Determination of gaskets characteristics
Gaskets characteristic values are an important component for the calculation of flange connections. The European standard DIN EN 13555 specifies the characteristic values for the design of gaskets and sealing materials according to DIN EN 1591-1. It also specifies test methods for establishing the appropriate numerical values, either determined by testing institutes or randomly tested and validated by the manufacturer's own tests. For many of the common sealing materials, the characteristic values according to DIN EN 13555 can now be retrieved via the database of the Center of Sealing Technologies (CST) at Münster University of Applied Sciences.
System designers use characteristic values for their calculation models, which are used to provide proof of strength and tightness according to DIN EN 1591-1 for flange connections with round flanges, screws and gaskets. Manufacturers use the comparative studies for their own quality assurance and interpretation of manufacturer or material-specific distinctions and characteristics.
In-house test benches
Our in-house test benches made by Amtec are regarded as a metrological standard with worldwide distribution. The gaskets allow, among other things Compression, pressure, creep and relaxation tests as well as classical leak tests. In addition, component tests in real flange connections are also possible in order to examine seals for their high quality in the sense of TA Luft. Here, the sealing behavior, as required in the VDI Guidelines 2440/2200, determined after a previous temperature aging. With our valve test stand, we check the high quality of the seals used (stuffing box packing and housing seal) in mounted valves. Tightness is checked by determining leakage rates under specified operating conditions in accordance with the standards of TA Luft and ISO 15848-1. For this purpose, individual test procedures can be defined or standardized tests (according to ISO 15848-1, VDI 2440 or API 622) can be carried out. The detection of the frictional forces in the spindle movements and the determination of the sealing properties of the sealing elements are the focus of these investigations. Our packing module focuses on the determination of characteristic values.
The requirements for sealing joints and the limitation of emissions have steadily increased in recent years. National and European regulations such.As the Pressure Equipment Directive, PED (Pressure Equipment Directive, PED] demand because of more stringent environmental requirements such.B. the German TA Luft (technical instructions for air pollution control) or VDI guideline 2290 a much more complex depth of investigation. In principle, the entire flange connection system - flange, screw, seal - is considered, for which "a professional design" and "the use of suitable sealing characteristics" are required. The European Standard DIN EN 1591-1 specifies a method of calculation for flange connections with round flanges, screws and gaskets, which has the purpose:
- To ensure the strength of the construction and
- to provide the leak proof
For this purpose, gasket parameters are applied which are based on definitions and test methods according to DIN EN 13555. The objective of the calculation according to the algorithm of DIN EN 1591-1 is therefore on the one hand the proof of strength for all considered load cases, the knowledge of the degree of utilization, if necessary to limit the load of the individual components, as well as a seal proof, the sufficient surface pressure of the seal during operation guaranteed. The calculation determines the required installation screw force (bolting force during installation], without whose knowledge and application no reliable installation and, finally, no safe system operation can take place; this value is mandatory and independent of whether it is a standard connection or a special construction. For the calculation of flange connections and pipe classes according to DIN EN 1591-1 we offer our customers analytical procedures according to DIN EN 1591-1. Together with our technology partners calculations according to KTA 3211.2 as well as detailed finite element calculations are possible.
Development, production, planning and engineering departments
- Flange and pipe spec calculation as an order-related service (DIN EN 1591-1: 2001 + A1: 2009 + AC: 2011)
- Flange calculation program for determining torques according to DIN EN 1591-1 (only with web login)
- Program for the simulated calculation of system emissions (without web login)
Flange Assembly Training
DIN EN 558-1
Since the publication of the European standard DIN EN 1591-4, there is a uniform set of rules for the qualification of fitters who work with flange connections. Meanwhile, such evidence for assembly personnel is often required by the operator, such.For example, for the staff employed in TAR projects.
The training and evaluation are carried out by our authorized in-house trainers in cooperation with qualified partners. Our training team has many years of experience in gasket testing, calculation methods, assembly techniques and measurement methods, and has long been actively involved in root cause detection and elimination of leaks.
The flange mounting training is based on the syllabi of the European standard and meets the requirements of DIN EN 1591-4 "Basic qualification" for bolting fitters. The training concept is subdivided into modules with theoretical and practical elements, which among other things convey the following contents to the participants:
- Function of flange connections
- Tightness requirements
- Health and safety arrangements
- Theoretical principles for the dismantling of flange connections
- Theoretical basis for the preparation of proper installation
- Emission monitoring
- Practical application for proper handling of torque wrenches
- Practical application of dressing patterns
- Practical application flange mounting
- Theoretical examination
- Practice test
A successfully completed basic qualification is a prerequisite for participation in possible additional modules, such as. "Torque controlled hydraulic tightening method", "Determination of bolt force after assembly", "Special connections / Special flanges." After a positive assessment of the qualification, the participants will receive a certificate in accordance with the specifications of DIN EN 1591-4.
All bolting fitters and their supervisors who need to mount or maintain flange connections in pressurized systems in critical use.
- Organization of the training, testing and certification is completely taken over by IDT
- Training and examination documents are provided for all participants
- Training is carried out according to the standard-compliant (DIN EN 1591-4) curriculum
- Training can be booked in the training center or "on site"
- After a positive assessment of the qualification to be obtained, the training participants receive a certificate according to DIN EN 1591-4
Dates & Prices
In addition to flange mounting training to DIN EN 1591-4, we also offer customized operator training. These training courses are developed individually for each customer and can be tailored to any specialist area. The contents include, among other things, the professional and safe handling of seals, damage analyzes, information on flange mounting and quality assurance measures. Upon request, this training can be carried out with practical elements and final evaluation.