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Discover how proper categorization and assembly standards enhance the sealing of flange joints. Comprehensive solutions for critical connections as well as common applications.
Experience from industrial operations shows that the reliability and sealing of flange joints can only be increased in the long term through a systematic approach and clearly defined assembly standards.
One of the most effective procedures is to categorize flange joints by their criticality and subsequently set appropriate assembly procedures, material requirements, tools, assembly workers, and leakage control.
The criteria for categorizing flange joints are always individual for each company. When defining them, factors such as the following are most often considered: - whether a potential leak could jeopardize worker safety, - whether it could cause production downtime, - whether leaks have recurred in the past for the given joint.
In practice, criteria are often established based on a combination of operating temperature and pressure, or according to the importance of the equipment in the technological process.
Long-term practice has shown that the division of flange joints into three categories is the most effective, allowing for the establishment of suitable standards for their assembly and maintenance.
Category I typically includes flange joints of technologically important equipment, such as: - heat exchangers, - reactors, - columns, - boilers, - other key apparatus.
A leak in these joints can jeopardize operational safety or cause significant economic losses.
Long-term practice shows that recurring leaks in critical flange joints can be reliably eliminated by implementing a so-called comprehensive solution.
A comprehensive solution includes all important factors that affect the sealing of a flange joint:
The advantage of this approach is that one supplier controls the entire assembly process of the flange joint and bears responsibility for its final sealing.
Categories II and III typically include less critical flange joints, often standardized DN / PN joints, which are assembled during regular service and maintenance work.
Although their leakage usually does not jeopardize operational safety, it can cause:
Therefore, it is advisable to set assembly standards for these joints as well and establish correct tightening torques.
For flange joints in categories II and III, we offer a small comprehensive solution that helps establish a correct and long-term repeatable assembly procedure.
This solution includes, for example:
The result is a standardized assembly procedure for the flange joint that can be easily repeated in future assemblies and often extends the joint's lifespan and reduces the risk of leaks.
A systematic approach to the assembly and maintenance of flange joints is increasingly being applied in many industrial sectors, such as:
For more than 30 years, we have been helping our customers increase the reliability and sealing of flange joints through proper sealing design, tightening parameter calculations, and the implementation of assembly standards.
We most often collaborate on comprehensive solutions for critical flange joints in category I, but we also assist customers with tightening torque calculations and setting assembly procedures for joints in categories II and III.
Our experience is available to you in establishing criteria that lead to the categorization of flange joints and in setting standards for their assembly. In section Most often we deal with, we demonstrate through examples that a reliable solution for the sealing of flange joints is a matter of interrelated factors.
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Homogeneous, easy spreading assembly paste suitable for lubricating any type of threads. It is suitable for any combination of thread materials for bolt and nut connections.
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