel Flanges
The most common carbon steel flange materials include ASTM A694, ASTM A105N (SA105N), and ASTM A350 LF2 in pressure ratings from class 150 to 2500.
- ASTM A105 steel grade is a typical common material (mild carbon steel) for forged carbon steel flange, it used in a lot of places for ambient and higher-temperature service in pressure systems. This material is durable, cost lower, and difficult to break. In case used in a stainless steel piping system it shall be adapted with a lap joint end ring.
- ASTM A350 (SA350) LF2 flange, also commonly known as low temperature steel flange, is similar with ASTM A105N (SA105N) grade. This grade requires notch durability testing, and applicable for many industries. This carbon steel grade is used in conjunction with low temperature carbon steel pipe fittings.
- ASTM A694 grade carbon steel flanges are used for more rigorous applications in comparison to above. Flanges produced as per ASTM A694 grade are mainly used for oil and gas applications, where the minimum yield strength required is higher.
Carbon steel is a steel with carbon content up to 2.1% by weight. Where in AISI defines:
- No alloy element (minimum content) required, as of Cr, Mo, Ni, Ti, Va and etc.
- Specified minimum of Cu shall not exceed 0.04%.
- Maximum Mn 1.65%, Si 0.06%.
- As carbon element content increases, the steel will become harder and stronger after heat treatment. On the contrary, it become less ductile. Where if without heat treatment, higher carbon will reduce weldability.
Types of Carbon Steel Flanges based on Carbon Content
- Low carbon steel: C content at 0.005% to 0.3%.
- Medium carbon steel: 0.3 to 0.8% of Carbon.
- High carbon steel: 0.8-2.0% of carbon.
- Ultra high carbon steel: 1.25% to 2.0% of C.
- B16.5 Dimensional standard for steel pipe flanges and flanges fittings
- B16.34 Valves connect by flanges, threaded and welding end
- B16.47 Large diameter steel flanges
- SP44 Standard for steel pipe line flanges
- API 605 large diameter carbon steel flanges
Coating Types for Carbon Steel Flanges
There are several types of coatings to protect carbon steel flange from rusting or corrosion:
- Anti-rust painting
- Oil Varnished
- Electric zinc coated (White or yellow zinc)
- Alloy material coated (Lined or Clad)
Difference between Forged Carbon Steel Flange and Cast Iron Steel Flange
- Forging process is more expensive than the cast iron process
- Casting iron can be manufactured to fit different complex profiles
- Forging process doesn’t lead to the manufacture of big or uneven brain
- Cast iron flange is used exclusively for non-pressure pipelines, while forged Steel Flange is used in higher pressure pipeline
- The centrifugal machine is used to manufacture high precision cast iron flange than standard cast flanges
- Forged Steel can easily be cut, and it can withstand higher tensile strength
- Overall, forged steel is better than cast iron flanges in terms of performance as it comes with a better shape and also much lower carbon content which leads to less rusting.
Production & Supply Range for Carbon Steel Flanges
|Product||Carbon Steel Flanges|
|Product Specification||ASTM/ASME A105, A350|
|Types of Flanges||Anchor Flanges, Blind Flanges, Expander Flanges, High Hub Flanges, Lap Joint Flanges, Long Weld Neck Flanges, Orifice Flanges, Plate Flanges, Ring Type Joint Flanges, Reducing Flanges, Slip On Flanges, Socket Weld Flanges, Spectacle Blind Flanges, Square Flanges, Spades & Ring Spacers, Threaded Flanges, Welding Neck Flanges|
|Flange Materials||Stainless Steel, Carbon Steel, Alloy Steel, Nickel Alloys, Aluminium, Copper Nickel|
|Size Range||1/2”- 60”(or as per customer drawing)|
|Pressure Ratings||150#, 300#, 600#, 900#, 1500#, 2500#, PN6, PN10, PN16, PN25, PN40, PN64|
|Dimensional Specifications||ANSI/ASME B16.5, B 16.47 Series A & B, B16.48, BS4504, BS 10, EN-1092, DIN, etc.|
|Surface Finish||Sand Blast, Black Painting, Galvanizing Finish|
|Production Technique||Forged, Heat Treated, CNC Machined, Drilled|
|Test Certificates||Test Certificates are available with materials, as per EN 10204 3.1 or 3.2|
|Inspection||Buyer Inspection or Third Party Inspection Acceptable. At Metallica, all fittings and flanges are subject to strict inspection at each stage of the production process, starting from raw material purchasing to product dispatch.|
|Packing||Wooden Pallets, Gunny Bags, Wooden Box, or As per Customer Request|
|Price and Quality Guarantee||100% Price and Quality Guarantee|
|Delivery||100% On Time Delivery, 2-3 Days for In Stock Items, 15-30 Days for Volume Products|
Carbon Steel Flanges & Related Fittings Specifcations
|Material||Pipes||Fittings||Flanges||Valves||Bolts and Nuts|
|Carbon Steel||A106 Gr A||A234 Gr WPA||A105||A216 Gr WCB||A193 Gr B7|
A194 Gr 2H
|A106 Gr B||A234 Gr WPB||A105||A216 Gr WCB|
|A106 Gr C||A234 Gr WPC||A105||A216 Gr WCB|
|A335 Gr P1||A234 Gr WP1||A182 Gr F1||A217 Gr WC1||A193 Gr B7|
A194 Gr 2H
|A335 Gr P11||A234 Gr WP11||A182 Gr F11||A217 Gr WC6|
|A335 Gr P12||A234 Gr WP12||A182 Gr F12||A217 Gr WC6|
|A335 Gr P22||A234 Gr WP22||A182 Gr F22||A217 Gr WC9|
|A335 Gr P5||A234 Gr WP5||A182 Gr F5||A217 Gr C5|
|A335 Gr P9||A234 Gr WP9||A182 Gr F9||A217 Gr C12|
|A333 Gr 6||A420 Gr WPL6||A350 Gr LF2||A352 Gr LCB||A320 Gr L7|
A194 Gr 7
|A333 Gr 3||A420 Gr WPL3||A350 Gr LF3||A352 Gr LC3|
Types of Flanges –What are the Various Types of Flanges?
A flange can be characterized and classified in various ways such as:
-Types of Connection
-Flange facing Types
-Pressure Temperature Ratings
The standard type of steel flanges mostly used are:
- Carbon Steel Welding Neck Flange: This type of flange has a neck that is welded to the end of pipes. It is used for high pressure applications to reduce the concentration of stress. Generally machined from a forging, these flanges are typically butt welded to a pipe. Weld-neck flanges have a higher life expectancy than slip-on flanges under duress.
- Carbon Steel Slip On Flange: Slip-On flanges or SO flanges are commonly lower in price than weld-neck flanges, and to this effect are a popular choice for many users. These pipe flanges slip over the pipe. They’re manufactured with an inside diameter that is slightly bigger than the pipe’s outside diameter. These attachments are connected to the pipe via fillet weld at the top and bottom of the flange.
- Carbon Steel Socket Weld Flange: A socket weld flange has a female socket in which pipe is fitted. Fillet welding is done from outside on the pipe. The socket welding flange is similar to a slip-on flange except it has a bore and a counter bore dimension. The counter bore is slightly larger than the O.D. of the matching pipe, allowing the pipe to be inserted into the flange similar to a slip-on flange. The diameter of the smaller bore is the same as the I.D. of the matching pipe A restriction is built into the bottom of the bore which sets as a shoulder for the pipe to rest on. When using a socket weld flange, the inner diameter needs to be the same as the inner diameter of the pipe. The socket flange is only suitable for pipes with a nominal diameter of 150 or less.
- Carbon Steel Lap Joint Flange: Lap Joint Flanges (LJ Flanges) are used on piping fitted with lapped pipe or with lap joint stub ends the combined initial cost of the two items being approximately one-third higher than that of comparable welding neck flanges. Lap joint flange is having two components, a stub end, and a loose backing flange. Stub end is butt welded to the pipe and Backing flange freely move over the pipe. The backing flange can be of different material than stub material and normally of the carbon steel to save the cost. Lap flange is used where frequent dismantling is required, and space is constrained. The lap joint flange is practically identical to a slip-on flange except it has a radius at the intersection of the bore and flange face. The lap joint flange is practically identical to a slip-on flange except it has a radius at the intersection of the bore and flange face. This radius is necessary to have the flange accommodate a lap joint stub end. Normally, a lap joint flange and a lap joint stub end are mated together is an assembly system.
- Carbon Steel Threaded Flange: Threaded Flanges are also known as screwed flange, and it is having a thread inside the flange bore which fits on the pipe with matching male thread on the pipe. Threaded flanges are widely demanded as pipe flanges i.e called as threaded pipe flanges used in different industrial applications. This type of joint connection is speedy and simple but not suitable for high presser and temperature applications. Threaded Flanges are mostly used in utility services such as air and water. Threaded (Screwed) flange is similar to the Slip-On flange, but the bore is threaded. Its chief merit is that it can be assembled without welding, explaining its use in low pressure services at ordinary atmospheric temperatures, and in highly explosive areas where welding create a hazard. Threaded flanges are not suitable for use where the temperature of the pipe changes sharply or the temperature is higher than 25°C and lower than -40°C.
- Carbon Steel Blind Flange: A Blind flange is round plate which has all of the relevant boltholes but no center hole, and because of this feature this flange is used to close off the ends of a piping systems and pressure vessel openings. It also permits easy access to the interior of a line or vessel once it has been sealed and must be reopened. The blind flange is used to close ends of piping systems. It is a kind of round plate with no center hold but with all the proper bolt holes. This blind flange is available in various sizes and materials and is used to provide positive closer on the ends of pipes, valves or equipment nozzles. This flange helps in easy access to a line once it has been sealed. The blind flange is sometimes custom made or machined to accept a nominal sized pipe to which reduction is being made. Blind Flanges are commonly used in petrochemical, pipe engineering, public services & water works. Blind pipe flanges are often used for high pressure applications.
In addition to the most used standard flanges, there are still a number of special steel flanges such as:
- Carbon Steel Orifice Flange: Orifice flanges are used instead of the standard pipe flanges when orifice plate or flow nozzle is used. In other words, orifice flanges are used with orifice meters. The basic purpose for this is to measuring the flow rate of either gases or liquids in the respective pipeline.
- Carbon Steel Long Welding Neck Flange: Long weld neck flange(LWN flange) is also call integral flange, it means a welding neck flange has a very long neck. Commonly, the welding neck flange has a tapered neck and a bevel end which is going to butt welding with the matching pipe. But the long weld neck flange, has a straight short pipe as the neck of a long weld neck flange.
- Carbon Steel Weldoflange & Nipoflange: The Weldoflange and Nipoflange is a combination of a Welding Neck flange and a supposedly Weldolet or Nipolet. The 2 components are manufactured in one piece, and not welded. These flanges are primarily in Branch connections. Furthermore, they have an expanded range of special flanges, fittings and branch connections.
- Carbon Steel Expander & Reducing Flange: Expanding and reducing flanges are used to increase or decrease the bore size of a pipeline. Expander and reducer flanges are a good alternative to butt weld reducers when the required pipeline bore reduction or increase is small (one or two sizes). For larger size changes, the use of buttweld fittings is recommended.
Selection of the Type of Flange Connection with Pipes
- Steel pipes can be connected to flanges by welding the pipe with the flange (welded connection, made with weld neck, socket weld, slip on and lap joint flanges) or by screwing the flange onto the pipe (threaded connection, made using threaded flanges).
- Welded connections are used for pipelines and piping systems featuring high pressures and temperatures, and diameters above 2 inches. Threaded connections are used for small diameter piping systems that are not subject to mechanical forces as expansion, vibration, contraction, oscillation (conditions that would crack the threaded joints). Let’s take a close look at the welded connections types.
Weld Neck Connection (Weld Neck Flanges)
- Weld-neck flanges have a tapered hub with a butt weld end that can be welded to a butt weld pipe. The quality of the welded joint should be examined by dye penetrant test (DP) or using radiography and/or ultrasounds (UT).
- The welded connection between a weld neck flange and a pipe features a good fatigue and mechanical stress performance.
Socket Weld Connection (Socket Weld Flanges)
- Socket weld flanges are most preferred for use in high pressure piping systems generally below 2 inches (DN 50).
- The pipe is fillet-welded to the hub of the socket weld flange. The quality of weld is of utmost importance in this kind of a flange connection, and appropriate inspection should be done before moving the system into operation.
Slip-On Connection (Slip On Flanges)
- Slip-on flanges are generally preferred to weld-neck flanges due to their lower cost and installation speed (and ease).
- The disadvantage of slip on flanges over weld neck flanges is that their strength is about 1/3 lower.
- Due to lower strength slip on flanges are typically used for low-pressure, non-critical services.
- The pipe is welded to both the hub and the bore of the flange. Slip-on flanges are used, generally, for pipe sizes greater than NPS 2¹⁄₂ (DN 65).
Lap Joint Connection (Lap Joint Flanges and Stub Ends)
- This type of connection is sometimes used for pipelines in high-cost materials (as stainless steel and nickel alloys) as it helps to reduce the overall cost of the required flanged connections.
- A lap joint connection is made by the combination of a stub end (which is the part welded to the pipe) and a backing flange, or lapped flange.
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Manufacturing Process for Carbon Steel Flanges
A flange is produced either by forging, casting, cutting, or rolling. We produce flanges mainly by forging, cutting, and rolling process.
Forged Carbon Steel Flange Manufacturing Process
The forging process is usually composed of the following processes, namely, the selection of quality steel billet, heating, forming and cooling.
- Inspection of Raw Material – The key raw material for producing flanges is steel billets or hot rolled bars. All raw materials purchased are supplied with test reports as per EN 10204 3.1, with full traceability. It is the first compulsory step in the production process for flanges to guarantee good quality. The raw materials are re-tested inhouse for assurance on chemical composition, mechanical capacity and metallographic analysis.
- Cutting Raw Material – Correctly and strictly controlling cutting size and proportion can ensure adequate control on the cost.
- Heating – It is a very important step for flange quality. It is the necessary to record the heating temperature in details to avoid overheating. Overheating will destroy the structure of the metal and mechanical properties pf the raw materials.
- Forging – Forging process is divided into free forging and die forging. The forging time and strength of flange is different for different pressure class.
- Heat Treatment – The purpose of heat treatment is to eliminate the stress inside of flange so that the density is more evenly. Carefully recording the temperature of heat treatment and cooling time are the keys.
- Forging Blank Inspection – After the heat treatment process has been carried out, a sample of the lot is chosen to test the chemical composition and mechanical property again to ensure all items are qualified.
- Machining of Forged Blanks – In the machining process, the inspection is carried out along with the processing, so that to guarantee each part of flange is qualified. Machining is undertaken on CNC and/or lathe machines.
- Finishing Goods Inspection – Finished products will be checked 100% before delivery to ensure the goods are perfect as per ASME, EN or customer standards.
- Documentation – The whole production process and quality checks at different levels is documented as per standard operation procedure under ISO compliance. It is the guarantee for good quality.
- Test Certificate: Since we are a ISO and PED certified manufacturer, we can issue test certificate as per EN 10204 3.1 for all the goods at the time of delivery and inspection.
- Packing: All forgings and flanges are packed in wooden crates or box or pallets to ensure secure movement of goods.
Carbon Steel Plate Cut Flanges Manufacturing Process
- The process here is relatively simple, with the key raw material being hot rolled plates. This process is mainly used for producing slip on plate flanges and blind flanges for lower thickness. All plates procured are accompanied with tested certificates as per EN 10204 3.1.
- Circles are cut from plates.
- Heat treatment is not involved in this process of manufacturing flanges.
- Drilling and machining is done on circles to achieve the desired dimensions.
- Goods are visually inspected and marked with relevant standards.