Hydraulic Flange Spreader and Wedges Injures Worker
Several pipefitters were working on a 16” flange in the tank farm of a major oil refinery.
Tank farm flanges are typically extra tight due to the piping going underground, allowing little space for spreading flanges. This job was originally scheduled to take the pipefitters only 3 hours.
The pipefitters began by using wedges to attempt to spread the flange and remove the blind but this method proved inadequate.
The blind used in the line was too thin and had distorted, causing the removal to be difficult. After several failed attempts, one of the pipefitters got a hydraulic flange spreader from the tool room. They installed the hydraulic flange spreader on the 16 inch flange and began applying hydraulic pressure to spread the flanges. But when the flanges spread, the wedges were removed. Then the hydraulic flange spreader slipped. One pipefitter grabbed the hydraulic flange spreader attempting to stabilize it, when the contraption suddenly slipped out, injuring the pipefitter.
Conclusion: Devices that do not connect to flange bolt holes are dangerous. They are prone to slipping and can seriously injure the worker. Most often a significant amount of energy has been applied to the devices, such as wedges and hydraulic flange spreaders, before they slip out and become dangerous objects. The only safe device for spreading flanges is one that attaches to the bolt holes of the flange, creating an anchor point, that prevents slippage. It is recommended that the devices used to spread flanges be connected to the bolt holes of the flanges to prevent slippage. Avoid using wedges and flange spreaders that do not connect to the bolt holes.
OSHA recognizes the need for proper flange spreaders
