Unit of competency Outline
Date retreived
22/07/2026 1:24 AM AWST
22/07/2026 1:24 AM AWST
Whilst all efforts are made to provide accurate and timely information from the relevant source/documentation, please be aware that the information supplied may not be the most current version. The accuracy of the detail has not been confirmed by the Department and therefore should not be relied upon without first confirming the contents.
Break and make flanged joints using hand tools
Break and make flanged joints using hand tools
Unit of competency
National Code
PMASUP245A
PMASUP245A
State Code
WI693
WI693
TGA Status
Replaced
Replaced
DTWD Status
Replaced
Replaced
State Implementation and Classification
Approved Date
07/03/2014
Field of Education
030707 - Metal Fitting, Turning And MacHining
Original Release Date
07/03/2014
Nominal Hours
25
Description
This unit of competency covers the skills and knowledge needed to break and make flanged joints using hand tools. It also includes solving problems with flanged pipe jointing processes and equipment.
Notes
Elements and Performance Criteria
1 Plan and prepare for job
- 1.1 Identify work requirements
- 1.2 Inspect job site
- 1.3 Confirm isolations have been completed to standard
- 1.4 Confirm hazard controls
- 1.5 Coordinate with appropriate personnel
- 1.6 Select appropriate tools
- 1.7 Check calibration and certification of tools as required
- 1.8 Re-check that work requirements fit within skill level
- 1.9 Complete checklists and records as required
2 Break flange in accordance with flange management procedure
- 2.1 Implement hazard controls
- 2.2 Prepare tools, drip trays, and so on with appropriate care
- 2.3 Connect any required drain lines
- 2.4 Undo nuts in accordance with procedures
- 2.5 Split flange and drain pipe as required
- 2.6 Identify any skills escalation required
- 2.7 Manage open pipe
- 2.8 Complete checklists and records as required
3 Inspect flange and components
- 3.1 Inspect removed gasket
- 3.2 Assess cold pull and refer if required
- 3.3 Assess degree of misalignment and refer if required
- 3.4 Clean and inspect flange surface both front and back
- 3.5 Check studs and nuts
- 3.6 Confirm compliance of components and refer as required
- 3.7 Identify any problems and take appropriate action
4 Make flange joint in accordance with flange management procedure
- 4.1 Select appropriate gasket
- 4.2 Check all components are to specification
- 4.3 Apply lubricant as required
- 4.4 Complete initial assembly of joint
- 4.5 Insert blind as required
- 4.6 Attach drain if required
- 4.7 Re-check the gasket
- 4.8 Re-check alignment
- 4.9 Tighten using appropriate hand tools to procedure
- 4.10 Use torque calibration charts as required
- 4.11 Complete checklists and records as required
5 Finish the job
- 5.1 Make a final check of joint alignment
- 5.2 Organise required checks
- 5.3 Confirm joint integrity as required
- 5.4 Complete checklists and records as required
The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.
Context
This competency includes breaking and making flange joints using hand tools. It does not include the use of:
pneumatic torqueing tools
hydraulic torqueing tools
powered torqueing tools
Work requirements
Work requirements may include but are not limited to:
flange and gasket specifications
stud and nut specification
process line and process materials
parts and equipment required
local detectors requiring isolation
required skill level
conflicting work
Work requirements may come from briefings, handovers, and work orders and may include:
compliance documentation
product specifications
nature and scope of tasks
achievement targets
operational conditions
lighting conditions
plant or equipment defects
hazards and potential hazards
coordination requirements or issues
Job site
Inspecting job site may include but is not limited to identifying:
location
authorisations required
access and egress needs
hazards
recent work undertaken on joint
flange type (matches specification)
Control hazards
Control hazards may include but is not limited to:
selection and use of appropriate personal protective equipment
obtaining appropriate authorisations
checking required isolations
controlling other work in area
Implement hazard controls
Implementing hazard controls may include but is not limited to:
controlling access to area
using gas tester
verifying and confirming isolation
safe flange breaking procedure (line of fire)
Manage open pipe
Manage open pipe includes:
all those actions required once the flange is broken to ensure the pipe and its contents are not contaminated or damaged
Inspect components
Inspecting flange components may include but is not limited to:
checking for asbestos in gaskets
looking for signs of damage, defects or deterioration in all components
cleanliness and correct surface roughness of mating surfaces
alignment
Refer to appendices of ASME PCC-1-2010 Guidelines for Pressure Boundary Bolted Flange Joint Assembly for technical details
Components
Components may include but are not limited to:
studs
nuts
washers
gaskets
Check studs and nuts
Checking studs and nuts may include but is not limited to checking:
integrity of studs and nuts
fit of nut to stud
need for new studs and nuts
conformance to specification
Initial assembly of joint
Initial assembly of joint may include but is not limited to:
aligning joint
inserting studs
assembling nuts to studs
inserting and aligning gasket
Blinds
Blinds may include but are not limited to:
blinds
blanks
spectacle/goggle blinds
Refer
Refer means to refer the issue to the person with the required skills, knowledge and/or authority to deal with the matter
Procedures
Procedures may be written, verbal, computer-based or in some other form. They may include but are not limited to:
flange management procedures
all work instructions
standard operating procedures
temporary instructions
any similar instructions provided for the smooth running of the plant
good operating practice as may be defined by industry codes of practice
Procedures would be expected to comply with any relevant government regulations.
Checklists and records
Checklists and records may include:
paper or electronic based and verbal/radio reports
reporting items found which require action
Appropriate action
Appropriate action includes but is not limited to:
determining problems needing action
accessing and applying relevant technical and plant data
applying appropriate problem solving techniques to determine possible fault causes
rectifying problem using appropriate solution within area of responsibility
following through items initiated until final resolution has occurred
reporting problems outside area of responsibility/ability to resolve to designated person
Typical problems
Typical problems may include but are not limited to:
seal/gasket leaks
pressure loss/low flow
blockages/build-up/fouling
erosion/wear
ancillary equipment problems
studs incorrectly tensioned
worn threads
misalignments
cold pull
isolation failure
leak test failure
Remedial actions
Remedial actions may include but are not limited to:
replacing existing components with new components
carrying out minor maintenance within operator's skill level
identifying and reporting problems outside operator's competence
identifying and controlling hazards related to flange joints
Health, safety and environment (HSE)
All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence.
Context
This competency includes breaking and making flange joints using hand tools. It does not include the use of:
pneumatic torqueing tools
hydraulic torqueing tools
powered torqueing tools
Work requirements
Work requirements may include but are not limited to:
flange and gasket specifications
stud and nut specification
process line and process materials
parts and equipment required
local detectors requiring isolation
required skill level
conflicting work
Work requirements may come from briefings, handovers, and work orders and may include:
compliance documentation
product specifications
nature and scope of tasks
achievement targets
operational conditions
lighting conditions
plant or equipment defects
hazards and potential hazards
coordination requirements or issues
Job site
Inspecting job site may include but is not limited to identifying:
location
authorisations required
access and egress needs
hazards
recent work undertaken on joint
flange type (matches specification)
Control hazards
Control hazards may include but is not limited to:
selection and use of appropriate personal protective equipment
obtaining appropriate authorisations
checking required isolations
controlling other work in area
Implement hazard controls
Implementing hazard controls may include but is not limited to:
controlling access to area
using gas tester
verifying and confirming isolation
safe flange breaking procedure (line of fire)
Manage open pipe
Manage open pipe includes:
all those actions required once the flange is broken to ensure the pipe and its contents are not contaminated or damaged
Inspect components
Inspecting flange components may include but is not limited to:
checking for asbestos in gaskets
looking for signs of damage, defects or deterioration in all components
cleanliness and correct surface roughness of mating surfaces
alignment
Refer to appendices of ASME PCC-1-2010 Guidelines for Pressure Boundary Bolted Flange Joint Assembly for technical details
Components
Components may include but are not limited to:
studs
nuts
washers
gaskets
Check studs and nuts
Checking studs and nuts may include but is not limited to checking:
integrity of studs and nuts
fit of nut to stud
need for new studs and nuts
conformance to specification
Initial assembly of joint
Initial assembly of joint may include but is not limited to:
aligning joint
inserting studs
assembling nuts to studs
inserting and aligning gasket
Blinds
Blinds may include but are not limited to:
blinds
blanks
spectacle/goggle blinds
Refer
Refer means to refer the issue to the person with the required skills, knowledge and/or authority to deal with the matter
Procedures
Procedures may be written, verbal, computer-based or in some other form. They may include but are not limited to:
flange management procedures
all work instructions
standard operating procedures
temporary instructions
any similar instructions provided for the smooth running of the plant
good operating practice as may be defined by industry codes of practice
Procedures would be expected to comply with any relevant government regulations.
Checklists and records
Checklists and records may include:
paper or electronic based and verbal/radio reports
reporting items found which require action
Appropriate action
Appropriate action includes but is not limited to:
determining problems needing action
accessing and applying relevant technical and plant data
applying appropriate problem solving techniques to determine possible fault causes
rectifying problem using appropriate solution within area of responsibility
following through items initiated until final resolution has occurred
reporting problems outside area of responsibility/ability to resolve to designated person
Typical problems
Typical problems may include but are not limited to:
seal/gasket leaks
pressure loss/low flow
blockages/build-up/fouling
erosion/wear
ancillary equipment problems
studs incorrectly tensioned
worn threads
misalignments
cold pull
isolation failure
leak test failure
Remedial actions
Remedial actions may include but are not limited to:
replacing existing components with new components
carrying out minor maintenance within operator's skill level
identifying and reporting problems outside operator's competence
identifying and controlling hazards related to flange joints
Health, safety and environment (HSE)
All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence.
The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge range statement and the Assessment Guidelines for the Training Package.
Critical aspects for assessment and evidence required to demonstrate competency in this unit
Critical aspects for assessment and evidence include:
the breaking and making of a flanged joint in accordance with the organisation’s flange management procedure
recognising own skill limits and when to refer to another person.
Context of and specific resources for assessment
Assessment of this competency will occur over a range of situations which will include typical disruptions to normal, smooth operation. This will require access to a plant over a period of time, or a suitable method of gathering evidence of operating ability. Where safety, lack of opportunity or significant cost is an issue, an industry-based simulation may be employed to assist the process.
Guidance information for assessment
Assessment processes and techniques must be appropriate to the language, competency and safety requirements of the site and consistent with workplace systems or procedures.
Critical aspects for assessment and evidence required to demonstrate competency in this unit
Critical aspects for assessment and evidence include:
the breaking and making of a flanged joint in accordance with the organisation’s flange management procedure
recognising own skill limits and when to refer to another person.
Context of and specific resources for assessment
Assessment of this competency will occur over a range of situations which will include typical disruptions to normal, smooth operation. This will require access to a plant over a period of time, or a suitable method of gathering evidence of operating ability. Where safety, lack of opportunity or significant cost is an issue, an industry-based simulation may be employed to assist the process.
Guidance information for assessment
Assessment processes and techniques must be appropriate to the language, competency and safety requirements of the site and consistent with workplace systems or procedures.
Replaced By
| State Code | National Code | Title | Type |
|---|---|---|---|
| AXM45 | PMASUP245 | Break and make flanged joints using hand tools | Unit of competency |
| State Code | National Code | Title | Type |
|---|---|---|---|
| J572 | PMA30113 | Certificate III in Process Plant Operations | Qualification |
| J570 | PMA20113 | Certificate II in Process Plant Operations | Qualification |
| J571 | PMA40113 | Certificate IV in Process Plant Technology | Qualification |