Course Overview
This course covers the essential knowledge and practical skills required for the safe and effective make-up and break-down of flanged joints in piping systems. It emphasizes correct procedures, torqueing techniques, safety protocols, and inspection requirements to ensure leak-free, reliable flange connections in industrial applications.
Course Objectives
By the end of this course, participants will be able to:
- Understand the types and components of flanges used in piping systems.
- Apply proper make-up and break-down procedures for flange connections.
- Use appropriate tools and techniques for tightening bolts and gaskets.
- Follow safety protocols to prevent accidents and equipment damage.
- Inspect flange joints for integrity and compliance with standards.
- Troubleshoot common flange joint problems such as leaks and bolt failures.
Who Should Attend
This course is designed for:
- Mechanical and piping engineers
- Maintenance technicians and fitters
- Inspection and quality control personnel
- Construction supervisors and safety officers
- Project engineers involved in piping systems
Course Outline
Introduction to Flanges and Flanged Joints
- Types of flanges (weld neck, slip-on, blind, socket weld, lap joint, etc.)
- Flange components: bolts, nuts, gaskets, studs
- Materials and standards (ASME, ANSI, API)
Flange Joint Design and Selection
- Factors affecting flange joint integrity
- Gasket types and sealing mechanisms
- Bolt materials and torque specifications
Make-Up Procedures
- Preparation and inspection before make-up
- Bolt tightening methods: manual, hydraulic tensioners, torque wrenches
- Bolt tightening patterns and sequences (cross, star pattern)
- Achieving proper bolt load and gasket compression
Break-Down Procedures
- Safe bolt removal techniques
- Preventing damage to flanges and gaskets
- Handling and storage of flange components
Safety Protocols
- Personal protective equipment (PPE) requirements
- Hazard identification and risk control during flange operations
- Lockout/tagout and permit-to-work systems
Inspection and Testing
- Visual and dimensional inspection of flange joints
- Leak testing methods: hydrostatic, pneumatic
- Documentation and quality assurance
Common Issues and Troubleshooting
- Causes and solutions for flange leaks
- Bolt failures and replacement criteria
- Gasket failure modes and corrective actions
Case Studies and Best Practices
- Real-world examples of flange joint failures and successful repairs
- Industry best practices for flange make and break operations