How to solve the leakage of flange interface?

Solving a leakage issue at a flange interface typically involves identifying the root cause of the leak and taking appropriate corrective measures. Here’s a step-by-step guide on how to address a flange interface leakage:

1. Safety Precautions:
   Ensure that safety precautions are in place, such as proper personal protective equipment and equipment isolation if necessary.
2. Identify the Leak:
   Locate the specific area of the flange interface where the leak is occurring. This may involve visual inspection or using a leak detection method, such as applying soapy water or using a leak detection spray.
3. Determine the Cause:
   There are several common causes of flange leakage, and you’ll need to identify the specific reason for the leak. Possible causes include:
   • Gasket Failure: Check the condition of the gasket, which is designed to create a seal between the flange faces.
   • Insufficient Bolt Torque: Ensure that the flange bolts are tightened to the proper torque specifications.
   • Flange Face Damage: Inspect the flange faces for any damage, irregularities, or corrosion.
   • Misalignment: Verify that the two flange faces are properly aligned.
   • Temperature and Pressure: Ensure that the operating conditions (temperature and pressure) are within the design limits of the flange and gasket material.
4. Gasket Replacement:
   If the gasket is damaged, deteriorated, or improperly seated, replace it with a new gasket of the correct material and size for the application. Ensure that the gasket is properly seated in the flange groove.
5. Bolt Tightening:
   Check the bolt torque and tighten the bolts to the manufacturer’s specifications using a calibrated torque wrench. Tighten the bolts in a crisscross pattern to ensure even pressure on the gasket.
6. Flange Face Maintenance:
   If the flange faces are damaged or have irregularities, they may need to be machined or lapped to achieve a smooth and flat surface. Make sure the flange faces are clean and free of debris.
7. Alignment:
   If misalignment is the issue, realign the flanges correctly to ensure proper sealing.
8. Check for Other Contributing Factors:
   Review the operating conditions, fluid characteristics, and system setup to ensure that there are no other contributing factors to the leakage issue. Address any issues accordingly.
9. Reassembly:
   Reassemble the flange components, ensuring that everything is properly aligned, and the gasket is correctly seated.
10. Pressure Test:
    Conduct a pressure test to confirm that the leak has been successfully resolved. Gradually increase the pressure to the system’s operating level while monitoring for any leaks.
11. Record Keeping:
    Maintain a record of the maintenance and corrective actions taken to address the leakage issue for future reference.
12. Preventative Maintenance:
    Consider implementing a regular maintenance schedule to inspect and maintain flange interfaces to prevent future leakage problems.

If you are unsure about the cause of the flange interface leakage or if it is a critical application, it’s advisable to consult with a qualified engineer or technician with expertise in flange connections and sealing to ensure a safe and effective resolution.