How to Correctly Use a Flange Spreader
Flanges are a common component in industrial piping systems, forming secure connections between pipes, valves, and other equipment. However, separating these flanges during maintenance procedures can be a challenge.
This is where flange spreaders come in. A flange spreader is a specialized tool designed to safely and efficiently create a gap between flanges, enabling tasks like gasket replacement, bolt removal, and inspection.
But how do you use a flange spreader correctly? This guide provides step-by-step instructions on how to use flange spreaders correctly, plus which safety precautions to follow in any flange spreading situation.
What is a Flange Spreader?
A flange spreader is a mechanical or hydraulic tool used to create a gap between two connected flanges. This gap provides the necessary space to complete various maintenance tasks. Flange spreaders come in various designs and sizes to accommodate different flange types, sizes, and pressure ratings.
Types of Flange Spreaders
The two main types of flange spreaders are mechanical and hydraulic:
Mechanical Flange Spreaders
Mechanical flange spreaders are a simpler and more cost-effective option for situations that require lower spreading forces. They typically use a screw mechanism to create a wedging action between the flanges. These spreaders are ideal for smaller flanges or applications with limited access.
Hydraulic Flange Spreaders
Hydraulic flange spreaders utilize a hydraulic pump to generate significant spreading forces. This makes them suitable for larger flanges, high-pressure applications, and stubborn connections. Hydraulic spreaders also offer more precise control over the spreading force than manual spreaders.
Using a Flange Spreader
Before attempting to spread any flange joint, always reference the manufacturer’s operation manual and job safety analysis. Identify potential pinch points and establish a safe working perimeter clear of non-essential personnel.
1. Select Your Flange Spreader
Select the appropriate spreader model for your task based on the flange size, pressure rating, and minimum access gap. Remember, larger diameter, higher-pressure flanges require sturdy hydraulic spreaders capable of generating tens of thousands of pounds of spread force.
2. Conduct a Thorough Safety Check
Once you’ve chosen the correct spreader, inspect it and all its accessories, like hoses, fittings, spare, and seals, for any damage. Ensure the pump operates smoothly without leaks and that the cylinder bores extend evenly.
3. Position the Flange Spreader
With safety protocols addressed, the next step is properly positioning the spreader components within the flange gap. As it’s recommended to use flange spreaders in pairs, choose two opposing locations on the flange circumference for wedge insertion. Ideally, you should space these points evenly to distribute spreading force.
4. Insert the Wedge Tips
Carefully insert the thin wedge tips of the spreaders into the gap between the flanges at the chosen locations. Ensure both wedge tips are fully seated and make full contact with the flange faces.
Tip: If you’re using stepped blocks, make sure the stepped block is securely attached to the wedge before inserting it.
5. Commence with Flange Spreading
Slowly and evenly operate the hydraulic pump (or turn the screw mechanism for mechanical spreaders) to advance the wedges further into the gap. This will begin creating separation between the flanges. While spreading, remember to:
- Monitor the spread – Keep observing the gap between the flanges as you apply pressure. Aim for a smooth and even separation process to avoid placing undue stress on the flanges or spreader.
- Maintain alignment – Ensure the spreader remains positioned squarely between the flanges throughout the process. Any misalignment can cause uneven spreading or damage to the flanges.
- Control the force – Apply pressure steadily and avoid exceeding the spreader’s rated capacity. Refer to the manufacturer’s specifications for the maximum safe operating pressure.
6. Maintain the Spread Once You’ve Reached the Desired Gap
Stop pumping once you’ve reached the desired gap size for your maintenance task (e.g., gasket replacement, bolt removal, etc.). Maintain hydraulic pressure on the spreader to keep the flanges separated. This will allow you to perform your maintenance task safely. For additional security, consider inserting safety blocks into the created gap. This can be helpful for larger flanges or situations requiring extended work time.
7. Release and Remove the Spreader
Once you’ve completed your maintenance task, slowly release the pressure from the hydraulic cylinder (or loosen the screw mechanism for mechanical spreaders). The flanges will begin to close. Once the pressure is fully released and the flanges are almost closed, carefully remove the spreader wedges from the gap.
Cheat Sheet: Safety Precautions When Using a Flange Spreader
Part of correctly using a flanger spreader means keeping these core safety precautions in mind, whether you’re completing maintenance tasks or offering flange spreader demonstrations:
- Inspect the flange spreader for damage before each use.
- Ensure you select the spreader that matches the necessary capacity and flange size.
- Use the spreader only for its intended purpose.
- Never exceed the spreader’s rated capacity.
- Position the spreader squarely between the flanges.
- Ensure the spreader is properly seated before applying pressure.
- Apply pressure slowly and evenly.
- Monitor the spreader for any signs of failure or distress.
- Stop spreading if the spreader shows signs of failure or distress.
- Vent the hydraulic pressure before disconnecting the spreader.
ALLTORC: Meeting All Your Flange Spreader Tool Needs
Flange spreaders are essential tools for safe and efficient flange maintenance. By understanding the different types of spreaders, selecting the right tool for the job, and following safety precautions every step of the way, you can ensure the successful completion of your maintenance tasks.
Contact ALLTORC today to discuss your flange spreading needs and explore our comprehensive selection of flange spreaders and other industrial bolting solutions.