One-Piece Flange

Overview of One-Piece Flange​

Sikerui One-Piece Flange​ is a precision-engineered piping component designed to create robust, leak-proof connections in high-pressure fluid and gas systems. Unlike traditional multi-part flanges, its integrated construction combines a flange ring with a clamping mechanism into a single unit, eliminating potential leakage points and simplifying installation. Manufactured from materials such as carbon steel, stainless steel (304/316/316L), and alloy steel, One-Piece Flanges meet international standards like ISO 6162, ASME B16.5, and DIN EN 1092-1, ensuring compatibility with global piping systems .

These flanges excel in demanding applications where reliability under extreme conditions is critical. They operate effectively across a temperature range of -50°C to 400°C​ and handle pressures from 3.5 MPa (35 bar) to 35 MPa (350 bar), depending on material and design specifications . Common sizes span DN13 to DN127​ (½” to 5″), with customization available for specialized requirements. The One-Piece Flange’s compact design reduces weight and bulk while maintaining superior structural integrity, making it ideal for hydraulic systems, industrial machinery, and chemical processing plants where space constraints and vibration resistance are priorities .

Key Features of One-Piece Flange​

1. Integrated Clamping Design​
   The One-Piece Flange features a unibody construction​ that merges the flange ring with a clamping collar, ensuring even pressure distribution and eliminating joint failures common in multi-component flanges. This design enhances sealing reliability under pressure fluctuations and mechanical stress .
2. High-Pressure and Temperature Resilience​
   Engineered for extreme operating conditions, these flanges withstand pressures up to 35 MPa (350 bar)​ and temperatures from -50°C to 400°C. Materials like ASTM A105 carbon steel and ASTM A182 stainless steel provide exceptional tensile strength and corrosion resistance, suitable for hydraulic systems and aggressive media .
3. Leak-Free Performance​
   The one-piece structure prevents leakage​ at seam points, with precision-machined sealing surfaces (e.g., raised face or ring-type joint) ensuring tight gasket compression. This is critical in high-stakes applications like oil and gas pipelines or chemical transport .
4. Easy Installation and Maintenance​
   With fewer components​ than split flanges, installation requires minimal effort. The design allows quick alignment and securing with metric or inch screws, reducing assembly time by up to 30% compared to traditional flanges .
5. Vibration and Fatigue Resistance​
   The monolithic construction dampens vibrations and withstands cyclic loading, making these flanges ideal for dynamic environments like industrial machinery or mobile hydraulic equipment .

Typical Applications of One-Piece Flange​

• Hydraulic Power Systems: Used in high-pressure hydraulic lines for construction machinery, agricultural equipment, and industrial presses, where leak-free connections are critical .
• Oil and Gas Pipelines: Employed in upstream and midstream operations to connect valves, pumps, and compressors, resisting sour gas corrosion and pressure surges .
• Chemical Processing Plants: Ideal for handling corrosive fluids like acids and solvents, with stainless steel variants preventing chemical degradation .
• Power Generation Systems: Secure connections in steam, coolant, and fuel lines within turbines and boilers, ensuring safety under thermal cycling .
• Marine and Offshore Applications: Certified for use in shipbuilding and offshore platforms, with materials resistant to saltwater corrosion .

Technical Specifications​

Table: Standard One-Piece Flange Specifications

SIZE	Number	D1	D2	H	L1	L2	D3	r-φ-e	D4/BCD
DN15	HFL15	20.3	26.3	13.1	16.5	25	95	4-φ-18	65
DN20	HFL20	25.3	31.9	14.7	19	28.5	105	4-φ-18	75
DN25	HFL25	32.35	39.95	16	22.5	31.5	115	4-φ-18	85
DN32	HFL32	40.4	49.8	17.5	26.5	34	140	4-φ-18	100
DN40	HFL40	50.45	60.25	18.6	31.5	38.5	150	4-φ-18	110
DN50	HFL50	63.5	75.9	20.3	38	45	165	4-φ-18	125
DN65	HFL65	75.5	88.91	23.6	44	51.5	185	4-φ-18	145
DN80	HFL80	90.55	105.15	26.3	51.5	60	200	8-φ-18	160
DN100	HFL100	110.6	127.39	28	61.5	70.7	220	8-φ-18	180
DN125	HFL125	140.6	161.4	33.2	76	86	250	8-φ-18	210
DN150	HFL150	160.7	184.5	34.1	86.5	95	285	8-φ-22	240
dn200	HFL200	200	340	36	106.2	113	340	8-φ-22	295
DN200	hf1250	226.2	253.8	35	118.5	130	340	8-φ-22	295
dn250	HFL250	250	395	40	131.5	138.5	395	12-φ-22	350
DN250	HFL250	281.5	314.8	41.4	147	165	405	12-φ-26	355
DN300	HFL300	316.7	344.5	41.7	165	188	445	12-φ-26	400
DN350	HFL350	356.8	386.2	45	183.5	193.5	510	16-φ-26	445-460
DN400	HFL400	402	432.7	47	208	231	572	16-φ-26	495-515
DN250 (PH10)	HFL250	280.6	304.7	41.4	147	165	405	16-φ-26	355
DN300 (PH10)	HFL300	315.7	341.5	41.7	165	188	445	16-φ-26	400
DN350 (PH10)	HFL350	355.8	385	45	183.5	193.5	510	16-φ-26	460
DN400 (PH10)	HFL400	401	429.5	46	208	231	570	16-φ-26	515

Frequently Asked Questions (FAQs)​

Q1: How does a One-Piece Flange differ from a split-flange design?​

A One-Piece Flange integrates the flange ring and clamp into a single unit, reducing potential leak paths and simplifying installation. Split flanges require assembly of multiple components, increasing failure risks under vibration or pressure spikes .

Q2: Can One-Piece Flanges be customized for non-standard sizes?​

Yes, manufacturers offer customization for dimensions, materials, and pressure ratings​ (e.g., sizes beyond DN127 or specialized alloys for extreme temperatures). Lead times vary based on complexity .

Q3: What maintenance is required for these flanges?​

Routine inspections for surface wear or corrosion are sufficient. The one-piece design minimizes maintenance needs, as there are no loose components to retighten .

Q4: Are One-Piece Flanges suitable for high-vibration environments?​

Absolutely. Their monolithic construction dampens vibrations​ better than multi-part flanges, making them ideal for engines, pumps, and heavy machinery .

Q5: What certifications ensure quality?​

Reputable products comply with ISO 6162, ASME B16.5, and PED directives, supported by material test reports (MTRs) and non-destructive testing certifications .