Flange guards may not get much attention, but these simple devices play a crucial role in protecting workers and equipment in industrial facilities. In this blog post, we’ll take a closer look at what exactly flange guards are, why they’re so important, and some best practices for using them effectively.
What Are Flange Guards?
A flange guard, sometimes called a flange cover, is a removable cover that goes over the opening of a pipe flange. Pipe flanges are ring-shaped connectors used to join sections of piping together. When two flanges are bolted together, they form a tight seal to prevent leakage from the pipeline.
The opening in the middle of a flange is where the actual flow of liquids, gases or materials passes through. This exposed opening creates a safety hazard, as workers could accidentally insert hands, fingers or tools into the opening and contact hazardous substances. Flange guards cover the opening to prevent this type of incident.
Flange guards are typically made of durable plastic or metal. They may be a solid piece or incorporate mesh or small windows so the flow inside the pipe can still be observed. Locks, clasps or bolts are used to securely fasten the guard in place over the flange opening.
Why Are Flange Guards So Important?
Flange guards serve the crucial purpose of protecting both workers and equipment from harm:
- Worker safety: Flange openings provide easy access to substances that may be toxic, extremely hot/cold, or under dangerous pressure. Contact could result in serious injuries or even death. Flange guards create a barrier preventing direct contact.
- Prevent foreign object debris: Tools, rags, or other items accidentally dropped into flange openings could make their way into the piping system and cause flow disruptions, damage to equipment, or dangerous pressure buildups. Flange guards prevent debris from falling in.
- Contain leaks/spills: Flange connections are common leak points. Flange guards help contain any leaks at the flange site, preventing spills and slippery floors.
- Avoid contamination: For flanges in sterile or sensitive processing systems, guards prevent airborne contaminants from entering the piping through open flanges.
- Compliance with regulations: Organizations such as OSHA require the use of flange guards as an essential safety measure for worker protection around industrial piping. Flange guards help facilities comply with safety rules and avoid costly fines.
Best Practices for Flange Guards
To maximize the benefits of flange guards, facilities should follow these best practices:
- Conduct hazard assessments: Determine which flanges truly require guarding vs. those with minimal risks. This ensures guards are focused where most needed.
- Create a management system: Have standard procedures for installing, inspecting, maintaining and replacing flange guards across the facility.
- Select proper guard types: Choose guards made of compatible materials for the application that provide sufficient flange coverage and flow observation if needed.
- Install guards correctly: Guards must fully cover the flange opening and be securely attached to withstand vibration, pressure and accidental bumps.
- Inspect and replace: Flange guards should be checked periodically for damage and replaced immediately if compromised.
- Train workers: Educate staff on proper flange guard procedures. Workers should never remove guards without authorization.
- Enforce discipline: Consistently enforce the use of flange guards and discipline those who violate safety procedures. Guards do no good if not utilized.
Though they don’t get much fanfare, humble flange guards are heroes that save lives and protect assets every day across industrial facilities. Following best practices keeps these protectors in peak operating condition. By making flange guards a priority, companies demonstrate their true commitment to safety.