Flange leaks can cause significant problems, including safety hazards and costly downtime. Identifying the common causes of these leaks can help in troubleshooting and fixing them effectively. Here’s a simple guide to understanding and addressing flange leaks.

One of the primary causes of flange leaks is incorrect bolt tightening. Bolts that are too loose or too tight can cause leaks, and uneven tightening can lead to gasket failure. Ensuring bolts are tightened to the correct torque specifications using a calibrated torque wrench and following a crisscross pattern can prevent this issue.

Another common cause is damaged or worn gaskets. Gaskets that are damaged, worn out, or of poor quality can fail to seal properly. Regularly inspecting gaskets and replacing them if they show signs of wear, damage, or aging, and using high-quality gaskets suitable for the specific application, can help maintain a proper seal. Improper gasket installation is also a frequent culprit. Misalignment or incorrect placement of the gasket can cause leaks. Surface irregularities on flanges, such as scratches, warping, or a lack of smoothness, can prevent a proper seal.

Incompatible gasket materials can lead to leaks as well. Using a gasket material that is not compatible with the media or operating conditions can cause failures. Selecting gaskets made from materials compatible with the chemical properties of the media and the operating temperature and pressure is essential.

To troubleshoot flange leaks, start by visually inspecting the flange and surrounding area to identify any obvious signs of damage or misalignment. Check the tightness of the bolts using a torque wrench and adjust as necessary to meet the specified torque values. Remove and inspect the gasket for signs of wear, damage, or improper installation, and replace it if necessary. Check the flange faces for scratches, warping, or other surface irregularities, and smooth or replace the flanges as needed. Ensure the gasket material is suitable for the media and operating conditions. Check and adjust the alignment of the flanges to ensure they are parallel and evenly spaced. Finally, monitor the temperature and pressure to ensure they remain within the acceptable range for the gaskets being used.