HOW TO SPECIFY HYDRAULIC

FLANGES
MAIN Manufacturing Products, Inc. has been designing and manufacturing hydraulic
flanges and components for more than 55 years. Over this time, MAIN has helped customers
solve many of the same issues we have encountered ourselves. This paper will help users
specify hydraulic flanges for pipe and tube connections and gives tips to avoid some of these
issues.

Users need to address the following parameters to specify the right flange for the application:
pad size; bolt hole size or tapped hole size and thread; flange type; connection type and size;
geometry; material; pressure; and extras. Information on the screw (length and thread) and
O-ring (size and material) is needed to determine the mounting kit.

PAD SIZE (bolt spacing)

Specifying a flange usually starts with matching the flange to the mounting pattern (pad) on
the equipment. The item that the flange is attaching to might list the standard and size or
bolt hole pattern. Knowing the origin of the equipment can be helpful. Knowing the outside
dimensions of the flange is often not
helpful, as there are variations. Many
international standards use the
abbreviations DN (nominal diameter) and
PN (nominal pressure) as part of the size
designation. Don’t confuse nominal and
actual. Nominal means name and is used
to designate convenient groupings. Also
don’t confuse DN with DIN, the German
standards organization. If the pattern is
rectangular, chances are it conforms to
either SAE J518-1 (Code 61) or SAE J518-
2 (Code 62). These two standards are
commonly used around the world but have
different bolt patterns and different
maximum rated pressures. A number of
Code 62 patterns are similar to Code 61
patterns one size larger. Flange size is designated by dash number or DN number. The dash
number is the maximum center hole size in 16ths of an inch (for example, a –32 flange has a
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2-inch nominal through hole size). SAE J518-1 (Code 61) flanges are sometimes nominally
referred to as “3000 psi flanges” even though the maximum rated working pressure varies
from 5000 psi to 500 psi depending on size.
If the standard of the bolt pattern is not known, the pattern must be measured. Because of
the number of possible patterns, it is
important to measure the pattern to +/-
.005 inches (+/- 0.1 mm). Standards are
written with inch or metric dimensions in
mind. Four bolts may be dimensioned as a
circle, where the diagonal distance
between bolts is considered, or a square,
where the distance between adjacent bolts
is key. For example, there are seven
“standard” patterns between 2.725” and
2.825” bolt squares; flanges conforming to
one of these “standards” do not function
properly with the other patterns because of
tolerancing issues, differences in bolt sizes,
and differences in O-ring sizes.
If a flange has been installed with socket
head cap screws, an easy method of measuring the pattern is to use digital calipers. Measure
the screw head (which is also used to calculate the screw size), zero the calipers on the screw
head, and then measure the distance from the outside of one screw head to the outside of
another. This is the center-to-center distance between the bolt holes.

BOLT HOLE (size & thread) (inch/metric)

Measure carefully. Because metric bolts and inch
bolts have similar diameter/lead combinations, it
is possible to screw them into the wrong hole,
resulting in incomplete thread engagement. The
bolts in the picture to the right are essentially the
same length and have been threaded into the
wrong holes. Clearance holes that are too large
will not locate the O-ring flange on the pad close
enough to avoid the potential of the O-ring getting
“nibbled” by the port hole. Clearance holes made
too small will not accommodate the tolerance
stack ups possible. New designs should be metric.

FLANGE TYPE
There are two types of solid hydraulic flanges:
O-ring style and flat faced style, which is also
known as a companion. O-ring flanges have a
groove for an O-ring and clearance bolt holes.
Flat faced flanges have a flat sealing surface and
generally have tapped bolt holes. The
combination of a flange head with either a flange
clamp or two split-flange clamps is generally the
same as an O-ring flange. A union is formed by
connecting a flat faced flange type to an O-ring
flange type or a flanged head with split flanges.

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However, O-ring flanges are often attached to equipment that has flat faced pads.

CONNECTION TYPE
Many connection types are available: welded (socket and butt weld), threaded (SAE straight
thread, NPTF, BSPP, BSPT, and ISO 6149), flange port, and others. Socket-welded
connections have a socket that is larger than the tubing or pipe; MAIN’s standard for pipe
(welded) socket is about .03” (0.8 mm) larger than the pipe. Tube sockets (brazed/soldered)
are generally .005”-.010” (0.15 mm-0.25 mm) larger than the tube. This helps accommodate
tolerancing of the pipe or tube and any damage to the end during storage and transport. As a
standard practice, MAIN adds a chamfer on the socket; this allows easier insertion and allows
a fillet-reinforced groove weld that reduces the footprint for the same size weld. The through
hole generally follows the SAE J518 port sizing and tolerance. Butt welds are sized by the
nominal pipe/tube sizes and schedule or wall thickness. The configuration of MAIN’s butt weld
hub generally follows the ANSI standards.
Understanding the difference between pipe and tube sizing is important. Pipe size is
designated by its nominal inside diameter and schedule, which refers to the pipe’s wall
thickness. To make matters complicated, pipe of the same nominal size designation has the
same outside diameter (e.g. ½” pipe has an actual OD of .866”), independent of the
schedule. There is no dimension of 2” on any 2” nominal pipe size in any wall schedule.
Nominal tube size designations generally relate to the actual outside diameter. Nominal size
designation of metric tubes varies from country to country. A 40 mm tube does not
necessarily have a 40 mm OD, but the common specification practice is to list the actual
nominal OD and the wall thickness in millimeters.
MAIN offers many female threaded port connection options. The fluid power industry
recommends connections that use elastomeric seals (O-rings, etc.) such as the SAE straight
thread, ISO 1179 (BSPP), and ISO 6149 (metric),
which are designed not to leak after repeated
assembly. The use of NPT/NPTF threads is not
recommended because they are designed for a
one-time assembly and will leak if reassembled.
A NPT thread has two helical holes between the
roots and the crests of the thread that under
pressure forms a leak path. The “F” in NPTF
means fuel and was referred to as the “dry seal;”
the NPTF thread is crushed to eliminate these
holes. The BSPT has similar characteristics.
MAIN can provide other thread forms.

CONNECTION SIZE
The connection size can differ from the pad size. Generally a connection that is smaller than
the pad size, called a reducer, can be priced the same as one in which the pad and connection
sizes are the same. Increasers, where the connection size is larger than the pad size, might
not be physically possible or might cost significantly more.

GEOMETRY
Geometry, or the shape, is generally easy to determine and describe. There are in-line,
elbow, tee (both run and branch), Y, and cross. MAIN uses the largest O-ring face as the
starting point of its numbering system. On a tee, if there is a port opposite the largest O-ring
face (referred to as “on the run”), the connector is a run tee. If the largest O-ring face is 90
from the port face (referred to as “on the branch”), it is a branch tee. A side outlet elbow has
three connection ends that are 90 from each other. If a connector has an asymmetric shape,

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it may have a hand, and it might be necessary to describe it in terms of “right hand or “left
hand”. For example, if the asymmetric feature points left, it is described as a having a “left
hand”.

MATERIAL
Many materials are available. MAIN offers flanges made from AISI 1018 CF, ASTM A516-70
PVQ, AISI 11L17 and AISI 1020 as stock items and can turn around any commercially
available material quickly. Most of our AISI 1018 and AISI 11L17 material is bought from the
mill to MAIN’s special requirements. This allows for improved material traceability and
certification.
Stainless steel flanges are stocked in 304L grade with many stocked in 316L grade as well.
The “L” in stainless grades stands for extra low carbon and aids in welding. Welding non “L”
grades can result in an area that is not stainless steel in the heat affected zone and will rust.
Other options such as aluminum, nickel, and cuprous-nickel and any commercially available
material are available quickly. Some installations might require the use of specific material to
meet applicable codes. Know these codes and who will inspect and approve the part;
sometimes one agency is required to inspect to another’s code with conflicting requirements.

PRESSURES
It is useful to know the pressure the flange will see, including spikes and intensified pressures
caused by a cylinder in the hydraulic circuit, both of which can sometimes be above system
pressure.

EXTRAS
Other options available include counterbored bolt holes, offset ports, mounting holes,
“chopped blocks”, and gauge/sampling ports. The flange is one of the least expensive
locations for a gauge or sampling port.

MOUNTING KITS

SCREWS -size & type (inch/metric and socket/hex)

To mount the O-ring flange to the pad, a mounting kit consisting of 4 screws, 4 washers, and
an O-ring is used. Unlike ANSI and API flanges, hydraulic flanges generally join metal to
metal without a flat gasket between the surfaces; sealing is achieved by means of an O-ring
that is compressed in a groove. This reduces fatigue issues and allows full torque to be
applied to the bolts. High strength fasteners are generally used (SAE grade 8 hex head, ANSI
B18.3 socket head, ISO grade 10.9 hex head or socket head or better). The screw size is
determined by the tapped holes and normally has a coarse thread.
The use of corrosion-resistant bolts presents separate issues. In general, what makes bolts
stronger also makes bolts less corrosion resistant. Finding 10.9 metric grade bolts in
stainless steel might not be possible, and they can be quite expensive. The SAE standard for
Grade 8 screws specifies a material other than stainless steel. Bolts made from a corrosion-
resistant material might not be able to match both the tensile strength and yield strengths of
the bolts specified in the relevant flange standard, so application-specific accommodations
have to be made.

O-RING

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Most hydraulic flanges use an O-ring for sealing. Many different materials and some different
designs are available but the most common material used is Buna “N”. The material to be
used is determined by the temperature and the fluid. The fluid supplier should be consulted
for the appropriate O-ring material.
In addition to material and size, O-rings are specified by stiffness (durometer). For many
years 70 durometer O-rings were used, but in the last 20 years or more 90 durometer O-rings
have been used. If a SAE J518 flange is being used within specifications, it is many people’s
opinion that it should not make a difference.

CONCLUSION
While care needs to be taken in all the aspects of selection described above, MAIN has seen
many users struggle because they have not
 measured the bolt pattern to an adequate degree of precision,
 used the right bolts,
 considered the flange type (O-ring or flat faced),
 considered the geometry, or
 considered taking advantage of a reducer or gauge port adapter.

We hope that this paper will reduce the number of issues users see. Fill out the “Flange
Specification” page below and send to [email protected] or fax to 810.953.1385

THE FLANGE YOU NEED - NOW

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