Special Flanges: Custom-Engineered Solutions for Demanding Applications
Image: A custom t-flange
What are special flanges?
Special flanges are advanced flanged connections engineered for complex industrial applications where standard flanges are not sufficient. Unlike conventional solutions, special flanges are designed to handle misalignment, extreme pressures, and specific project needs across industries such as oil & gas, petrochemical, offshore, subsea, power generation, and nuclear plants.
At M.E.G.A., we specialize in the design, forging, and manufacturing of special flanges in all steel grades, including carbon steel, stainless steel, duplex and super duplex, nickel alloys, titanium, and other high-performance materials. Every product is developed according to international codes such as ASME, API, and MSS, and validated through Finite Element Analysis (FEA).
Types of special flanges
We provide a wide range of special flanges, tailored to customer requirements and project specifications. Key categories include:
- Flanged Tee – Provides a branch connection with flanged termination, available in sizes from 1/2” to 12” and pressure ratings up to Class 2500#, RF or RTJ.
- Nipoflange – A combination of a nipolet and a welding neck flange, designed for compact installations and reduced welding operations.
- Flanged Spool – Sections with flanged ends that simplify on-site assembly and reduce downtime.
- Flanged Nozzle – Engineered for pressure vessels and heat exchangers, ensuring reliable sealing and fatigue resistance.
- Anchor Flanges & Riser Flanges – Heavy-duty flanges designed to withstand pipeline stresses and anchor loads.
- Misalignment Flanges – Unique spherical connectors that compensate for misalignment up to ±10°, ensuring leak-tight sealing even under high pressure.
Image: Flanged welded lateral
Advantages of special flanges
Special flanges are not off-the-shelf components, but tailor-made solutions created for projects that would otherwise struggle to find suitable products. They are fully customizable to the specific needs of both the application and the customer, ensuring that every technical and operational requirement is met. Thanks to M.E.G.A.’s extensive know-how, clients receive exactly the flange solution they need, with no compromises.
These custom-engineered flanges guarantee performance, safety, and reliability even in the harshest conditions. Their design simplifies installation by reducing welding operations and on-site adjustments, while also offering superior fatigue resistance against cyclic loads, vibrations, and pressure fluctuations.
Engineering & manufacturing excellence
M.E.G.A. integrates in-house engineering, forging, machining, and testing to deliver high-quality special flanges. Our capabilities include:
- Design & FEA Analysis – Advanced CAD/CAM and FEM tools for precise stress analysis and design validation.
- Closed-die forging facility – Equipped with presses up to 2500 tons, ensuring superior metallurgical quality.
- Weld overlay & cladding – Application of corrosion-resistant alloys (CRA) such as Inconel 625, Hastelloy, and stainless steels.
- Testing & certification – Non-destructive tests (UT, PT, MT, RT), hydrostatic tests, and destructive tests performed in our ISO 17025 certified laboratory.
- Global Standards compliance – Conforming to ASME, EN, PED, RCC-M, and other industry standards.
Image: Forged and finished nipoflanges
Applications of special flanges
Special flanges play a vital role in projects that demand tailored engineering solutions:
- Oil & Gas pipelines – Subsea tie-ins, risers, piggable systems.
- Petrochemical plants – High-pressure process lines and critical branch connections.
- Power generation – Nuclear and conventional power plants requiring heavy-wall flanges.
- Offshore & Subsea – Misalignment flanges for deepwater connections without costly repositioning.
- Pressure vessels & heat exchangers – Custom flanged nozzles to ensure long-term reliability.
Why choose M.E.G.A. for special flanges?
With over 60 years of expertise, M.E.G.A. is a global leader in the production of high-performance special fittings. Our fully integrated manufacturing process, from forging to final testing, guarantees unmatched quality, traceability, and compliance.
We collaborate directly with EPC contractors, operators, and distributors worldwide to deliver special flanges designed for project-specific challenges.