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Flaring and Installation Instructions - LC Production A/S Flipbook PDF
2 GS–FLANGE SYSTEM GS 90° Flare Flange System Introduction Selection of the pipe Cutting of the pipe Cleaning operations
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GS 90° Flare Flange System
Flaring and Installation Instructions
GS–FLANGE SYSTEM 2
GS 90° Flare Flange System
Table of contents page Introduction ..........................................................3 Selection of the pipe ............................................4 Cutting of the pipe ...............................................5 Cleaning operations before flaring ....................6 Clamping the pipe ................................................6 Flaring operations ................................................7 Checking of the flaring ........................................8 Assembling of parts ............................................9 Connecting the joint ..........................................10 Appendix 1. Flared joint DIN 90°/St37.4 ...........11 Appendix 2. Flared joint DIN 90°/AISI 316 ........12 Appendix 3. Flared joint SAE 90°/St37.4 ..........13 Appendix 2. Flared joint SAE 90°/AISI 316 ......14 Appendix 2. Bolt torques and sizes .................15
GS–FLANGE SYSTEM GS 90° Flare Flange System
Introduction These are GS-Hydro’s guidelines for the manufacture and assembly of the GS-Hydro 90° flare flange system. In the case of special applications (special sealing arrangements, non-conductive connections, special materials etc) please contact GS-Hydro for further instructions. In order to achieve the integrity required in any piping system it is imperative that operators are fully trained and conversant with the tools and machines to be used. GS Hydro can provide training and instruction as well as installation supervision if required.
Refer to the relevant health and safety instructions for protective measures. Protect yourself always by using required personal protective equipments.
The GS 90° flare system is used for class III piping systems with operating pressures of up to 40 bar. Extensive test programs – including rigorous vibration testing – have proven the suitability of the GS 90° flare flange system for a wide range of different materials and applications. GS Hydro solutions are approved by many Classification companies for a wide range of materials and applications.
pressure, bar size, pipe size, flange
SAE
DIN/BS/ANSI/JIS/GOST
10 – 40
10 – 40
16x1.5 – 220x6
21.3x2.1 – 608x12.5
1/2” – 8”
1/2” – 24”
material, pipe mild steel, galvanised steel, copper-nickel, aluminium/brass duplex, super duplex, titanium, tungum material, flange
electric zinced carbon steel, hot dip galvanized carbon steel, stainless steel or titanium
material, seal
based on media inside pipe (example Klinger® SIL C-4430)
3
GS–FLANGE SYSTEM 4
GS 90° Flare Flange System
Selection of the pipe GS-Hydro recommends the use of cold drawn pipes & tubes due to the inherent quality, (precision dimensions and shape) and cleanliness (no scale) characteristics. As a comparison, hot rolled tubes will always have scale both inside and outside due to the manufacturing process and may not be exactly round. GS-Hydro’s cold forming process ensures there will not be any scale inside the cold drawn tube after the manufacturing. Original GS-Hydro high-pressure piping can be recognised from the marking GS-PIPING along the tube length.
GS-Hydro maintains a large stock of carbon and stainless steel pipes & tubes to be utilised in hydraulic and other piping systems: Carbon Steel Material Specification Manufacturing Tolerances Technical Terms of Delivery Material Specification Manufacturing Tolerances
DIN 1630
–
DIN 2391-1
EN 10305-4
DIN 2391-2/C
EN 10305-4
Stainless Steel (mm)
Stainless Steel (sch)
ASTM A269/A213 (A.W.)
ASTM A312
ASTM A269
ASTM A530
All precision steel pipes are supplied with trace numbers.
Always keep the tubes stored indoors away from rain and moisture. Make sure all the tubes are fitted with plastic plugs in the ends.
GS–FLANGE SYSTEM GS 90° Flare Flange System
Cutting off the pipe Cut tubes squarely by using cold saw. Do not use roller cutter or grinder. After cutting the tube, make sure to put a plastic plug in the tube you do not use.
After cutting, the pipe is de-burred inside and outside; then wiped clean by a clean cloth in order to remove any metal particles. Especially with small size pipes (below 60 mm) it is recommended also to shoot foam projectiles by means of compressed air through pipes – use Jet Clean, Compri Tube Clean or respective method.
5
GS–FLANGE SYSTEM 6
GS 90° Flare Flange System
Cleaning operations before flaring Place the GS 90° flare flange on the pipe end with the chamfer facing outwards. Inspect the flange type before placing it on to the tube. The original GS-flange has a GS-PIPING text, marking of flange type and a charge number for traceability.
Clean the flaring cone and dies before fitting to the flaring machine. Ensure the correct size cone and dies are selected for the tube size.
Tools must be kept clean and lubricated. Tools must be checked regularly. Worn-out tools must be replaced. Damaged, worn, or dirty tools will affect the sealing efficiency.
Clamping the pipe Place the pipe between the dies and push it against the stopper. Check that the pipe is positioned horizontally and aligned with the flaring machine. Use pipe supports with long and heavy pipes.
GS–FLANGE SYSTEM GS 90° Flare Flange System
Flaring operations Use only GS-Hydro flaring machine and genuine flaring cones and clamping dies. It is recommended to carry out a test flare to find the exact setting of the stopper, the right pressure of the clamping jaws and the flaring pressure as well as the right time setting for the work cycle. Before beginning the flaring operation check that the surface of the flaring cone has been thoroughly oiled or treated with Gleitmo 830 (Fuchs Lubritech) lubricating paste for cold forming. After the flaring machine has been set up, the pipe to be flared is pushed into its jaws against the stopper and the jaws are locked (1). Then the pipe is flared (2). GS-90° flaring is done in two steps – at first with 37° cone...
... and then with 90° cone.
Ensure that the flange is placed on the pipe before beginning flaring operation. When the flare has formed completely, it should be rolled another 3 to 5 more turns, before the cone is retracted.
7
GS–FLANGE SYSTEM 8
GS 90° Flare Flange System
Checking of the flaring The flared pipe is cleaned with a cloth before visually checking quality.
Verify the outside dimension of the flaring (Appendix 1–4, pages 11–14 ) and check that flare is concentric with the pipe.
Check the wall thickness of the flared part. The thickness should be approx. 80% of the nominal thickness of the pipe. Ensure that the flare is at 90° angle to the pipe.
GS–FLANGE SYSTEM GS 90° Flare Flange System
Assembling of parts Inspect components prior to assembly: • Use non-abrasive soft cloth to ensure all components are free from grease, dirt or any contaminants • use non-abrasive soft cloth to clean all components from grease and dirt • verify that all components are of correct material and size
Insert the bolts and gasket which will centralize on bolts.
9
GS–FLANGE SYSTEM 10 GS 90° Flare Flange System
Connecting the joint Verify that you are using right type and size of bolts (Appendix 5, page 15). Torque bolts in diagonal sequence in small increments to appropriate torque level. See illustrated example. Tighten bolts in sequence in small increments to appropriate torque level. See illustrated example. Bolt torques for 90° flare flanges are shown in Appendix 5, page 15. Bolt torque values are based on friction factor µ=0,15 (slightly greased bolts). Effective greasing can reduce the friction factor 30–50 %. 1. 2. 3. 4.
Tighten lightly with a wrench. Tighten crosswise with 30% of the recommended torque. Tighten crosswise with 70% of the recommended torque. Tighten crosswise with 100% of the recommended torque.
Do not tighten further after step 4.
It is recommended to use calibrated bolt torque wrench in all cases.
Remember! The given tightening torques are working values when the system is in operation. This means that the torques must be checked either after the pressure test and/or a week after the start-up.
GS–FLANGE SYSTEM GS 90° Flare Flange System 11
Ød max
Appendix 1. Flared joint DIN 90°/St37.4
C1
C
Size DN40 DN50 DN65
PN 10–40 10–40 10–40
Pipe O.D. 48.3 60.3 76.1
C 13 18 17
C1 14 22 20
d max 73 92 105
DN80
10–40
88.9
23
27
127
DN100
10–16
114.3
24
28
158
DN100
25–40
114.3
26
31
162
DN125
10–25
139.7
25
32
188
DN150
10–16
168.3
23
27
212
DN150
25
168.3
26
31
218
DN200
10–16
219.1
23
29
268
DN200
25
219.1
32
36
278
DN250
10–16
273.0
24
27
320
DN300
10
323.9
25
28
370
DN300
16
323.9
29
31
378
DN350
10
355.6
43
41
430
DN350
16
355.6
47
46
438
DN400
10
406.4
45
44
482
DN400
16
406.4
49
48
490
GS–FLANGE SYSTEM 12 GS 90° Flare Flange System
Size DN40 DN50 DN65
PN 10–40 10–40 10–40
Pipe O.D. 48.3 60.3 76.1
C 9 10 12
C1 9 10 12
d max 65 80 100
DN80
10–40
88.9
16
15
120
DN100
10–40
114.3
15
14
143
DN125
10–25
139.7
16
15
170
DN150
10–25
168.3
16
15
200
DN200
10–25
219.1
21
19
260
DN250
10–16
273.0
24
22
320
DN300
10–16
323.9
24
22
370
DN350
10–16
355.6
26
24
407
DN400
10–16
406.4
27
25
459
Ød max
Appendix 2. Flared joint DIN 90°/AISI 316
C1
C
GS–FLANGE SYSTEM GS 90° Flare Flange System 13
Appendix 3. Flared joint SAE 90°/St37.4
Ød max
Type 24N 32N 40N
C1
C
Pipe O.D. 48.3/50 60.3/60 76.1/75
C 8 8 8
C1 9 10 9
d max 65.3 76 90
48N
88.9/90
8
10
107
56N
101.6/100
11
13
123
64N
114.3/115
10
12
135
80N
139.7/140
11
12
161
96N
168.3/165
12
15.5
191
28N
219.1/220
17
20
254
GS–FLANGE SYSTEM 14 GS 90° Flare Flange System
Type 16NSS 24NSS 32NSS 40NSS
Pipe O.D. 30.0 48.3 60.3 76.1
C 7.5 8 8 8
C1 9 9 10 9
d max 45 65.3 76 90
48NSS
88.9
8
10
107
56NSS
101.6
11
13
123
64NSS
114.3
10
12
135
80NSS
139.7
11
12
161
96NSS
168.3
12
15.5
191
28NSS
219.1
17
20
254
Ød max
Appendix 4. Flared joint SAE 90°/AISI 316
C1
C
GS–FLANGE SYSTEM GS 90° Flare Flange System 15
Appendix 5. Bolt Torques and sizes
Size 1 1/2” 2” 2 1/2” 3” 3 1/2”
SAE 10–40 bar Flange Bolt Type Torque 124N 50 Nm 132N 50 Nm 140N 60 Nm 148N 100 Nm 156N 130 Nm
Bolt DIN 931, 8.8 Flange to Flange to flange block M12x70 x40 M12x70 x40 M12x70 x40 M16x80 x50 M16x90 x50
4”
164N
140 Nm
M16x90
x50
5”
180N
175 Nm
M16x110
x60
6”
196N
150 Nm
M16x110
x60
8”
228N
220 Nm
M20x120
x70
Bolt DIN 931, 8.8 Flange to Flange to flange block M16x60 x40 M16x60 x40 M16x60 x40 M16x70 x45 M16x70 x45
DIN 2576 10–40 bar Size 1 1/4” 1 1/2” 2” 2 1/2” 3”
Flange Type DN32PN10-40-GS DN40PN10-40-GS DN50PN10-40-GS DN65PN10-40-GS DN80PN10-40-GS
Bolt Torque 40 Nm 40 Nm 50 Nm 70 Nm 45 Nm
4”
DN100PN10-16-GS
50 Nm
M16x80
x50
4”
DN100PN25-40-GS
70 Nm
M20x80
x55
5”
DN125PN10-16-GS
50 Nm
M16x80
x50
5”
DN125PN25-40-GS
110 Nm
M24x100
x70
6”
DN150PN10-16-GS
100 Nm
M20x90
x60
6”
DN150PN25-40-GS
130 Nm
M24x120
x80
8”
DN200PN10-GS
120 Nm
M20x100
x65
8”
DN200PN16-GS
90 Nm
M20x100
x65
8”
DN200PN25-GS
140 Nm
M24x120
x80
10”
DN250PN10-GS
102 Nm
M20x100
x65
10”
DN250PN16-GS
143 Nm
M24x100
x70
12”
DN300PN10-GS
126 Nm
M20x120
x70
12”
DN300PN16-GS
179 Nm
M24x120
x75
14”
DN350PN10-GS
128 Nm
M20x120
x70
14”
DN350PN16-GS
188 Nm
M24x120
x75
16”
DN400PN10-GS
183 Nm
M24x130
x80
16”
DN400PN16-GS
253 Nm
M27x130
x90
© GS-Hydro Oy. 2006. All rights reserved.
High Quality, Clean and Reliable Piping without Welding The innovative GS Piping System is used primarily in hydraulic applications, but it is also ideal for both low and high pressure applications with high demands on quality, reliability and cleanliness. In addition to being inherently clean, the GS Piping System is easy, fast and flexible to install. Taking complete responsibility for the piping system allows GS-Hydro to optimise every phase of the delivery, thus ensuring a high quality, cost-efficient, on-time delivery of the entire piping system.
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