Deutsch (German) English

Services

It is our aim to offer you support and to take measures together with you to ensure

  • Health
  • Safety
  • Environment

which, with increased assembly safety, environmental safety and operational safety, improve your legal security, lower your costs and boost your yield.

Flange Repair
When it comes to leakage at flange joints, we determine the causes and offer repair solutions, such as examining the components and replacing faulty ones with suitable spares if necessary. Plus, we provide support for flanges that are too soft and carry out a process of flange optimization.
Flange Optimization
We examine your flange joints to determine options for maximum bolt capacity utilization. With the use of the greatest possible tension within the bolt, the flange joints are improved in terms of their operational safety and any issues are reduced due to the optimal use of the gasket materials.
Flange Calculation
Mathematical documentation of flange joints on apparatus and pipelines according to the AD 2000-Code B7/B8, ext. ASME VIII Div. 1, App. 2, EN 1591-1 and EN 13445-3 with all commercially available calculation programs (e.g. TÜV DIMy, PV-Elite, Compress and Probad), showing the effective utilization of bolt materials (preferably 70% Rp0.2) and defining the bolt’s necessary clamping torque.
Flange Documentation According to TRBS
For DIN flanges with a smooth sealing strip and flat-face gaskets, which should be regarded as having a permanent technical seal, we provide operational safety according to the Technical Regulations for Operational Safety, TRBS 2152-2:2006-6 (avoidance of explosive atmospheres) and TRBS 2141-3:2009-09 (risk posed by steam and pressure upon release of media), and mathematical documentation for adequate safety against the yield point.
Flange Documentation for Plain Carbon Steel – High-alloy Steel Joints
According to DIN EN 13480-3, D.4.2, mixed joints must be separately documented in all cases when the calculation temperature is over 120°C and/or the materials’ coefficients of thermal expansion at 20°C deviate by more than 10%.
Materials and Regulations
Clarification of questions regarding regulations and materials for the components of flange joints, within the scope of standard regulations such as:
  • Betriebssicherheitsverordnung (BetrSichV, German Industrial Safety and Health Ordinance)
  • Druckgeräterichtlinie (DGRL, Pressure Equipment Directive [PED])
  • Wasserhaushaltsgesetz (WHG, German Water Management Act)
  • TA-Luft (Technical Instructions on Air Quality Control)
  • TRD (Technical Regulations for Boilers)
  • TRBS (Technical Regulations for Operational Safety)
  • TRGL/DVGW (Technical Regulations for High-pressure Gas Pipelines/German Technical and Scientific Association for Gas and Water)
Adaptation of available materials to the regulations and requirements of the Pressure Equipment Directive. Search and support for the licensing (e.g. individual certification by ZÜS) of improved materials, for example for higher temperatures.
Material Standardization
Proposals for the creation or amending of the materials and construction specifications of flanges, bolts and gaskets, while taking into account the individual applicable regulations.
Specifications
Optimization of customers’ own specifications for flanges, fittings, pipes, bolts and gaskets, while taking into account the following aspects:
  • Standardization of gaskets and bolts
  • Coordination of regulation requirements
  • Availability and supply
  • Standardization of the components
  • Reduction of the risk of material discrepancies thanks to stricter specifications
Update of customer-specific materials specifications according to current standards and regulations (for maintaining the ability for repair).
Individual Expert Reports
Compilation of individual expert reports in accordance with the Pressure Equipment Directive for Flange and Bolts Materials, in collaboration with the responsible ZÜS office if necessary.
Procedure Instructions for Flange Assembly
Optimization of customer-specific assembly regulations for flange joints, with procedure instructions in line with the Industrial Safety and Health Ordinance (BetrSichV).
Risk Analysis
Support for or compilation of risk analyses according to TRBS 1111 (Technical Regulations for Operational Safety) for procedures that are associated with an especially high risk for personnel, facilities and the environment (e.g. retightening of sealed joints under pressure and/or at high temperature), and which are required under the terms of the Industrial Safety and Health Ordinance.
Trainings
Employee trainings on subjects such as flange joints, gaskets, bolts and bolt assembly procedures, also in accordance with individual factory-specific requirements upon request. Trainings for assembly staff to work on flange joints, while taking into account the Industrial Safety and Health Ordinance, the accident prevention regulations and the specific factory regulations.
Assembly Support
Supervising the assembly of flange joints as well as the measurement of the flange joints following assembly, with evaluation of the assembly outcomes.
Excerpt from our List of Customers
  • ConocoPhillips Wilhelmshavener Raffinerie GmbH, Wilhelmshaven
  • GVS Gasversorgung Süddeutschland GmbH, Stuttgart
  • INEOS Chlor Vinyls Deutschland GmbH, Wilhelmshaven
  • NWO Nord West Ölleitung GmbH, Wilhelmshaven
  • PROTEGO Braunschweiger Flammenfilter GmbH, Brunswick
  • SASOL Germany GmbH, Brunsbüttel
  • SHELL Deutschland Oil GmbH, Harburg
  • STATKRAFT GmbH Kraftwerk Robert Frank, Landesbergen
  • swb AG, Bremen
  • Tesium GmbH für Symrise AG, Holzminden
  • Vattenfall Kernkraftwerk Brunsbüttel Gmbh & Co. oHG, Brunsbüttel
  • Welland & Tuxhorn AG, Bielefeld
  • Wintershall Libya Wintershall AG, Tripoli, Libyen