Leakage Issues in Flange Connections and Their Solutions

Flange connections are widely used in piping systems due to their convenience and reliability. However, leakage remains a common challenge, especially in high-pressure or corrosive environments like shipbuilding, petrochemical, and power industries. Understanding the causes and solutions is essential for maintaining system integrity.

1. Common Causes of Flange Leakage

Improper Gasket Selection
Choosing the wrong gasket material or type can result in inadequate sealing, especially under temperature or pressure fluctuations.

Incorrect Bolt Tightening
Uneven or insufficient bolt torque can lead to uneven compression of the gasket, creating leak paths.

Surface Damage or Misalignment
Damaged flange faces, warping, or misalignment during installation may prevent proper sealing.

Thermal Expansion and Vibration
Temperature changes or mechanical vibrations can cause bolts to loosen over time, leading to leakage.

Aging and Deterioration
Gaskets and bolts may degrade over time due to exposure to chemicals, heat, and environmental conditions.

2. Solutions to Prevent and Address Leakage

Proper Gasket Selection
Choose gaskets that are compatible with the fluid, pressure, and temperature of the system. Materials such as spiral wound or PTFE gaskets are often used in demanding conditions.

Correct Bolt Torque and Sequence
Use a calibrated torque wrench and apply torque in a cross-pattern sequence to ensure even pressure distribution. Re-tighten bolts after the initial operation period if needed.

Flange Surface Inspection
Inspect and clean flange surfaces before assembly. Ensure there are no scratches, dents, or warping that could compromise the seal.

Use of High-Quality Fasteners
Select bolts and nuts with appropriate strength and corrosion resistance. Consider using washers or anti-vibration devices in high-stress environments.

Regular Maintenance and Monitoring
Implement a scheduled inspection and maintenance plan. Replace gaskets and retighten bolts as part of routine checks.

By addressing these factors, engineers and maintenance teams can significantly reduce the risk of flange leakage and enhance the safety and reliability of piping systems.