What is flange facing?
Flange facing is the act of machining the sealing surface of a flange to restore its ability to create a reliable leak-free seal. A common application where this is needed would an industrial plant where there are thousands of flanged connections, all of which need to be reliably leak-free. When flanges become corroded over time or when they are otherwise damaged, they can create a leak path which can be at a minimal a costly repair for the plant and at worst fatal to plant personnel; so it is extremely critical that all the flanged connections within an industrial plant are leak-free.
How is flange facing performed?
There are basically two methods: 1 remove the flange and either send it to a machine shop to be machined or replace it altogether 2 utilize a portable flange facing machine to machine the flange surface in-place. Removing and sending the flange off is costly in that is requires down time to cut the flange off of the pipe and ship it to a nearby shop and have them machine it as fast at they can and send it back to the plant. Once back the flange must be welded back onto the pipe which again takes time and risks the chance that the weld could fail and require re-work which will cost the plant even more downtime.
The second method, utilizing a portable flange facing machine to machine the flange in place saves time and thus money and with rental machines readily available from GSI Machinery, this can be done at a minimal cost. The flange can be left in place and the contractor performing the work retains complete control of their timeline and budget with this method. There are many portable flange facing machines on the market today and many of them have their specific place. Our flange facing machine, the FlangeHog 110 from Esco Tool is a compact, lightweight, yet impressively rigid little machine that can re-surface flanges from 1"-10.39" ID with a 14" overall swing radius.
How do I Choose a Portable Flange Facing Machine?
The easiest way to determine which machine you need is to just call GSI Machinery and we can recommend the proper machine for your application. If you are machining flanges in place in the field and they fall within the working range of the FlangeHog, there are a few considerations to keep in mind.
Do the flanges you need to repair require weld build up?
Are the flanges raised face, flat face or require a groove such as an RTJ?
How many flanges do you need to resurface and what is your timeframe for performing the work?
What is around the flanges and how much working space will you have for the machine to operate in?
What is the field machining skill level of your operators?
Is there enough straight run of pipe to allow you to mount an ID mounted flange facer on the pipe?
I've Determined the FlangeHog will Fit My Application, How Does it Work?
The FlangeHog is a hand-powered, portable, compact ID-mounted flange facing machine. Most field personnel can learn to use the machine with a few hours of training. First, you measure the ID of the flange you that you need to machine. Next, you select the appropriate clamping ribs for the tool specific to the ID of the flange that you are machining. Next, you simply hold the flange facer in place inside the ID of the pipe while you tighten the ratchet which extends all three mounting ribs simultaneously. This clamping system allows the flange facing machine to be self-centering and in most cases self leveling. You then attach your carbide tool holder to the tool post and touch-off of the flange surface. Return the tool holder to the ID of the flange and select your depth of cut. We typically recommend removing 8 thousandths per pass and doing multiple passes if needed. As opposed to performing one thick pass, it is much easier and less effort to make multiple lighter passes and this won't really cost you much time practically. Once depth of cut is selected you simply turn the flange facing machine clockwise (for in --> out travel direction) or counter-clockwise (for out--> in travel direction). Turn the machine until the complete mating surface of the flange has been machined and you will see a phonographic finish. The flange facer comes with several different surface finish feed screws for smooth and stock finishes.
How Do I Get Started?
Call the number below, email or submit a query on our contact page to get in touch with a GSI representative who can walk you through the process of seeing a demo at your shop, getting your questions answered or acquiring rental or purchase flange facing machines. Every machine we rent or sell comes with a complementary 4 hour training session with a flange facing machine expert. We are available 24/7 for emergency rental needs and tool deliveries!
George Ficken
678-387-7885
