Material Design for 700℃ Ultra-Supercritical High-Pressure Boiler Pipe
May 6, 2025
Super-Large Forged Flanges by Abter Steel
Introduction to Abter Steel’s Forged Flanges
At Abter Steel, we pride ourselves on being a global leader in the production of super-large forged flanges, engineered to meet the most demanding requirements of modern industrial applications. Our state-of-the-art manufacturing facilities and advanced forging technologies enable us to produce high-quality flanges ranging from 1/2” to 98” in diameter, with pressure ratings from Class 150 to 15,000 PSI. Specializing in a wide array of materials, including duplex steel, stainless steel, carbon steel, titanium, nickel alloys, and more, we deliver customized solutions for critical applications in industries such as petrochemical, oil and gas, power generation, marine, and subsea systems.
Our product portfolio includes:
- Duplex Steel Forged Flanges: Compliant with ASME B16.5, available in grades F44, F51, F53, and F55, for sizes 1/2” to 98” and pressure classes up to 15,000 PSI.
- Compact Flanges (RCF): Designed to NORSOK L005 standards, offering space and weight savings for critical sealing applications.
- Custom Forgings: Tailored to client specifications, covering a broad range of materials and configurations, including weld neck (WN), slip-on (SO), blind (BL), flat face (FF), raised face (RF), and ring type joint (RTJ).
With a commitment to quality, innovation, and customer satisfaction, Abter Steel ensures that our flanges meet stringent international standards, delivering unmatched performance in high-pressure, high-temperature, and corrosive environments.
Duplex Steel Forged Flanges: Robust and Versatile
Our duplex steel forged flanges are engineered for superior corrosion resistance, high strength, and durability, making them ideal for harsh environments in oil and gas, chemical processing, and marine applications. Compliant with ASME B16.5, these flanges are available in sizes from 1/2” to 98” and pressure ratings from Class 150 to 15,000 PSI. The key duplex steel grades include:
- F44 (UNS S31254): Offers excellent resistance to pitting and crevice corrosion.
- F51 (UNS S31803): Balances strength and corrosion resistance for general applications.
- F53 (UNS S32750): Super duplex grade for extreme corrosion resistance.
- F55 (UNS S32760): Enhanced mechanical properties for high-pressure systems.
Key Features:
| Parameter | Details |
|---|---|
| Size Range | 1/2” to 98” |
| Pressure Ratings | Class 150 to 15,000 PSI |
| Flange Types | Weld Neck (WN), Slip-On (SO), Blind (BL), Flat Face (FF), Raised Face (RF), Ring Type Joint (RTJ) |
| Standards | ASME B16.5, ASME B16.47, API, DIN, EN |
| Testing | Hydrostatic, Ultrasonic, Tensile, Hardness, Impact |
| Certifications | ISO 9001, EN 10204 3.1/3.2, NACE MR0175, PED 97/23/EC |
These flanges are forged to ensure a uniform grain structure, enhancing their mechanical properties and resistance to fatigue. Available in configurations like weld neck for high-pressure connections, slip-on for ease of installation, and blind for sealing pipe ends, our duplex steel flanges meet the diverse needs of global industries.
Compact Flanges (RCF): NORSOK L005 Excellence
Our Compact Flanges (RCF), designed to NORSOK L005 standards, represent a breakthrough in flange technology, offering significant advantages over traditional ANSI flanges. These flanges are engineered for critical sealing applications with high thermal expansion and cyclic loading, such as risers, single point mooring systems, manifolds, X-Trees, subsea pipelines, heat exchangers, and process piping systems. The RCF design incorporates double independent seals, ensuring robust sealing under extreme conditions.
RCF Advantages:
- Space Saving: Compact design reduces footprint in tight installations.
- Weight Saving: Up to 70–80% lighter than ANSI flanges, reducing structural loads.
- Enhanced Sealing: Double independent seals (heel seal and IX seal ring) provide superior leak prevention.
- Positive Sealing Method: Elastic stored energy in the IX seal ring ensures consistent sealing.
- Wide Temperature and Pressure Range: Suitable for extreme design conditions.
RCF Working Principle:
The RCF design features two independent seals. The heel seal is created by applying seating stress at the flange heel, while the IX seal ring serves as the main seal. The seal ring’s elastic stored energy generates radial sealing forces, intensified by internal pressure acting on the ring’s inner surface. With increased preload, the flange bevel closes, achieving face-to-face contact at the outer wedge, transferring most bolt preload as compressive forces at the heel.
RCF Specifications:
| Parameter | Details |
|---|---|
| Size Range | 1/2” to 48” (larger sizes on request) |
| Pressure Ratings | Class 150# to 2500# (higher ratings on request) |
| Materials | A182 F316/316L, F51, F53, F55, Inconel 625, Incoloy 825, A105, A350 LF2, A694 F52–F70, AISI 4130, AISI 8630 |
| Gasket | RCF IX Seal Ring |
| Standards | NORSOK L005, ASME Section VIII, API |
The RCF IX seal ring exerts axial forces on the metal seal ring’s taper, translating into radial sealing forces, ensuring a reliable seal even under cyclic loading and thermal expansion.
Comprehensive Material Portfolio
Abter Steel offers an extensive range of materials to meet diverse application requirements, ensuring our flanges perform optimally in corrosive, high-temperature, and high-pressure environments. Our material portfolio includes:
| Category | Grades |
|---|---|
| Carbon & Low Temperature | A105, A105N, A516-GR.70, A350-LF2 |
| Chromium | A182-F1, F5, F9, F11, F12, F22, F91 |
| Stainless & Duplex | A182-F304, F304L, F304H, F304N, F309S, F310S, F310H, F316, F316L, F316Ti, F316H, F317L, F321, F321H, F347, F347H, F904L, F44, F51, F53, F55, F60 |
| Copper & Bronze | SB151-C70600, C71500, C71520, C44300, C68700, C71640 |
| Titanium | SB381-GR.F1, F3, F5 |
| Nickel Alloy | B564-NO2200, NO6022, NO10276, NO4400, NO6600, NO6601, NO6625, NO8800, NO8810, NO8811, NO8825, NO10665, NO10675, B160-NO2201, B462-NO8020 |
Material Highlights:
- Carbon & Low Temperature: A105 and A350-LF2 offer excellent toughness for low-temperature applications like LNG systems.
- Chromium: F22 and F91 provide superior creep resistance for high-temperature pressure vessels.
- Stainless & Duplex: F51, F53, and F55 excel in corrosive environments like seawater and chemical processing.
- Copper & Bronze: C70600 and C71500 are ideal for marine and desalination systems.
- Titanium: SB381-GR.F1 and F5 offer lightweight, corrosion-resistant solutions for aerospace and chemical applications.
- Nickel Alloy: Inconel 625 and Incoloy 825 provide exceptional resistance to extreme corrosion and high temperatures.
Our ability to work with such a diverse material range ensures that we can meet the specific needs of any project, from subsea pipelines to nuclear reactors.
Advanced Design and Verification
At Abter Steel, we go beyond manufacturing by offering advanced design and verification services to ensure our flanges meet the highest performance standards. Our engineering team leverages industry-leading tools and methodologies, including:
- ASME Section VIII Calculation Services: Covering Divisions 1, 2, and 3, ensuring compliance with pressure vessel and piping standards.
- ANSYS Software Analysis: Finite element analysis (FEA) for stress, thermal, and fatigue verification.
- Custom Design Solutions: Tailored flange designs for unique project requirements, including super-large sizes and high-pressure ratings.
Our rigorous verification process ensures that each flange performs reliably under the specified operating conditions, whether in cyclic loading, high thermal expansion, or extreme pressure environments. This commitment to precision engineering sets us apart as a trusted partner for critical applications.
Applications of Abter Steel Flanges
Our super-large forged flanges are designed for a wide range of critical applications, ensuring safety, reliability, and efficiency. Key applications include:
| Industry | Applications |
|---|---|
| Oil and Gas | Risers, subsea pipelines, manifolds, X-Trees, single point mooring systems |
| Petrochemical | Refinery piping, chemical reactors, catalyst transfer lines |
| Power Generation | Boiler systems, steam piping, turbine connections |
| Marine | Seawater heat exchangers, desalination systems, shipboard piping |
| Nuclear | Reactor vessel closures, steam generator flanges |
| Chemical Processing | Acid production, high-pressure vessel covers |
Detailed Applications:
- Oil and Gas: RCF flanges in F51 and F55 are used in subsea pipelines and risers, resisting corrosion from seawater and sour gas.
- Petrochemical: F316/316L and Inconel 625 flanges ensure reliable connections in chemical reactors handling corrosive fluids.
- Power Generation: F22 and F91 flanges serve as boiler covers, withstanding high-pressure steam up to 816°C.
- Marine: Copper-nickel (C70600) flanges are ideal for seawater heat exchangers in desalination plants.
- Nuclear: F6 and F91 flanges provide robust closures for reactor vessels, ensuring safety under extreme conditions.
Our flanges are engineered to meet the unique challenges of each industry, delivering performance and longevity in the most demanding environments.
Why Choose Abter Steel?
Abter Steel stands out as a premier manufacturer of super-large forged flanges due to our:
- Advanced Manufacturing: Cutting-edge forging and heat treatment facilities capable of producing flanges up to 98” in diameter.
- Material Expertise: Comprehensive material portfolio, from duplex steel to nickel alloys, tailored to specific application needs.
- Engineering Excellence: In-house ASME and ANSYS-based design and verification services for precision and reliability.
- Quality Assurance: Compliance with ISO 9001, ASME, API, and NACE standards, with rigorous testing (hydrostatic, ultrasonic, impact).
- Global Reach: Trusted supplier to industries worldwide, with a proven track record in critical projects.
Our commitment to innovation, quality, and customer satisfaction ensures that every flange we produce meets or exceeds client expectations, delivering value in even the most challenging applications.
Contact Us
For inquiries, technical specifications, or custom flange solutions, contact Abter Steel today. Our team of experts is ready to assist with your project needs, from design to delivery.
- Website:www.abtersteel.com
- Partner with Abter Steel for super-large forged flanges that redefine performance and reliability in industrial applications.
