Hydraulic flange separators and mechanical flange separators are one of the most important tools used in flange separation projects. Then, how to choose the appropriate separator according to project requirements becomes very important. In this article, TorcStark will introduce the characteristics of each flange separator in detail, hoping to help you understand them better.

What is a flange separator?

A flange separator is an industrial device used to separate flange connections in piping systems. The design of the flange separator allows the operator to easily separate flange connections without affecting other parts of the piping system, which is very practical for industrial applications that require frequent maintenance or replacement of components in the piping system.

There are two main types of flange separators: mechanical and hydraulic, each with its own unique characteristics.

Features of mechanical flange separator:

  1. The weight of a single machine is only 3kg, and the total length is only 185mm;
  2. The maximum separation force reaches 16 tons;
  3. Each step of separation reaches 20mm; the maximum separation reaches 60mm;
  4. The minimum separation gap is only 6mm; and it can be operated at all angles;
  5. Mechanical automatic retraction design;
  6. The large step distance is 15mm, which provides the first-stage large-area separation force;
  7. During operation, the separation piece is close to the flange surface. The unique design ensures that it will not expand excessively and is manually returned when closed.
  8. Each set of separators contains two working heads that separate flanges in symmetrical positions;
  9. The table is equipped with flat pads and can be used as an extra thin jack;
  10. Overall separation concept: friction-free, parallel smooth motion, eliminating the risk of flange damage and separation wedge damage;
  11. The unique interlocking wedge design has no bending or slipping risk in the first stage;
  12. The design of the step arm allows each step to bear full load;
  13. Fewer moving parts, durable and easy to maintain.
  14. Comes with a lightweight tool box for easy storage and portability.

Application fields of mechanical synchronous flange separator:

Suitable for repair, overhaul, testing and valve replacement applications. It is widely used in oil fields, fertilizer plants, chemical plants, steel plants, refineries, thermal power plants, pharmaceutical plants, long-distance pipelines, petrochemical plants, nuclear power plants, hydropower plants, natural gas plants, and other industries.

Features of hydraulic synchronous flange separator:

  1. The maximum separation force reaches 2×14 tons;
  2. The weight of a single machine is only 6.5kg, and the total length is only 286mm;
  3. The flange surface clearance is only 6mm and can be operated at all angles;
  4. The separation amount at each stage is up to 25mm, and the maximum separation amount is up to 65mm;
  5. The unique internal locking mechanism ensures that the separation piece is close to the flange when opening, and the separation piece will not expand excessively when opening; the hydraulic pressure returns quickly when closing;
  6. Each set of separators contains two working heads that separate flanges in symmetrical positions;
  7. The table is equipped with flat pads and can be used as an extra thin jack;
  8. The self-locking and large-step design of the first stage makes the flange separation work safe and simple.
  9. Friction-free, parallel smooth operation eliminates the risk of flange damage and separation wedge damage;
  10. Flange separators are generally operated in pairs and work more efficiently;
  11. The arc steps with a radius of 150mm can effectively get close to the flange, allowing each step to bear greater load;
  12. Forged alloy steel separation steps for longer life;
  13. The integrated design eliminates the need to connect a manual hydraulic pump for oil supply, making it more convenient to use.
  14. Comes with a lightweight toolbox for easy storage.
  15. Fewer parts, durable and easy to maintain;
  16. Lightweight reinforced plastic steel handle design, easy to carry;

Application fields of hydraulic synchronous flange separator:

Suitable for pipeline commissioning, maintenance, overhaul, testing and valve replacement applications;
It is widely used in petrochemicals, metallurgy, electric power, paper mills, and other industries for the maintenance and repair of liquid and gas transportation pipelines. It is the most ideal and safe special hydraulic tool.

Disadvantages of flange separators

1. Higher cost
The flange separator is a relatively complex equipment that requires high manufacturing costs and will increase production costs.

2. Difficulty in maintenance
The flange separator has many internal parts, making cleaning and maintenance difficult. If it is not maintained in time, it will affect the separation efficiency and equipment life.

3. High requirements for the working environment
The flange separator needs to be installed in a place with a good working environment, otherwise the separation effect and equipment life will be affected.

In the end

Based on the above characteristics of hydraulic flange separators and mechanical flange separators, it can be concluded that no matter which flange separator you choose, the work can be completed quickly. They are just different sources of power.

Relatively speaking, hydraulic flange separators are more expensive and more labor-saving. Mechanical flange separators are safer and more convenient to carry.

However, in terms of application areas, both flange separators are basically the same and are suitable for repair, overhaul, testing and valve replacement applications. Therefore, you can choose the appropriate flange separator according to your budget, safety, and other needs.