Flange Adaptor Manufacturer
Flange adaptor is a pipe fitting designed to connect plain end of different materials or sizes pipes to a flanged component, such as a valve, pump, or another pipeline.flange ends is connected rigidly ,socket ends with gasket is flexible connection with pipes plain ends which can allow small deflection. It provides a secure and leak-proof connection between pipes and flanged equipment, ensuring that the system functions correctly.
Judberd is china competitive flange adaptor manufacturer, we have more than 10 types flange adaptor design and we can design according to client requirement.We can offer very competitive price and outstanding quality products based on automatic moulding line.
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JUDBERD ADVANTAGE
Judberd is a Chinese manufacturer specializing in flange adaptor. Judberd can supply flange adaptor in ductile iron, carbon steel and stainless steel material. The pressure can be PN10, PN16, PN25, PN40, PN63 or PN100, where for PN25 and below, the material of the gland and body of the flange adaptor is ductile iron (ductile iron grade can be ENGJS400-18, ENGJS450-10, EN GJS500-7,ASTM65-45-12 or as per client requirement), for PN40 and above, the material of the gland and body of the flange adaptor is carbon steel or stainless steel (carbon steel or stainless steel can be Q235 ,Q275 or other grade as per client requirement). Judberd’s flange adaptor can be used to connect ductile iron pipes, steel pipes, PVC pipes, AC pipes, GRP pipes etc. For these common pipes, we have dedicated flange adaptor that can be used to connect one type pipe. We also have wide range flange adaptor that can connect several different pipes in order to reduce the stock quantity of distributors. We can also design restrained or mechanical joint flange adaptor for special pipe or service conditions.
Judberd can design flange adaptor according to customer’s usage requirements
Judberd has many types of flange adaptor that can be selected by customers
Judberd’s flange adaptor is with flower shape flange, the same flange can be connected to EN1092 PN10 and EN1092 PN16 flange, ANSIB16.48/ANSIB 16.5 and AS4087 flange is also available
We have added a stopper design in the following position, which both increases the sealing surface and improves the sealing performance of the flange adaptor, and the stopper also prevents the pipe from being inserted too deep and thus causing damage to other pipework products such as the valve sealing surface.
The end ring of flange adaptor has a edge ring designed to fix rubber ring, which can ensure that the rubber ring is evenly wrapped around the pipe when it is tight, making it easier to install
There are many types of tie rods to choose from, 4.8 grade, 6.8 grade or 8.8 grade carbon steel, SS304, SS316 and other stainless steel are available.
Rubber can be EPDM, NBR or other materials
The powder on the surface can have multiple colors or different authentication, thus meeting the different needs of customers.
Production Process for Flange Adaptor
1,For the production of castings, the process is the same as for ductile iron pipe fitting, see the following link
https://pipefittingandvalve.com/ductile-iron-pipe-fitting/
2,Polishing
3,Rough shot blasting
4,Machining
5,Fine shot blasting
6,FBE Coating,nylon 11 coating or as per client requirement
7, Assembly
Please note inspection should be followed for every step , non qualified products shouldn’t go to the next step
Flange Adaptor Parts
The flange adaptor has four main parts:
- End Rings: Usually made of ductile iron or steel, they are high-strength components that will deform the gasket when tightened down by the tie rods.
- Flange Adaptor Body: Typically a cylinder with a flange on one end. The flange can be flat or raised, depending on the application. The size and number of holes in the flange are determined by the standard to which the flange is to be connected. The other end of the cylinder is bell-mouthed to match the gasket. When the tie rods are tightened, the gasket is compressed between the end rings.
- Seal/Gasket: The seal can be an O-ring, an A-shaped gasket, or another appropriate shape to ensure that liquids or gases do not escape from the piping system.
- Tie Rods: The tie rods are chosen based on the application and the required pressure rating. Bolts are usually treated to resist corrosion and extend the life of the flange adaptor.
By working together, these components connect different piping or equipment reliably, ensuring the safety and efficiency of the system.
Flange Adaptor Use
The main function of flange adapter is to connect different components in the pipeline system(connect flange valves to pipe plain ends etc), so that the pipeline system can achieve safe, reliable connection and sealing. Specifically, the function and working conditions of flange adapter are as follows:
Flange adaptors can connect pipes of different materials (such as steel pipes, ductile iron pipes, PVC pipes, etc.), providing flexible solutions.
Provide sealing and leak-proof function:
Through sealing components (such as A type gaskets, O-rings etc.), flange adaptors ensure the sealing of the connection to prevent medium leakage.
Easy to install and disassemble:
Flange adaptors make it more convenient to install and dismantle the pipeline system, especially in places where frequent maintenance or replacement of equipment is needed.
Absorb vibration and displacement:
To a certain extent, flange adaptors can absorb the vibration and small displacement in the pipeline system to protect the pipeline and equipment.
Working conditions
Water supply and sewage treatment systems:
Flange adaptors are widely used in municipal water supply and sewage treatment pipeline systems to connect flanged pipeline parts to pipes plain ends of different materials and sizes to ensure the reliability and sealing of the system.
Industrial pipeline systems:
In industrial fields such as chemical industry, oil, natural gas, food processing, etc., flange adaptors are used to connect various process pipes and equipment to meet the requirements of complex pipeline layout and operation.
Heating and air conditioning systems:
In heating, ventilation, and air conditioning (HVAC) systems, flange adaptors are used to connect different pipes and equipment to ensure the efficient operation of the system and convenient maintenance.
Marine and offshore facilities:
In marine and offshore facilities, flange adaptors are used to connect pipeline systems with high corrosion resistance requirements, such as seawater desalination, offshore oil drilling platforms, etc.
Agricultural irrigation systems:
In agricultural irrigation systems, flange adaptors are used to connect pipeline parts flanges to pipes plain ends of different materials to ensure the normal operation and maintenance of the irrigation system.
Power and energy systems:
In power and energy systems, flange adaptors are used to connect boilers, heat exchangers, gas pipelines and other equipment to ensure the safety and efficient operation of the system.
Flange Adaptor Installation
Flange Adaptor Types
By material
Flange adaptors can be divided into different types based on the material they are made of. Some common types of flange adaptors include:
Ductile iron flange adaptor: Ductile iron flange adaptors are mainly used in municipal water supply and sewage treatment pipeline systems to connect pipes of different materials and sizes. They are also used in industrial pipeline systems to connect various process pipes and equipment.
Mild steel flange adaptor: Mild steel flange adaptors are used in a wide range of applications, including industrial pipeline systems, heating and air conditioning systems, marine and offshore facilities, agricultural irrigation systems, and power and energy systems.
Stainless steel flange adaptor: Stainless steel flange adaptors are mainly used in applications where high corrosion resistance is required, such as marine and offshore facilities, food and beverage processing plants, and pharmaceutical manufacturing facilities.
These are just a few examples of the different types of flange adaptors available. The type of flange adaptor you choose will depend on the specific requirements of your application and the material compatibility needed for your pipeline system.
By function
Based on different working conditions, we need to select different types of flange adaptors. Common types of flange adaptors include universal flange adaptor, quick flange adaptor, restrained flange adaptor, and mechanical joint flange adaptor. Among them, the universal flange adaptor is the most versatile. One universal flange adaptor can be used to connect pipes with different outside diameters, which can reduce the distributor‘s inventory.
Quick flange adaptors are designed for fast installation and removal, making them ideal for applications where frequent maintenance and replacement of equipment is required. Restrained flange adaptors are used in applications where the pipeline system is subject to high internal or external pressure, vibration, or movement. The restrained design helps to prevent the pipe from moving or coming apart under these conditions. Mechanical joint flange adaptors are used in applications where the pipeline system requires a high degree of flexibility and movement. The mechanical joint design allows for movement in all directions, providing a high degree of flexibility for the pipeline system.
Flange Adaptor Dimension
There are several key dimensions to pay attention to when selecting and installing a flange adaptor to ensure proper sealing and connection of the pipeline. These dimensions include:
Nominal Pipe Size : The nominal diameter of the pipe that the flange adaptor is adapting. It is important to make sure that the DN of the flange adaptor matches the DN of the pipe.
Flange Dimensions: The connection dimensions of the flange (bolt hole center distance, number of bolt holes, bolt hole diameter) should match the flange to which it is being connected to ensure that it can be connected and sealed properly. Additionally, the outer diameter, thickness, and inner diameter of the flange do not necessarily have to match the flange to which it is being connected, but it is important to ensure that there are no sealing issues.
Outside diameter of the pipe: The outside diameter of the pipe to which it is being connected should match and ensure a proper seal.
Length of the flange adapter: The length of the flange adapter should meet the sealing requirements of the pipe and should be determined by the actual working conditions (such as whether the ground is moving, etc.) to decide whether to use a longer flange body.
Flange Adaptor Drawing
Judberd have rich experience for flange adaptor design, below drawings are for your reference.
Flange Adaptor Material
Flange adaptors are made up of multiple components, and the specific material of these components depends on the application environment, medium properties, and operating conditions. Here are some common components of flange adaptors, their materials, and their use cases:
Common Components of Flange Adaptors and Their Materials
Flange Body
Common materials: Ductile Iron, Carbon Steel, Stainless Steel, Alloy Steel, Copper and its alloys, Plastics (such as PVC, PP, PE).
Use cases: Select the appropriate material based on the medium and operating conditions. For example, ductile iron is suitable for water, oil, gas, and other media at normal temperature and pressure, carbon steel is suitable for high-temperature and high-pressure water, oil, gas, and other media; stainless steel is suitable for corrosive media and high-temperature and high-pressure environments; plastic materials are suitable for chemical corrosion environments and low-pressure systems.
Sealing Gasket
Common materials: EPDM, NBR, SBR, PTFE.
Use cases: Choose materials that are resistant to medium corrosion and have good temperature resistance. For example, PTFE gaskets are suitable for chemical media and high-temperature environments.
Bolts and Nuts
Common materials: Carbon Steel, Stainless Steel, Alloy Steel, High-Strength Steel.
Use cases: Select the material of bolts and nuts based on the pressure level and medium characteristics of the flange connection. For example, stainless steel bolts are suitable for corrosive environments, and high-strength steel bolts are suitable for high-pressure connections.
Coatings and Corrosion Protection
Common methods: Galvanization, paint corrosion protection coating, oxidation treatment, powder coating.
Use cases: Used to enhance the anti-corrosion performance of flange adaptor body and bolts, suitable for water supply and drainage, marine environments, chemical environments, and outdoor pipeline systems etc.
Flange Adaptor Standard
EN 545(Flange standard is ISO 7005-1/EN 1092)
AWWA C219(Flange standard is ANSI/ASME B16.5/B16.47)
AS/NZS2280(Flange standard is AS 4087)
RFQ
Mechanical joint vs restrained joint flange adaptor
The restrained joint is a type of mechnical joint designed to prevent the pipe from being pulled out longitudinally. The restrained joint type flange adaptor is designed to prevent the pipe from being pulled out and thus causing leaks.This type of flange adaptor is particularly useful in areas where the ground is unstable or prone to movement, as it prevents the pipe from being pulled out and causing leaks. It is also useful in preventing the tube from being pulled out in the case of HDPE pipes. This type of adapter is easy to install and does not require welding, making it a popular choice for many applications.
Advantage for restrained flange adaptor for hdpe pipe
The restrained flange adaptor has the following advantages over conventional PE pipe hot-melt connections
1. The restrained flange adaptor takes only about 5 minutes to install, compared to 30-40 minutes for hot fusion
2. The restrained flange adaptor requires no special tools or installation experience, whereas the hot fusion connection requires specialist skills and equipment.
3, Restrained flange adaptor is 100% restrained and reliable
4, Restrained flange adaptor saves time and money compared to hot fusion connections.
How to choose the right flange adaptor?
1, You need to make sure that the outer diameter of the pipe is matchable with the socket end of the flange adaptor. If using a wide range flange adaptor, make sure that the range of the flange adaptor includes the outer diameter of the pipe. For dedicated flange adaptor, ensure that the outer diameter of the pipe can be inserted into the socket end of the flange adaptor and that it is well sealed.
2. Make sure that the flange of the flange adaptor is of the same standard, pressure and size as the flange on the pipe, only then can the connection be made.
3, make sure that the length of the flange adaptor is appropriate.
4, To confirm whether the pressure of the flange adaptor meets the pressure requirements of the pipe
What is the different from flange adaptor for hdpe pipe,flange adaptor for pvc pipe and quick flange adaptor for HDPE pipe, quick flange adaptor for PVC pipe?
For PVC and PE pipe,we have same function flange adaptors
one is mechnical flange adaptor with tie rods(for PVC pipe,wide range flange adapor is ok.For HDPE pipe,restrained flange adaptor is needed.),Compare to quick flange adaptor,mechnical flange adaptor with tie rods can offer more stable connection and higher pressure.Both small and big size are available(judberd can offer from DN40 to DN2500),but the Max. size for quick flange adaptor is DN400/OD400,larger than OD400 will not work well.
But quick flange adaptor can be installed more quickly and easier.
