Insert Flanges for Jacketed Piping
paragraph applies when Appendix 2 or Appendix Y are
Technical Data
1. GENERAL INFORMATION
1.1 Unit Description. An insert flange unit is com-
prised of an insert and bolting ring (flange) and are sold
jointly as one unit unless otherwise requested.
Most often, insert flanges are comprised of a stainless
insert and a carbon steel bolting ring, but are available in
other alloys (see 5.0 Materials).
1.2 Association to ASME B16.5. References in this
catalog to classes of insert flanges, e.g. 150LB,
300LBetc. designate compatibility to ASME B16.5
flanges and are not intended to denote conformance to
ASME B16.5 standards. Insert flanges are not ASME
B16.5 flanges. SIFCO does, however, design and man-
ufacture insert flanges for complete bolting compatibili-
ty to ASME B16.5 flanges and offers insert flanges that
meet ASME B16.5 Maximum Allowable Working
Pressures in each specific class. (see 1.6, 2.1.2, & 2.2.2)
1.3 Code References. Any references to the “Code” are
limited to the ASME Boiler and Pressure Vessel Code,
and not other state or governmental codes which may
have jurisdiction.
1.4 Established Criterion. SIFCO insert flanges for
jacketed piping have been used extensively by the pro-
cessing industries for more than forty years. During
these years, insert flanges have established a standard
for dependable service by meeting the demands of criti-
cal jacketed piping systems.
1.5 Insert Flanges Per ASME B31.3. ASME B31.3,
Process Piping, provides requirements for the design of
flanges which are not listed as standards in Table 326.1,
of the specification. These requirements are found in
paragraph 304.5.1. This states that flanges may be
designed in accordance with the Boiler Pressure Vessel
Code, Section VIII, Division 1, Appendix 2 or Appendix
Y, depending on whether the gasket OD is inside or out-
side the bolt circle. It also states that flanges may be
qualified by the requirements of paragraph 304.7.2. This
2 1-800-87-SIFCO • 610-494-1800 • FAX 610-494-1803
not applicable and states that the design is to be based on
calculations consistent with the design criteria on B31.3
and substantiated by one or more of the following:
a) extensive & successful service experience under com-
parable conditions with similarly proportioned compo-
nents.
b) experimental stress analysis similar to that described
in BPV Code, Section VIII, Division 2, Appendix 6.
c) proof testing in accordance with ASME B16.9, MSS
SP-97, or BPV Code Section VIII, Division 1, UG-101.
d) detailed stress analysis such as finite element.
Since SIFCO’s insert flanges are very similar to ASME
B16.5 flanges, containing the same ring-type elements,
they can be reliably designed to Appendix 2 of the BPV
Code, Section VIII, Division 1.
1.6 ASME Rated. When SIFCO refers to an Insert
Flange as ASME rated they are stating that calculations
conforming to the ASME Boiler and Pressure Vessel
Code, Section VIII, Division 1, have been performed
which determine minimum flange thickness to meet
ASME B16.5 PSIG at material group 2.2 (see table 1).
These calculations are based on the use of carbon steel
to SA-515/516 Gr70 or SA-105 material for the bolting
ring and stainless steel type 304, 304L, 316, 316L to SA-
479 or SA-182 for the insert. The bolting is to SA-193-
B7 and the gasket material is spiral wound. Any changes
to the material, bolting, or gasket could change the
required dimensions of the insert flange, if meeting the
P/T rating of B16.5 is desired.
2. STYLES OF JACKET INSERT FLANGES
2.1 Reducing Jacket Insert Flange. This phrase refers
to the style or design of insert flange in which the nom-
inal core pipe size is smaller than the nominal flange
size.
The reducing jacket insert flange style is ideal for sys-
tems in which temperature changes cannot be tolerated
at flange connection. By minimizing the distances at
flange connections, it assists in eliminating the frequent-
ly encountered problem of product buildup and solidifi-
cation at critical points.
 Insert Flanges for Jacketed Piping
2.1.1 Conventional Reducing Jacket Insert Flanges.
These reducing jacket insert flanges have been used suc-
cessfully for decades. This style of insert flange is only
available in class 150 and 300. They utilize the econom-
ical advantage of the ASME B16.5 flange thickness for
their design but are not recommended for critical appli-
cations which must meet code.
2.1.2 ASME Rated Reducing Jacket Insert Flanges.
This style of insert flange is available in all classes. On
this style of insert flange calculations conforming to the
ASME Boiler and Pressure Vessel Code, Section VIII,
Division 1, have been performed which determine mini-
mum flange thickness to meet ASME B16.5 PSIG values
at material group 2.2 (see table 1). Therefore this style of
insert flange can be used for ASME Code and Pressure
Vessel Applications.
2.2 Non-Reducing Jacket Insert Flange. This phrase
refers to the style or design of insert flange in which the
nominal core pipe size is equal to the nominal flange
size.
Non-reducing jacket insert flanges require smaller
flanges. Along with the use of smaller valves and other
fittings, considerable cost and space savings in fabricat-
ing jacketed systems can be realized.
2.2.1 Conventional Non-Reducing Jacket Insert
Flanges. These non-reducing jacket insert flanges have
been used successfully for decades. This style of insert
flange is only available in class 150 and 300. They uti-
lize the economical advantage of the ASME B16.5
flange thickness for their design but are not recommend-
ed for critical applications which must meet code.
2.2.2 ASME Rated Non-Reducing Jacket Insert
Flanges. This style of insert flange is available in all
classes. On this style of insert flange calculations con-
forming to the ASME Boiler and Pressure Vessel Code,
Section VIII, Division 1, have been performed which
determine minimum flange thickness to meet ASME
B16.5 PSIG values at material group 2.2 (see table 1).
Therefore, this style of insert flange can be used for
ASME Code and Pressure Vessel Applications.
1-800-87-SIFCO • 610-494-1800 • FAX 610-494-1803
3. SIZE
3.1 How to Reference Size. When referencing the size
of a jacket insert flange: First, designate the class and
nominal flange size. Second, designate the nominal core
pipe size. If it is a buttweld style indicate the core pipe
schedule. Third, designate the nominal jacket pipe size
with its schedule. And last, designate the SIFCO part
number, if known. (e.g. 150LB, 3” x 2”-sch 10 x 3”-sch
40, 02H) See Ordering Information in this catalog for
more details.
3.2 Nominal Size. References to the size of a flange,
pipe, or bolt is its nominal size. Use of “nominal” indi-
cates that the stated size or dimension is only for desig-
nation, not measurement.
3.3 Sizes and Classes Not Cataloged. The sizes and
classes in this catalog are listed due to their frequency of
request and are not meant as a capacity range. Insert
Flanges can be manufactured in all ASME B16.5 classes
and sizes.
4. MARKINGS
4.1 Bolting Ring or Flange Markings. The edge or
outside diameter of each insert flange is marked in accor-
dance with ASME B16.5 and MSS SP-25; the manufac-
turer’s registered trademark SIFCO, the material’s
ASTM or ASME specification grade identification and
the melt identification, rating class and nominal size.
4.2 Insert Markings. The outside diameter of each
insert is marked, as is the bolting ring, with the addition
of SIFCO’s part number if space allows.
3
Insert Flanges for Jacketed Piping
5. MATERIALS
5.1 Insert Material. Inserts can be manufactured from
any machineable alloy. Inserts of the most popular sizes
are stocked in 316L stainless steel. Other materials
which have been used to manufacture inserts are: carbon
steel, other grades of stainless steel, Nickel, Hastelloy™,
AL6XN™, Aluminum, Inconel™, monel, titanium, and
Duplex 2205™.
The inserts for the ASME Rated Jacket Insert Flanges for
ASME Code and Pressure Vessel Application Flanges
are manufactured of stainless steel to SA-479 or SA-182
type 304, 316, 304L or 316L.
5.2 Bolting Ring/Flange Material. Bolting rings or
flanges can be manufactured from any machineable
alloy, but are stocked in A105 carbon steel. To inhibit
rust, the carbon steel bolting rings or flanges are coated
with a black enamel paint. Other coatings, such as gal-
vanizing, zinc or epoxies, are available upon request.
Other materials which have been used to manufacture
bolting rings or flanges are: stainless steel, nickel,
Hastelloy™, AL6XN™, aluminum, Inconel™, titanium,
and other grades of carbon steel.
The bolting rings for the ASME Rated Jacket Insert
Flanges for ASME Code and Pressure Vessel Application
Flanges are manufactured of carbon steel to SA-
515/516-Gr70 or SA-105.
5.3 Mill Test Reports. Test reports from the supplier of
the raw material are available upon request. Normally
these test reports are available without cost. However,
SIFCO reserves the right to pass on additional cost
incurred.
5.4 Material Meeting ASME Code Requirements.
Raw materials are normally manufactured to ASTM
standards (e.g. A-105). SIFCO also stocks, or can obtain,
materials which are dual certified to meet ASTM stan-
dards and the ASME Boiler and Pressure Vessel Code
(e.g. SA-105). This requirement must be made known
when ordering and quoting.
4 1-800-87-SIFCO • 610-494-1800 • FAX 610-494-1803
5.5 Domestic Only Requirement. Most raw materials
inventoried are from domestic mills. If domestic materi-
al is required, this requirement must be made known
when ordering and quoting to assure receiving “domestic
only” material.
6. FACINGS
6.1 Flange Facings. SIFCO insert flanges are manufac-
tured with a standard raised face to ASME B16.5 dimen-
sions. This is the facing that will be supplied unless oth-
erwise specified.
Other flange facings can be ordered. These include, but
are not limited to, large male and female, small male and
female, large tongue and groove, and small tongue and
groove.
Due to the two piece design of the insert flange a flat face
insert flange cannot be offered.
6.2 Raised Face Dimensions. SIFCO inserts are manu-
factured with a raised face thickness equal to the corre-
sponding ASME B16.5 dimension. The diameter of the
raised face on the inserts are equal to, or greater than, the
corresponding ASME B16.5 dimension. Larger raised
face diameters are found on a few of the non-reducing
jacket flanges. This is necessary when a jacket pipe’s
inside diameter is greater than the standard ASME B16.5
raised face dimension. However, in all cases there is ade-
quate bolting clearance.
6.3 Flange Facing Finish. SIFCO’s standard facing fin-
ish for the gasket surface of the insert is a continuous spi-
ral or phonographic finish to an average roughness in the
range of Ra 125 to 250 µin. This is the facing finish that
will be supplied unless otherwise specified.
Other surface finishes for flange faces can be ordered.
These included, but are not limited to, specified smooth
or unpolished finishes (e.g. Ra 32, 63, 125, 250, or 500
µin.), or a concentric serrated surface.
 Insert Flanges for Jacketed Piping

7. PRESSURE TEMPERATURE RATINGS
7.1 ASME Boiler and Pressure Vessel Code calcula-
tions to establish Maximum Allowable Working
Pressure (MAWP) for the Conventional Jacket Insert
Flanges. Due to the differences between the SIFCO
insert flange design and standard ASME B16.5 flanges,
calculations were performed to establish an MAWP Table
(see Table 2). In some cases, values exceed the ASME rat-
ings, and in others, values are below the ASME ratings.
These calculations conform to the procedures detailed in
Appendix 2 of the ASME Boiler and Pressure Vessel
Code, Section VIII, Division 1. They were based on the
use of standard 1/8” thick asbestos-equivalent gaskets and
carbon steel bolts to SA-307 B. Flanges are forged carbon
steel to SA-105 and inserts covered by these ratings may
be type 304, 316, 304L or 316L.
The MAWP on SIFCO’s standard insert flanges have
been established without calculating for flange protection
due to overbolting using SA-193-B7 bolts. The ASME
code has specifically allowed the use of alloy steel bolts
to SA-193-B7 with ASME B16.5 flanges without calcu-
lation. This is primarily because ASME B16.5 flanges
cannot always meet the overbolting protection require-
ments of the code, due to extremely high bolt strength.
Since the bolting and flange thickness of conventional
SIFCO insert flanges are identical to those of ASME
B16.5., but do not share the code’s exemption, SIFCO’s
MAWP (see Table 2) was calculated using carbon steel
bolts to SA-307 B. For piping systems using SA-193-B7
bolts, that must meet the ASME Code requirements,
SIFCO has designed insert flanges which meet code
requirements. (see 2.1.2 and 2.2.2)
7.2 Use of the ASME B16.5 Maximum Allowable
Working Pressure (MAWP) for SIFCO’s ASME
Rated Jacket Insert Flanges. The ASME B16.5
Pressure Temperature Ratings at material group 2.2 (see
Table 1) can be used for the Jacket Insert Flanges marked
“ASME Rated”, for ASME Code and Pressure Vessel
Application. Calculations conforming to the ASME
Boiler and Pressure Vessel Code, Section VIII, Division
1, have been performed which determine minimum
flange thickness to meet ASME B16.5 MAWP. These
calculations are based on the use of carbon steel to SA-
515/516 Gr70 or SA-105 material for the bolting ring
and stainless steel type 304, 304L, 316, 316L to SA-479
or SA-182 for the insert. The bolting is to SA-193-B7
and the gasket material is spiral wound. Any changes to
the material, bolting, or gasket could change the required
dimensions of the insert flange.
7.3 Jacket Pipe Pressure. References to pressure tem-
perature are limited to the pressure temperature of the
process pipe. Insert flanges are not a limiting factor to the
pressure of the jacket pipe.

Table 1
(from Table 2-2.2 of ASME B16.5-1996)
Working Pressures by Classes
Class 150 300 400 600 900 1500 2500
Temperature PSIG Values
-20 to100˚ F 275 720 960 1440 2160 3600 6000
200˚ F 235 620 825 1240 1860 3095 5160
300˚ F 215 560 745 1120 1680 2795 4660
400˚ F 195 515 685 1025 1540 2570 4280
500˚ F 170 480 635 955 1435 2390 3980
600˚ F 140 450 600 900 1355 2255 3760
650˚ F 125 445 590 890 1330 2220 3700
700˚ F 110 430 580 870 1305 2170 3620
750˚ F 95 425 570 855 1280 2135 3560
800˚ F 80 420 565 845 1265 2110 3520
850˚ F 65 420 555 835 1255 2090 3480
NOTE: 304L material is limited to 800˚ F.

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