Flange Connections Under Scrutiny: Strong Results in Turnarounds, Gaps in Smaller Projects
How safe are flange connections in German industrial plants?
IDT addressed this question last year through a systematic analysis conducted during audits and turnarounds (TAR). More than 10,000 flange and pipe connections were inspected across over 30 industrial facilities.
The findings point to a generally high level of plant safety. The overall defect rate was eight percent, meaning that only one in twelve inspected flange connections showed deficiencies. A key success factor was the early integration of structured flange management processes into project planning.
Large-scale projects with solid results #
The impact of clearly defined inspection and qualification processes was most evident in large shutdown projects within the chemical, petrochemical, and general process industries. In these projects, only 2.5 percent of flange connections were identified as non-conforming. Thorough preparation proved to be a decisive factor in ensuring quality and reliability during plant restart.
Higher risk in smaller shutdown projects #
A different picture emerged in small and medium-sized projects. Where inspection scopes were limited to up to 500 flange connections, defect rates reached as high as 20 percent. These projects often lack standardized flange management, sufficient time, or adequate awareness of the technical and economic risks associated with improper assembly.
The results make one thing clear: the decisive factor is not the industry itself, but the project framework and the maturity of flange management practices when it comes to achieving tight and reliable pipe connections.
Our data and practical observations show that even correctly designed flange connections fail if installation is inaccurate or incorrect.
Published in PROCESS #
The latest inspection results and their relevance for industrial plant safety were reviewed and contextualized by the trade magazine PROCESS. Read the full article here:
Learn more at maintenance / Pumps & Valves #
Gain deeper insights into flange management during turnarounds at maintenance / Pumps & Valves on February 25 and 26 in Dortmund.
Visit IDT at booth 521 and attend our presentation on flange tightness on the SolutionCenter stage on February 26.
Learn from real-world experience which factors are essential for achieving long-term, leak-free flange connections.