March, 2009

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WHATS UP WITH FLANGE RATINGS?

Theres a lot of confusion regarding pressure ratings of flanged valves for water works service. Industry standards, manufacturers literature and project specifications often contradict or are subject to interpretation which leads to delays, improper equipment and potential system failures. ASME and ANSI Most flanged valves for water works service in North America are supplied with flanges conforming to dimensional standards developed by the American Society of Mechanical Engineers (ASME) and accredited by the American National Standards Institute (ANSI). Various committees within ASME are charged with developing, issuing and maintaining individual standards. The ASME B16 committees have this responsibility for valves, flanges and flanged fittings. Standardized dimensions for cast iron flanges and flanged fittings are provided in ANSI/ASME B16.1 standard, steel and stainless steel dimensions in the ANSI/ASME B16.5 standard and ductile iron in the ANSI/ASME B16.42 standard. Compliance with the applicable standardized flange and flanged fitting dimensions is voluntary but ensures uniformity so that flanged valves from one manufacturer will bolt to flanges from another. Flange Classes There are four common pressure classes within the ANSI/ASME standards listed above. Class 125 and Class 250 are cast iron flanges and flanged fittings while Class 150 and Class 300 are ductile iron, steel or stainless steel. Hence, ANSI/ASME B16.1 Class 125 flanges are made from cast iron, ANSI/ASME B16.5 Class 150 can be made from steel or stainless and ANSI/ASME B16.42 Class 150 is made from ductile iron. However, the bolting pattern is the same for both Class 125 and 150 so, regardless of material, they will bolt together . This is also the case for Class 250 and 300. Cast iron flanges are usually supplied flat faced while ductile iron and steel are usually raised face. When bolting a cast iron flange to a steel or ductile iron flange, the raised face of the mating flange should be removed to avoid breaking the cast iron flange when tightening the bolts. Pressure and Temperature The ANSI/ASME standards also provide pressure ratings for various classes of flanges and flanged fittings. The pressure ratings change based on the material from which it is made and/or the temperature at which it operates. The nominal flange Class (e.g., Class 125) generally represents the maximum working pressure at the temperature of saturated steam at that pressure. For example, an ANSI/ASME B16.1 Class 125 flange is rated for 125 PSI at 353 F. But when used at colder temperatures, such as that of water, the ANSI/ASME maximum working pressure is higher than the nominal class. ANSI/ASME B16.1 rates Class 125 flanges and flanged fittings made from high strength cast iron for 200 PSI at temperatures up to 150 F. ANSI/ASME B16.42 rates Class 150 ductile iron flanges and fittings for 250 PSI at temperatures up to 100 F. Complete flange and flanged fitting pressure-temperature ratings can be found in tables within the applicable ANSI/ASME B16.x standard. Are you confused? It gets worse. See Page 2.

GA INDUSTRIES, LLC 9025 Marshall Road, Cranberry Township PA 16066 USA

March, 2009

Page 2 of 2

Enter AWWA The American Water Works Association (AWWA) also has committees charged with addressing the needs of the water works industry. The AWWA C110 committee considered the ANSI/ASME pressure ratings too conservative when used on water. Through burst testing they determined flanges and fittings made from high strength cast iron and with dimensions conforming to ANSI/ASME B16.1 Class 125 could be rated for a working pressure of 250 PSI with at least a 3.0 safety factor. This allows Class 125 cast iron flanges and flanged fittings to have the same pressure rating as Pressure Class 250 ductile iron pipe. AWWA C110 does not address ANSI/ASME B16.1 Class 250 cast iron flanges or flanged fittings that have a 300 to 500 PSI or higher pressure rating and a totally different bolt pattern than Class 125. Mistakes sometimes occur because cast iron or ductile iron flanged fittings have 250 cast in them (indicating a 250 PSI pressure rating) but the flange dimensions and bolt pattern conform to ANSI/ASME B16.1 Class 125 (or ANSI/ASME B16.42 Class 150). These will not bolt to an ANSI/ASME B16.1 Class 250 flange! Valve Pressure Ratings ANSI/ASME B16 and AWWA C110 pressure ratings are based on flanges and flanged fittings conforming to standardized geometry and dimensions, including wall thickness. By comparison, valves are available in countless types, shapes, configurations and geometries that vary from one manufacturer to the other. While the valves connecting flanges may conform to ANSI/ASME B16.x dimensions, there are many reasons why its pressure rating may not be the same as a flange or flanged fitting made from identical material as the valve. It is the responsibility of the valve manufacturer to establish the pressure ratings for their products. The design professional should consult the manufacturers published information and not assume it is the same as the flange or fitting being bolted to it. However, the pressure ratings of many ANSI/ASME B16.x flanged valves used in waterworks service are defined in AWWA standards applicable to that type of valve. The pressure rating (or Pressure Class) listed in the AWWA valve standard may or may not conform to the ANSI/ASME B16.x or the AWWA C110 pressure rating, leading to even more confusion. The AWWA valve standards which define a Pressure Class or pressure rating are too numerous to detail in this commentary but include C500 gate valves, C504 butterfly valves, C507 ball valves, C508 check valves and C517 eccentric plug valves. The design professional should become familiar with the applicable AWWA valve standard and select the pressure class that is adequate for the working pressure and be aware that the valves pressure class and connection flange class may not correspond. One should remember that a chain is only as strong as its weakest link so every component of a piping system should be able to withstand the highest pressure that could be realized at the location where it is installed. Its hoped the above sheds some light on the pressure ratings for flanges and flanged valves. GA Industries LLC factory engineers will be happy to provide assistance on any specific application involving our valves.

9025 Marshall Road, Cranberry Township, PA 16066 USA

Telephone: 724-776-1020 Fax: 724-776-1020 E-mail: ga@gaindustries.com