Flange Leakage is a common issue that can arise from several factors. Here are the seven primary causes:
Misalignment occurs when the pipe and flange are not perpendicular or concentric, leading to non-parallel flange faces. When the internal pressure exceeds the load pressure of the gasket, leakage can occur. This issue is often a result of improper installation or maintenance and can be easily detected during a final inspection. Ensuring correct alignment during assembly can prevent such incidents.
Offset refers to a situation where the pipe and flanges are vertical, but the flanges themselves are not concentric. This misalignment prevents the surrounding bolts from passing freely through the bolt holes. In the absence of alternative solutions, drilling larger holes or using smaller bolts may be necessary, which reduces the clamping force between the flanges and can lead to leakage due to an imperfect sealing surface.
A gap between the flanges that is too large can create issues. When external loads, such as axial or bending forces, act on the flanges, they can cause the gasket to experience impact or vibration, resulting in a loss of compressive strength and ultimately leading to sealing failure.
Misdrilled holes occur when the bolt holes of the flanges are not correctly aligned, even though the pipes are concentric. This misalignment creates stress on the bolts, and if not addressed, the bolts can experience shear forces over time, potentially leading to bolt breakage and sealing failure.
The thermal expansion and contraction of the fluid medium can cause the bolts to expand or contract. This results in gaps that allow the medium to leak through pressure changes, exacerbating the leakage issue.
Thinking that as long as the bolts are tightened, no leakage can be guaranteed: Excessive Bolt Tightening force may lead to deformation of the flange or breakage of the bolts, which is not conducive to sealing.
Ignoring the importance of the gasket: The gasket is a key part of the flange sealing, and the selection and installation of the gasket should be paid attention to.
Thinking that it doesn't matter if the flange leaks a little: flange leakage will not only cause material loss but also may cause safety accidents.
The causes of flange leakage are multiple, involving design, installation, materials, working conditions, and other factors. Flange leakage can be effectively prevented by installing in strict accordance with the design requirements, choosing suitable sealing materials, and regular inspection and maintenance.
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