Shanxi Xinshunda Flange Manufacturing Co., Ltd. specializes in the production of Class 900 Orifice Flanges, a critical component designed for flow measurement in ultra-high-pressure industrial environments. Representing the upper tier of standard ASME B16.36 pressure ratings, the Class 900 Orifice Flange is engineered to withstand operating pressures up to approximately 2,220 psi (at ambient temperature for Carbon Steel) and maintains structural integrity at extreme temperatures where lower classes are inadequate. With nearly 20 years of advanced forging and precision machining expertise, we deliver these heavy-duty metering components to the global upstream oil & gas, deep-water offshore, and high-pressure petrochemical sectors, ensuring uncompromising safety and metrological accuracy in the most hostile process conditions.
Heavy-Duty Design and Advanced Engineering Features
The Class 900 Orifice Flange is characterized by massive hub thicknesses, large-diameter high-strength bolts, and robust sealing mechanisms required to contain extreme internal forces. Our manufacturing process integrates specific features to ensure safe operation and maintenance under these severe conditions:
- Superior Material Integrity: Due to the extreme wall thickness, the Class 900 Orifice Flange is forged from premium grades including Carbon Steel (A105), Low-Temp Carbon Steel (A350 LF2/LF3), Stainless Steel (A182 F304/F316/F316L/F321), Duplex/Super Duplex (F51/F53/F55), and High-Temp Alloy Steels (F11, F22, F91). We strictly control grain flow during forging to prevent internal defects under high stress.
- Precision Deep-Hole Tapping: Accurate differential pressure measurement relies on perfect tap geometry. Drilling orifice taps into the thick hubs of a Class 900 Orifice Flange requires specialized deep-hole drilling rigs with optical guidance. We ensure taps (Flange, D, or D/2 configurations) are perfectly perpendicular to the bore and free of burrs to prevent signal damping or turbulence.
- High-Torque Jack Screws: The bolt preload required to seal a Class 900 Orifice Flange is immense. Prying these flanges apart is dangerous and can damage the sealing surfaces. We integrate hardened, high-tensile alloy steel jack screws directly into the hub design, allowing operators to mechanically and evenly separate the faces for orifice plate inspection without risk.
- Mandatory RTJ Sealing: For Class 900 services, Raised Face (RF) seals are rarely sufficient. The Class 900 Orifice Flange is almost exclusively supplied with Ring Type Joint (RTJ) grooves (typically R-series or RX/BX series for higher security). These metal-to-metal seals, combined with oval or octagonal ring gaskets, provide the leak-tight integrity essential for containing high-pressure hydrogen, sour gas, and superheated steam.
Critical Applications in Extreme Environments
The Class 900 Orifice Flange is deployed in sectors where failure is not an option and operating pressures consistently exceed 1,500 psi.
- Upstream Oil & Gas (Wellhead): Essential for Christmas tree assemblies, wellhead flow lines, and manifold systems where wellhead shut-in pressures can reach 2,000+ psi.
- Deep-Water Offshore Production: Used in subsea trees, manifolds, and riser systems where high reservoir pressures and harsh environmental conditions demand the highest rating standards.
- High-Pressure Hydrogen Service: Critical in refineries and emerging hydrogen energy plants for hydrocracking units, hydrotreating reactors, and hydrogen recycle loops operating at extreme pressures.
- Geothermal Energy: Deployed in geothermal wellhead stations and high-pressure steam transmission lines where both pressure and temperature extremes are present.
- Enhanced Oil Recovery (EOR): Utilized in high-pressure CO2 injection lines and water flood injection systems requiring precise flow monitoring at depths.
Rigorous Quality Assurance for Ultra-High Stakes
In ultra-high-pressure applications, the margin for error is zero. Shanxi Xinshunda adheres to ASME B16.36, API MPMS Chapter 14.3, ISO 5167, NACE MR0175/MR0103, and API 6A (where applicable) standards.
- Comprehensive NDT Protocols: Given the massive cross-sections of the Class 900 Orifice Flange, every unit undergoes 100% Ultrasonic Testing (UT) per ASTM A388/A577 to detect internal laminations or inclusions. Surface and sub-surface defects are identified via Magnetic Particle (MT) and Liquid Penetrant (PT) testing.
- Metrological Precision: We utilize high-precision Coordinate Measuring Machines (CMM) to verify bore concentricity, RTJ groove dimensions (angle, depth, surface finish), and the exact spatial relationship of orifice taps. Deviations of even a few thousandths of an inch can cause catastrophic leaks or measurement errors at 2,200+ psi.
- Extreme Hydrostatic Validation: Each Class 900 Orifice Flange is hydrostatically tested at 1.5 times its rated pressure (approx. 3,330 psi for carbon steel) to validate structural integrity before leaving our facility.
- Full Traceability: We provide comprehensive EN 10204 3.1/3.2 Mill Test Certificates, detailing chemical composition, mechanical properties (including Charpy V-Notch impact tests for low-temp service), heat treatment records, and NDT reports for complete traceability from melt to final product.
Specialized Heavy-Lift Packaging and Global Logistics
The substantial weight and critical precision of the Class 900 Orifice Flange require specialized logistics handling. We ship flange pairs pre-assembled with heavy-duty steel spacers to maintain alignment and protect the delicate RTJ grooves. Threads are capped with reinforced plugs, and units are coated with heavy-duty, long-term corrosion inhibitors, wrapped in VCI paper, and secured in reinforced, steel-strapped wooden crates designed for ocean freight and heavy-lift crane operations. Our documentation package includes dimensional reports, NDT certificates, material traceability records, and pressure test certificates to ensure seamless integration into your high-pressure projects.
Partner with Shanxi Xinshunda for Extreme Pressure Reliability
Selecting Shanxi Xinshunda for your Class 900 Orifice Flange requirements means partnering with a manufacturer dedicated to safety, precision, and durability in the world's most demanding environments. We offer custom alloy solutions for sour service (NACE compliant), specialized RTJ groove machining (including BX/RX types), and expert technical support for ultra-high-pressure metering skid design. With 19 years of experience serving global energy giants, our Class 900 Orifice Flanges deliver the reliability and accuracy required to keep your extreme-pressure operations safe and efficient. Contact our specialized sales team today for technical specifications, catalogs, and competitive pricing.
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