Extra-large flanges are typically manufactured using a segmented production process, where individual sections are produced separately and then assembled on-site. These flanges are defined as those exceeding the size limits specified by national standards, generally referring to flanges larger than DN2000. The manufacturing of such large flanges is usually carried out by the construction party or specialized manufacturers.
There are several standard systems used globally for flange production:
1. **DIN Standard**
- Common pressure ratings: PN6, PN10, PN16, PN25, PN40, PN64, PN100, PN160, PN250
- Flange sealing surfaces include raised face (DIN 2526C) and grooved surfaces (DIN 2512N).
2. **ANSI Standard**
- Common pressure classes: CL150, CL300, CL600, CL900, CL1500
- Flange sealing surface type: ANSI B16.5 RF (Raised Face) flanges.
3. **JIS Standard**
- Less commonly used in international projects.
- Pressure grades typically include 10K and 20K.
The production process for extra-large flanges often involves forging and rolling techniques. These flanges are commonly made from materials such as stainless steel, carbon steel, and alloy steel. Due to their size and complexity, they are usually fabricated in segments and then welded or spliced together at the construction site.
This approach ensures structural integrity while allowing for easier transportation and installation. Proper alignment and welding procedures are essential to maintain the performance and safety of these critical components in piping systems.
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