Introduction to Abter Steel’s Forged Flanges

em Abter Aço, we pride ourselves on being a global leader in the production of super-large forged flanges, engineered to meet the most demanding requirements of modern industrial applications. Our state-of-the-art manufacturing facilities and advanced forging technologies enable us to produce high-quality flanges ranging from 1/2” to 98” em diâmetro, with pressure ratings from Classe 150 Para 15,000 LIBRAS POR POLEGADA QUADRADA. Specializing in a wide array of materials, incluindo a duplex steel, aço inoxidável, aço de carbono, titânio, ligas de níquel, e muito mais, we deliver customized solutions for critical applications in industries such as petroquímico, petróleo e gás, geração de energia, marinho, e subsea systems.

Our product portfolio includes:

• Duplex Steel Forged Flanges: Compliant with ASME B16.5, available in grades F44, F51, F53, and F55, for sizes 1/2” to 98” and pressure classes up to 15,000 LIBRAS POR POLEGADA QUADRADA.
• Compact Flanges (RCF): Designed to NORSOK L005 standards, offering space and weight savings for critical sealing applications.
• Custom Forgings: Tailored to client specifications, covering a broad range of materials and configurations, including weld neck (WN), escorregar em (SO), blind (BL), face plana (FF), raised face (RF), and ring type joint (RTJ).

With a commitment to quality, inovação, and customer satisfaction, Abter Steel ensures that our flanges meet stringent international standards, delivering unmatched performance in high-pressure, Temperatura alta, e ambientes corrosivos.

Duplex Steel Forged Flanges: Robust and Versatile

Nossa duplex steel forged flanges are engineered for superior corrosão resistência, alta resistência, e durabilidade, making them ideal for harsh environments in oil and gas, processamento químico, e aplicações marítimas. Compliant with ASME B16.5, these flanges are available in sizes from 1/2” to 98” and pressure ratings from Classe 150 Para 15,000 LIBRAS POR POLEGADA QUADRADA. The key duplex steel grades include:

• F44 (US S31254): Offers excellent resistance to pitting and crevice corrosion.
• F51 (EUA S31803): Balances strength and corrosion resistance for general applications.
• F53 (UNS S32750): Super duplex grade for extreme corrosion resistance.
• F55 (UNS S32760): Enhanced mechanical properties for high-pressure systems.

Características principais:

These flanges are forged to ensure a uniform grain structure, enhancing their mechanical properties and resistance to fatigue. Available in configurations like weld neck for high-pressure connections, slip-on for ease of installation, and blind for sealing pipe ends, our duplex steel flanges meet the diverse needs of global industries.

Compact Flanges (RCF): NORSOK L005 Excellence

Nossa Compact Flanges (RCF), designed to NORSOK L005 padrões, represent a breakthrough in flange technology, offering significant advantages over traditional ANSI flanges. These flanges are engineered for critical sealing applications with high thermal expansion and cyclic loading, tal como risers, single point mooring systems, manifolds, X-Trees, dutos submarinos, trocadores de calor, e process piping systems. The RCF design incorporates double independent seals, ensuring robust sealing under extreme conditions.

RCF Advantages:

• Space Saving: Compact design reduces footprint in tight installations.
• Weight Saving: Up to 70–80% lighter than ANSI flanges, reducing structural loads.
• Enhanced Sealing: Double independent seals (heel seal and IX seal ring) provide superior leak prevention.
• Positive Sealing Method: Elastic stored energy in the IX seal ring ensures consistent sealing.
• Wide Temperature and Pressure Range: Suitable for extreme design conditions.

RCF Working Principle:

The RCF design features two independent seals. o heel seal is created by applying seating stress at the flange heel, while the IX seal ring serves as the main seal. The seal ring’s elastic stored energy generates radial sealing forces, intensified by internal pressure acting on the ring’s inner surface. With increased preload, the flange bevel closes, achieving face-to-face contact at the outer wedge, transferring most bolt preload as compressive forces at the heel.

RCF Specifications:

The RCF IX seal ring exerts axial forces on the metal seal ring’s taper, translating into radial sealing forces, ensuring a reliable seal even under cyclic loading and thermal expansion.

Comprehensive Material Portfolio

Abter Steel offers an extensive range of materials to meet diverse application requirements, ensuring our flanges perform optimally in corrosive, Temperatura alta, e ambientes de alta pressão. Our material portfolio includes:

Material Highlights:

• Carbono & Temperatura baixa: A105 and A350-LF2 offer excellent toughness for low-temperature applications like LNG systems.
• Crómio: F22 and F91 provide superior creep resistance for high-temperature pressure vessels.
• Inoxidável & Duplex: F51, F53, and F55 excel in corrosive environments like seawater and chemical processing.
• Cobre & Bronze: C70600 and C71500 are ideal for marine and desalination systems.
• Além de ferro e carbono: SB381-GR.F1 and F5 offer lightweight, corrosion-resistant solutions for aerospace and chemical applications.
• Liga de Níquel: Inconel 625 e Incoloy 825 provide exceptional resistance to extreme corrosion and high temperatures.

Our ability to work with such a diverse material range ensures that we can meet the specific needs of any project, from subsea pipelines to nuclear reactors.

Advanced Design and Verification

At Abter Steel, we go beyond manufacturing by offering advanced design and verification services to ensure our flanges meet the highest performance standards. Our engineering team leverages industry-leading tools and methodologies, incluindo a:

• ASME Section VIII Calculation Services: Covering Divisions 1, 2, e 3, ensuring compliance with pressure vessel and piping standards.
• ANSYS Software Analysis: Análise de elementos finitos (FEA) for stress, térmico, and fatigue verification.
• Custom Design Solutions: Tailored flange designs for unique project requirements, including super-large sizes and high-pressure ratings.

Our rigorous verification process ensures that each flange performs reliably under the specified operating conditions, whether in cyclic loading, high thermal expansion, or extreme pressure environments. This commitment to precision engineering sets us apart as a trusted partner for critical applications.

Applications of Abter Steel Flanges

Our super-large forged flanges are designed for a wide range of critical applications, garantindo a segurança, confiabilidade, e eficiência. Key applications include:

Aplicações detalhadas:

• Óleo e gás: RCF flanges in F51 and F55 are used in dutos submarinos e tirantes, resisting corrosion from seawater and sour gas.
• Petroquímica: F316/316L and Inconel 625 flanges ensure reliable connections in Reatores químicos handling corrosive fluids.
• Geração de energia: F22 and F91 flanges serve as boiler covers, withstanding high-pressure steam up to 816°C.
• Fuzileiro naval: Copper-nickel (C70600) flanges are ideal for seawater heat exchangers in desalination plants.
• Nuclear: F6 and F91 flanges provide robust closures for reactor vessels, ensuring safety under extreme conditions.

Our flanges are engineered to meet the unique challenges of each industry, delivering performance and longevity in the most demanding environments.

Why Choose Abter Steel?

Abter Steel stands out as a premier manufacturer of super-large forged flanges due to our:

• Advanced Manufacturing: Cutting-edge forging and heat treatment facilities capable of producing flanges up to 98” in diameter.
• Material Expertise: Comprehensive material portfolio, from duplex steel to nickel alloys, tailored to specific application needs.
• Engineering Excellence: In-house ASME and ANSYS-based design and verification services for precision and reliability.
• Garantia da Qualidade: Compliance with ISO 9001, ASME, API, and NACE standards, with rigorous testing (hidrostático, ultra-sônico, impacto).
• Global Reach: Trusted supplier to industries worldwide, with a proven track record in critical projects.

Our commitment to innovation, qualidade, and customer satisfaction ensures that every flange we produce meets or exceeds client expectations, delivering value in even the most challenging applications.

Contact Us

For inquiries, Especificações técnicas, or custom flange solutions, contact Abter Steel today. Our team of experts is ready to assist with your project needs, from design to delivery.

• Web site:www.abtersteel.com
• Partner with Abter Steel for super-large forged flanges that redefine performance and reliability in industrial applications.