Piping solutions with using a flared flange system

Paul Boughton

Thomas Rüdiger and Frank Wiele outline the updates to the expansion of a flared flange system and the introduction of a piping solution service.When Parker Hannifin's Parflange F37 flared flange programme was introduced in 2008, an alternative to welded high-pressure tube fittings for larger outside diameters up to 140mm was created. Now, after a good two years, this product programme is being expanded.

The range has been broadened not only with additional flange sizes but also with new system components such as T and L flanges, bends, welding adaptors and non-return valves.

A new product line for low pressures has also been introduced. New, too, is the global introduction of the Piping Solution Service, which in particular covers the prefabrication of complete piping lines configured specifically to customers' requirements, and thereby creates for the end-customer new, flexible possibilities regarding piping design and assembly.

Parker offers the Parflange F37 flaring system for tubes up to 273mm outside diameter, wall thicknesses up to 9mm and pressures up to 420bar - a system which in the meantime has been proved hundreds of thousands of times over in the marketplace. The F37 retaining ring system is available for connections where pre-flared pipework or orbital flaring on site are not possible or very difficult. For this kind of connection, a retaining ring is fitted into a groove in the tube end to be machined and the flange pressed against this retaining ring during assembly, whereby solid form connections are achieved. When fitted on the sealing side with Bonded Seal or Seal Carrier types, this version also guarantees leak-free pipe connections, in particular for thick-walled pipelines.

Low-pressure system

Based on standard SAE and ISO flange connectors, the pipe connector programme for SAE 3000/ISO 6162-1 was designed in the first instance for pressures of only 210 to 350bar, and respectively for SAE 6000/ISO 6162-2 up to 420bar. In particular, this satisfies the requirements of the offshore, shipbuilding and heavy machinery industries. The new additional F37 SAE 1000 psi system low pressure programme is tailored for applications up to 70bar. For example, cooling circuits and tank and return lines can be rapidly constructed with them, saving cost and weight, and staying leak-proof. The flange hole pattern corresponds to that of the SAE3000 series and can, wherever the pressure conditions allow, be directly screwed to the SAE 3000 connection system. Conceived as standard parts for pipe sizes from 1 1/2-in to 60-in (F37) and 1 1/2-in to 10-in (retaining ring) at a permissible 50-70bar, with the new low-pressure range 10 distinct pipe sizes with different connection components are available from stock.

The variety of components is enormous: pipe to pipe, pipe to port connections, reducers, bends, T and L flanges - the new Parker low-pressure flange connector system is ideally equipped for the solution of complex piping designs. It goes without saying that all the pressure series of the Parflange F37 1000psi system are approved by recognised accreditation bodies such as Det Norske Veritas (DNV) and the American Bureau of Shipping (ABS).

The Parflange F37 SAE 3000 programme covers the pressure range from 210 to 350bar. This product line has undergone a significant expansion and now starts at 1/2-in, followed by 3/4-in pipes, instead of as previously only at the 1-in pipe. With the individual components, too, Parker has been able to again significantly extend the variety of types. An additional flange type with integrated thread renders the conventional nut superfluous and makes assembly even easier. New in the range is the Pipe Seal Carrier (PSC), which makes machining the face side of the pipe unnecessary.

But piping systems should not always be changed over completely from the conventional welding solution to the flange system. Here, too, Parker has a recipe in the new catalogue - welding adaptors in various dimensions are now available with additional sizes. There is also a range extension to the valves. Non-return valves are the newcomers here. In a comparable way, the SAE 6000 series of the F37 Parflange programme has been extended. Permitted up to 420bar, for this series too there are many more sizes/components than previously. Here, too, special mention should be made of more flange types, such as, for example, jump-size flanges with and without thread.

Important innovations have also been made in the ISO 6164 system for pressures from 350 to 400bar. The retaining ring system is now approved for up to 10-in pipe/flange combinations.

The appropriate pipe with the proper pipe quality is of course an integral part of this comprehensive product programme. In this respect Parker can fall back on its experience over the years in the pipe market and offers an extensive pipe programme in the new F37 catalogue.

The enormous outlay of the time and costs of welding, and the given safety risks associated with, for example, faulty welding, careless X-rays or ultrasound testing, militate in favour of screwed connectors. Compact, weld-free lines with the possibility of using jump sizes open up for both machine and equipment builders an enormous degree of design freedom. The Parflange F37 system connects pipes together with absolute positive locking.

Neither expensive tests nor welding certificates are required for the assembly of Parflange F37 connections. A calculation programme obtainable from Parker makes clear at a glance the economic benefits of this connection system; based on the number of welded connections per unit and per year, and also the labour cost per hour, it gives the time and cost savings that can be achieved with the Parflange F37 system.

Installation comparisons for welded lines show that - depending on the number of weldseams there are to be calculated - cost savings in the 5 and even 6-digit area are very quickly achievable.

Parflange F37 technology saves energy and does not require any external heat input. In comparison with welding, neither environmentally critical degreasers nor anti-corrosion agents are required and neither is subsequent tube cleaning. When galvanised pipes are being used, re-galvanising can be dispensed with, since the zinc layer is not affected by flaring. Furthermore, the stress corrosion cracking caused by welding cannot occur. This reduces maintenance costs and increases the service life of the piping system.

Unlike welding, the Parflange F37 system does not produce any noxious gases needing extraction, either from flaring or during assembly. There is no risk of fire or explosion - a very positive feature of Parflange F37 assembly on sites with strict safety requirements, such as for example offshore platforms and process engineering installations. The Parflange F37 assembly is user-friendly - the F37 flange is not firmly fixed to the pipe yet is still positively locked and axially rotatable. This lightens the workload, especially for heavy piping cross-sections. Parker flange connectors are designed as standard with Cr(VI)-free surfaces. In addition, components in stainless steel and alternative surfaces are available.

Parker knows all about being a system partner for pipe connections. Piping Centres have been set up worldwide in which Parker produces tailor-made customer solutions centred on hydraulic pipework. This service can include measurement surveys, engineering, manufacturing pipe flange connectors, including bending and end-machining of pipes, as well as installation of the connectors.

In their role of system partners for pipe connectors, Parker engineers and technicians are available already at the design stage of machines and installations to ensure that the optimal piping system design is developed. The engineering includes guidance and design through to recommendations on what type of connection would be ideal. This service covers more than the choice of products and materials to be used. In line with the Parker Piping Solutions concept, experienced specialists worldwide are available to generate these benefits. These professionals at the Piping Solutions Centres also carry out flushing and pressure tests and generate piping system documentation. The Piping Solution system ranges over perfect logistics all the way to user training. This also includes specialist presence during installation. In this respect, it makes no difference whether it involves original equipment or the modernisation of a machine or installation.

The employment of prefabricated components makes the build-up of Parflange F37 connection systems easier. Flanged pipework allows easy integration into existing piping systems, which can be conveniently expanded or converted to Parflange F37. Piping components which are flanged can be much more quickly and economically exchanged or altered in the pipework routing than welded connections. Tailor-made, screwed hydraulic connections with cold-manipulated pipes also offer enormous time savings when converting, extending or dis-assembling. And there's even more - because of its design, the employment of Parflange F37 means significantly fewer leakage risks, bringing obvious environmental advantages.

The English-language catalogue No. CAT/4162-1/UK for the Parflange F37 programme is available free of charge to interested parties (Fig. 2).

Enter √ at www.engineerlive.com/iog

Dipl-Ing Thomas Rüdiger has been the project leader responsible for the Parflange F37 programme. Frank Wiele is Product Manager is responsible for the F37 programme. Parker Hannifin GmbH is based in Kaarst, Germany. www.parker.com

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