Flange Management & Hydraulic torque/tensioning

This flange management course has 2 modules

Module 1: PMASUP245 Break and make flanged joints using hand tools (Nationally Recognised Training)
Module 2: Hydraulic torque/tensioning (Non-Accredited training)

Module 1:

This training material is based on the PMASUP245 Break and make flanged joints using hand tools it is a nationally recognised training unit that trains operators how to safely dismantle and assemble flanged pipe joints

This course provides workers with foundational knowledge of bolted flange joints—covering component mechanics, pressure performance, and rigorous maintenance guidelines—to keep operations safe and secure.

To ensure full compliance, this flange management training aligns directly with PMASUP245 (Break and make flanged joints using hand tools), the ASME PCC-1 framework, statutory WHS regulations, and site-specific procedures."

 

COURSE TOPICS

• The types of flanges used in industrial pipework and pressure systems, how to identify signs of damage or degradation, and the criteria that determine when a flange must be taken out of service
• The different types of gaskets — including non-metallic, semi-metallic and metallic — their correct application for different service conditions, and how to identify a gasket that is no longer fit for purpose
• The types of fasteners used in bolted flange joints, including bolt grades, thread terminology and torque requirements, and the inspection and discard criteria that apply to studs, bolts and nuts
• The tools and equipment used in flange assembly and disassembly, including hand tools and torque equipment — how to use them correctly, how to inspect them for faults, and when they should be removed from service
• How to safely assemble and disassemble a bolted flange joint, including correct bolt tightening sequences, alignment checks, and the steps required to ensure a leak-free joint under pressure
• How to inspect a flanged joint for leakage, misalignment, corrosion and damage — and how to interpret inspection findings to determine whether a joint is safe to return to service
• The testing methods used to verify joint integrity after assembly, including what a successful test looks like and what actions are required if a test fails

 

Module 2:

Hydraulic torque and tensioning equipment

Non-accredited training course focused on the safe theory and practical application of hydraulic torque and tensioning equipment for joint integrity

 Standards Alignment:

 Aligns with industry guidelines such as ASME PCC-1 (for pressure boundary bolted flange joint assembly)

 

COURSE TOPICS

• Hydraulic Torquing: Application of controlled rotational force using hydraulic torque wrenches and pumps.
• Hydraulic Tensioning: Direct axial load application using hydraulic bolt tensioners for critical high-pressure joints.
• Safety & Operations: High-pressure hydraulic safety, tooling setup, dismantling, and sequential tightening patterns

 

PREREQUISITES & ASSESSMENT REQUIREMENTS

To enrol in this course participants must:

• Be a minimum of 16 years of age

• Have a (USI)-Unique Student Identifier, please visit https://www.usi.gov.au/ if you do not have one

• Provide a copy of their photo identification (driver's licence, proof of age card, or passport)

• Demonstrate the ability to speak and write English to a basic level & have basic numeracy skills

• Be able to speak English well enough to carry out work safely with other people, please inform us upon registration if you feel you have any literacy or numeracy difficulties. Some reasonable adjustments to the course can be made to assist.

 

COURSE DURATION

• 2 Days
• 8 Hours per day

 

PARTICIPANTS WILL NEED TO BRING

• Photo identification as listed in the prerequisites for this course

• Please bring your own lunch however water, tea, coffee & biscuits are provided. You will be able to leave the facility during your lunch break if you wish

• PPE including protective footwear and high visibility shirt or vest will be required to be worn for the practical training session, we have hard hats, high visibility vests, gloves & whistles available for use if required.

 

ASSESSMENT PROCESS

• The course will be a combination of theory & practical training where participants will be required to demonstrate industry skills & knowledge described in the units of competency included in this course.

• Students will be required to pass a written assessment to complete the course all critical components must be demonstrated and answered correctly

 

COURSE OUTCOME

Upon completion, participants deemed competent will be issued with a Statement of Attainment:

• Wallet size competency card

• Break and make flanged joints using hand tools  - PMASUP245

• The certificate is nationally recognised within the Australian Qualifications Framework and issued under the authority of the National Vocational Education and Regulator Act 2011.

&

A Certificate of Attendance

• Aligns with ASME PCC-1 technical specifications and safety standards for hydraulic controlled bolt tightening.

 

MAXIMUM PARTICIPANTS

10 people

 

UNIT OF COMPETENCY

• Break and make flanged joints using hand tools  - PMASUP245

 

PRICE

$813.60

• For your registration into a course to be approved, all course fees are required to be paid in full at the time you make your booking.

 

PAYMENT OPTIONS

• CREDIT CARD - over the phone or the ONLINE CREDIT CARD payment option through our website (preferred) 1.75% surcharge will apply 

• EFTPOS

• INVOICE (an approved 7-day credit application must be in place, available to corporate customers only)

• Individuals registering for a course must use the credit card payment option

 

REFUND POLICY

• Please refer to our refund policy in the terms and conditions on our website,
• https://www.iwpt.com.au/w/termsandconditions/

 

RECOGNITION OF PRIOR LEARNING (RPL)

• Participants should speak with the IWP administration team at the time of enrolment to further discuss this option

 

IWP CONTACT DETAILS & RTO INFO

• Address: 37 Kemblawarra Road Warrawong NSW 2502
• Phone: 02 42743864
• Email: admin@iwpt.com.au
• Website: https://www.iwpt.com.au
• RTO Code 91671
• ABN 18133156993