Flange Spreader Insights
We offer a full line of innovative tools designed for making flange maintenance safer and easier. When considering a flange spreader for your application, precision and safety are paramount. Let’s review what factors you need to know.
Laws of Physics and How they Apply to Your Job.
Newton’s First Law states, “An object at rest remains at rest, and an object in motion remains in motion at constant velocity unless acted upon by an unbalanced force.”
Similarly, Newton’s Third Law asserts, “For every action, there is an equal and opposite reaction.” These principles highlight the importance of precision in force applications.
Now, let’s connect these physics gems to flange spreaders: Just like Newton’s laws govern the dance of planets and ping pong balls, precision matters when applying force to those stubborn flanges. Whether you’re spreading, tightening, or loosening, remember: Equal and opposite reactions are the name of the game, and making the right choice is vital to safe and efficient operations.
At ESI, we provide flange spreaders that empower operators to apply force with precision, ensuring controlled and measured force is used for every task, aligning with the core principles of physics for optimal results.
How to Choose the Right Flange Spreader
Remember, accuracy matters. Choosing the right flange spreader ensures efficient and safe maintenance or installation.
Application Include but not limited to…
Flange facing: Resurfacing flange faces for maintenance purposes.
Pipeline maintenance and construction: For spreading pipe flanges during repair or replacement of gaskets and valves.
Pressure vessel servicing: Accessing the internals of pressure vessels for maintenance or modification.
Power plant operations: Maintenance and repair of various equipment within power plants.
Offshore platforms: Performing maintenance tasks on flanged connections in offshore oil and gas operations.
Compact Flanges: Flange Spreaders which use the bolt holes to spread a joint.
Flange Type: Identify the type of flange you’re working with (e.g., raised face, flat face, ring joint). Different flanges require specific spreader designs.
Flange Size: Measure the flange diameter accurately. This ensures compatibility with your spreader.
Pressure Class: Understand the pressure rating of your flange. Choose a spreader that can handle the required pressure.
Supervisor Records: If available, consult any existing records your supervisor may have. They might contain essential details about the flange.
Measuring Tools: If no records exist, grab your measuring tools. Old-fashioned, but effective! Measure the flange dimensions.
Gap or Gapless: Check if there’s a gap between the flanges. If yes, measure the gap size. Step Wedge Flange Spreaders require at least .20″ of a gap, depending on the model. Mini Gap Flange Spreaders require 3/32″.
Bolt Hole Size: For gapless flanges or gaps less than 3/32″, measure the bolt hole diameter.
Outside-to-Outside Distance: Measure the distance from the outer edge of one flange to the outer edge of the other.
Bolt Hole Size: If you’re removing a valve, measure the bolt hole diameters.
Valve Length: Also measure the length of the valve itself.
Flange Spreaders Designed for...
The Step Wedge’s unique design allows the operator to perform the task in a controlled and predictable manner. Each Spreader, like others has a handle, but unique to their flange spreader, they include high quality soft grip technology to avoid hand fatigue in difficult locations.
|
Hydraulic Twin Step Wedge Flange Spreader & Pump Kit |
Mechanical Step Wedge Flange Spreader |
|
 |
|
Distinctive Features: Robust Spreading Capability: Delivers a formidable 98,425 – 183,727 foot-pounds per wedge, equivalent to 15 – 28 metric tons of force per wedge, ensuring powerful and efficient spreading. Minimizes Operator Exposure: The dual-port pump enables a single operator to deploy a spreader on both sides of a flange simultaneously. Versatile Fit: Accommodates narrow openings as slim as .20″ (5mm) and expands to fit wider gaps with the integration of step blocks, offering flexibility across various applications.
|
Distinctive Features: Pinch-Point Free: Ensures a safer user experience by design. Precision Tooling: Equipped with a calibrated torque wrench for accurate force application. Spreading Force Delivers up to 12 metric tons or 88,189 ft. lbs of spreading force. |
Key Benefits:
- Operator Safety: Prioritizes the operator’s safety with its thoughtful design.
- Enhanced Control: Offers superior control during operation, enhancing precision and efficiency.
- Simplified Operations: Tasks that were once intricate and demanding are now effortlessly manageable.
Designed initially for underwater use by divers, this flange spreader has expanded its utility to a variety of challenging environments. It proves invaluable for flanges situated in hard-to-reach areas or at towering heights. The task of transporting an 80-pound case can be formidable, and when the work site is situated 100 feet above ground, the challenge intensifies. However, the integrated pump feature is a game-changer, offering ease of operation that minimizes operator fatigue and significantly reduces the risk of accidents.
| THE VIPER-28P Flange Spreader with built in Pump | Hydraulic Mini Gap Flange Spreader (AKA Pop It) |
|
Click to Enlarge  |
Click to Enlarge  |
|
Distinctive Features: Integrated Pump: Enhances operational readiness. Substantial Force: Models can generate between 8.7 – 28 tons (63,937-205,774 ft. lbs.) of spreading power. Versatile: Fits Gaps from 0.20″ (6mm) |
Distinctive Features: Slim & Light weight: Enhances mobility and control. Substantial Force: Models can generate 5 tons of spreading power. Versatile: Fits Gaps from 0.3/32″ (2.4mm) |
Key Benefits:
- Reduced Maintenance: Maintenance and repairs are a breeze with the Viper-28’s user-friendly single-pin disassembly and assembly feature. This ensures dependability and longevity, keeping your operations running smoothly.
- Safety Enhancements: Includes a safety lanyard and blocks for secure operations.
- Reduced Downtime: Enhanced efficiency, fewer parts, and decreased fatigue help keep your operators focused and productive.
For years, maintaining flanges, especially those without gaps, was a daunting task. Traditional methods involving cranes, pulleys, and crowbars not only posed significant safety risks but also demanded an excessive amount of time and labor. Enter ZG Collet/Pin Technology – the game-changer in flange maintenance.
Safe and Efficient Operations ZG Collet Technology is engineered to provide operators with a safe and efficient solution for maintaining challenging flange joints. Innovative Design for a Firm Grip The tool’s innovative design allows you to insert the arms into the bolt hole easily. Whether you’re manually tightening or using a hydraulic pump, the collets expand seamlessly inside the bolt hole, securing a firm grip from within. This ensures a stable and reliable setup, essential for the task at hand.
| Zero Gap Flange Spreader |
Valve Removal Tool Kit |
|
Click to Enlarge  |
Click to Enlarge 
|
|
Distinctive Features: Internal Grip: Collets firmly secure the flange from within the bolt hole. Size Versatility: A variety of collet sizes to accommodate different bolt hole dimensions. Precision Instrumentation: The kit comes with a calibrated torque wrench for precise force measurement. Click Image to enlarge  |
Distinctive Features: The Valve Removal Tool is a specialized instrument designed for operators who need to perform valve replacements with utmost precision and control. Precision: The Valve Removal Tool is engineered to be precise. When you’re dealing with critical components like valves, accuracy matters. This tool minimizes the risk of damage during removal. Lightweight and Compact: Portability matters in maintenance work. The tool’s lightweight design ensures ease of handling, even in tight spaces. Versatility: By adding spacer bars, the Valve Removal Tool can handle valves of various sizes—whether they’re small, medium, or large. |
Key Benefits:
- Simultaneous Flange Spreading: The valve bar segments of the tool allow for simultaneous flange spreading. This feature is particularly useful when you need to create space between flanges for maintenance or repair.
- Economical Solution: Operators appreciate that it provides a cost-effective solution without compromising safety or performance. Maintenance tasks can be expensive, so having an efficient tool matters.
- Efficient: Offers controlled and precise operation for optimal results and recuced accidents.
Flange Spreader Video Gallery
