VGB-Standard

Guidelines for quality

assurance during the
assembly of flange
connections

VGB-S-052-00-2020-06-DE
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 VGB-Standard
Guidelines for quality
assurance during the
assembly of flange
connections
VGB-S-052-00-2020-06-DE

Publisher:
VGB PowerTech e.V.

Publisher:
VGB PowerTech Service GmbH
Verlag technisch-wissenschaftlicher Schriften
Deilbachtal 173, 45257 Essen, Germany

Phone: +49 201 8128-200

Fax: +49 201 8128-302
E-mail: mark@vgb.org

ISBN 978-3-96284-159-1 (Print, German)

ISBN 978-3-96284-160-7 (eBook, German)
ISBN 978-3-96284-161-4 (Print, English) ISBN
978-3-96284-162-1 (eBook, English)

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VGB PowerTech.
www.vgb.org

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Copyright notice
VGB-Standards, hereinafter referred to as the "Work", and all articles and illustrations
contained in the Work are protected by copyright. It is the sole responsibility of VGB
PowerTech to exercise the rights of use.
The term "work" includes this publication in both printed and digital form. Copyright
protection covers this work as a whole as well as parts or excerpts.
Any use outside the limits of copyright law is not permitted without the written consent
of VGB PowerTech. This applies to any form of reproduction, translation, digitization
or modification.

Disclaimer
VGB-Standards are recommendations whose application is optional. They take into
account the known state of the art at the time of issue. However, they do not claim to
be complete or correct.
Use is at your own risk and responsibility. VGB PowerTech e.V. excludes any liability
in this respect.

The German-language version of this VGB standard is the authoritative reference

edition for translations.

Note on the treatment of proposed amendments

Suggestions for changes can be sent to the e-mail address vgb.standard@vgb.org.
The subject line should contain the short name of the document in question so that
the content can be clearly assigned.

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 VGB-S-052-00-2020-06-DE

Foreword
Within the scope of the industrial safety regulations, TRBS 2141 [1] lists the
influencing factors relevant to the safety of detachable connections for pressurized
work equipment. For example, the following safety objectives are listed:
- Closures and detachable connections are assembled and installed in such a
way that they are technically tight and remain technically tight when used as
intended.
- Only suitable seals are used. Auxiliaries such as sealing pastes and release
agents are only used in justified individual cases.
- The connections are installed with low stress. Screw connections / screw
plugs are tightened evenly to the extent required or specified for sealing.
Torque-limiting tools are preferably used for this purpose.
- During installation, care is taken to ensure that flanges, gaskets, screws and
nuts can withstand the expected mechanical, thermal and chemical stresses
and comply with the technical specifications.
While various regulations have existed for some time for the design of detachable
connections, in particular flanges, more recent regulations now also formulate
requirements for quality assurance during assembly and for the personnel carrying
out the work.
In Germany, various national regulations are already in force (TA Luft [2], DVGW
Information Gas 19 [3]), according to which the qualification of personnel and quality
assurance are required for the installation of flange connections.
In chemical apparatus and pipeline construction, VDI 2290 [4] has already
established itself as an implementation aid for the requirements of TA Luft. Flange
assembly is also addressed in this context.
The standard DIN EN 1591-4 [5] - formerly issued as Technical Specification CEN/TS
- is a set of rules that is aimed in particular at the qualification of personnel for flange
installation.
This guideline therefore addresses the question of what requirements are to be
placed on quality assurance during the assembly of flange connections and on the
qualification of assembly personnel in the environment of thermal power plants in the
context of the regulations outlined above.

Essen, June 2020 VGB

PowerTech e.V.

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 VGB-S-052-00-2020-06-DE

Authors
We would like to take this opportunity to thank the following authors for their cooperation.
Christoph Bolte, STEAG
Tino Fischbeck, RWE Technology International
Jens Hälbig, RWE Power AG
Peter Heitmann, RWE Power AG
Clemens Koalick, Vattenfall AG
Martin Miksch, Mainova AG
Renato Rachel, LEAG
Christian Stolzenberger, VGB PowerTech e.V.

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 VGB-S-052-00-2020-06-DE

Contents

1 References ............................................................................................................7

2 Scope of application ...........................................................................................8

3 Objective................................................................................................................8

4 Requirements for professional flange installation .....................................8

5 System for defining requirements for ..................... Quality assurance

of flange assembly ..............................................................................................9
5.1 Classification...........................................................................................................9
5.2 Labeling of the assembly classes .....................................................................11

6 Additional requirements for flange mounting ...........................................11

6.1 Preventive fire protection....................................................................................11
6.2 Explosion protection ............................................................................................11
6.3 Corrosion protection ............................................................................................12

7 Documentation of the flange assembly.......................................................12

8 Quality assurance during flange assembly................................................12

9 Qualification of personnel ..............................................................................13

Appendix 1 - Quality assurance measures ...................................................................15

Appendix 2 - Installation protocol....................................................................................16

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1 References
[1] TRBS 2141, Hazards due to steam and pressure, edition 03/2019
[2] TA Luft, Technical Instructions on Air Quality Control, in particular draft bill
as of July 16, 2018, otherwise current valid version published by the BMU
[3] DVGW Information Gas No. 19, Flange connections in gas systems,
Issue 04/2016
[4] VDI 2290, emission reduction, characteristic values for tight flange connections,
Issue 06/2012
[5] DIN EN 1591-4, Flanges and their joints, Part 4: Qualification of personnel for
the assembly of bolted joints in pressurized systems in critical service,
Edition 12/2013
[7] AD 2000 data sheet B8, flanges, edition 11/2015
[8] DIN EN 1591-1, Flanges and their joints - Rules for the design of flanged
joints with circular flanges and gaskets
Part 1: Calculation; Issue 04/2014
[9] VDI 2230, Systematic calculation of highly stressed bolted
connections, edition 11/2015
[10] VGB-M 117, Asbestos-free static and quasi-static seals,
Issue 11/2000
[11] VGB-R 507, Piping Systems in Thermal Power Plants
second edition 10/2010
[12] VGB-S-503-00-2017-06-EN, VGB-Standard for the internal piping of turbine
systems, Edition 06/2017
[13] DVGW Information Gas No. 10, Natural gas systems on factory premises
and in the area of operational gas use; information on the applicable
DVGW regulations, edition 08/2015
[14] Regulation (EC) No. 1272/2008 on classification, labeling and packaging
of substances and mixtures (CLP), as amended from time to time

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 VGB-S-052-00-2020-06-DE

2 Area of application
This guideline applies to quality assurance during the assembly of flange connections
and to the qualification of assembly personnel in accordance with DIN EN 1591-4 [5].
It is to be used for flange connections in pressurized systems such as
z. e.g. pipelines, tanks, pumps and fittings as well as comparable process
engineering components in thermal power plants.

3 Objective
The aim of this VGB Guideline is to present the necessary requirements with regard
to quality assurance during installation and the requirements for the qualification of
installation personnel, especially for applications in the field of thermal power plants,
depending on the hazards to be assumed for flange leakage.
As part of his risk assessment for the implementation of the above requirements from
TRBS 2141, the employer determines the system for defining the requirements for
the flange connections. In doing so, the employer can refer to this VGB guideline.
The employer can transfer the responsibility for defining the respective requirements
and for implementing these requirements to a specialist company, provided that this
company works in accordance with the provisions of this VGB Guideline.
If a manufacturer places a scope of delivery on the market as pressure equipment or
an assembly in accordance with the Pressure Equipment Directive (PED
2014/68/EU), the subsequent employer (operator) should contractually oblige the
manufacturer to also work in accordance with these VGB guidelines.

4 Requirements for professional flange installation

This VGB guideline assumes that the following minimum information is available f o r
professional flange installation:
• Technical data of the flange connection (e.g. nominal
diameter, nominal pressure, material),
• Seal (e.g. type, material, dimensions),
• Fasteners (e.g. screws, washers, nuts),
• Information on the fasteners (e.g. materials, dimensions, screw class,
lubricants),
• Tightening torques,
• Tightening process,
• Observe additional requirements, see section 6.

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In the case of maintenance measures in existing systems, the relevant information

must be specified by the employer in the work order or determined and documented
by the specialist company.
The flange connection is designed in accordance with DIN EN 1591-1 [8] or AD 2000
B8 [7], for example, including the determination of the bolt tightening torques, e.g. in
accordance with VDI 2230 [9]. The characteristic gasket values from the gasket
manufacturer, from VGB-M 117 [10] or - as part of the preliminary planning - from
generally accessible databases such as www.gasketdata.org should be used as a
basis.
Work instructions must be drawn up and observed for flange installation.
Trained and qualified personnel in accordance with section 9 are required for
professional flange installation.

5 System for defining requirements for the quality

assurance of flange assembly

5.1 Classification
The requirements for the flange connections are defined according to the assignment
to assembly classes.
The assembly classes correspond to the hazards to be assumed in the event of a
leakage.

Assembly class 3:
Flange connections that release medium with hazardous properties in the event of a
leak and that are installed in system parts that must be tested by the ZÜS before
commissioning in accordance with BetrSichV.
According to Regulation (EC) No. 1272/2008 [14], hazardous properties are those
which result in the following hazard labeling:
1 explosive substances/mixtures with the hazard
statements H200, H201, H202, H203, H204 or H205,
2 flammable gases with the hazard statements H220 or H221,
3 flammable liquids with the hazard statements H224,
H225 or H226,
4 pyrophoric liquids with the hazard statement H250,
5 Acutely toxic with hazard statements H300, H310 or H330,
6 oxidizing liquids with the hazard statements H271 or H272,
7 oxidizing gases with the hazard statement H270,
8 corrosive with the hazard statement H314.
Fluids with hazardous properties also include ammonia in aqueous solution with a
concentration of more than 10 %.
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For orientation purposes, the following limits can be used to determine whether a
ZÜS inspection is mandatory (see Annex 2, Section 4, Number 6, BetrSichV):
• Pipes > DN25
• Tank > 200 bar * l
Flange connections in system components and pipelines up to and including the gas
pressure regulating and measuring system (GDRM system), which are subject to
DVGW regulations [13], must also be included in installation class 3.

Assembly class 2:
Flange connections that may be tested by a qualified person in deviation from
assembly class 3.
Flange connections in pipelines of system group 1 (p > 40 bar or in the creep range)
in accordance with VGB-R 507 also belong to installation class 2
[11] are installed. This also includes flange connections in heating oil supply systems
or other supply systems with liquid fuels.
This also includes the flange connections of the steam-carrying systems (p > 40 bar
or in the creep range) of the internal piping of turbine systems in accordance with
VGB-S-503 [12], including the generator sealing oil system.

Assembly class 1:
Flange connections that are installed in system components and pipelines of system
group 2 (p ≤ 40 bar) in accordance with VGB-R 507 that are exposed to steam or
superheated water.
Flange connections that are installed in system components and pipelines of system
group 5 (environmentally relevant systems) in accordance with VGB-R 507, unless
these are already assigned to assembly classes 3 or 2 due to the hazard
characteristics.

Mounting class 0:
All other flange connections that are not covered by the aforementioned assembly
classes and/or are installed in system components and pipelines of system groups 3
and 4 in accordance with VGB-R 507.

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 VGB-S-052-00-2020-06-DE

5.2 Labeling of the assembly classes

The respective assembly class for flange connections of assembly classes 1 to 3
should be determined in existing systems as part of maintenance measures either
- on the work order,
- in the relevant P&I schemes or
- must be specified in the relevant isometric drawings
and component drawings.
In the case of new systems or partial systems that are made available on the market
by a manufacturer, the assembly classes must be specified in consultation with the
client.

6 Additional requirements for flange installation

6.1 Preventive fire protection

For flange connections in system components and their pipelines that carry
flammable liquids - even if the flash point of the liquid is above 55 °C - flanges with
projections and recesses or shields as splash protection, e.g. of the type Safe Ring® ,
must be used.
The requirements for installing a shield must be included in the documentation of the
requirements in accordance with section 4.

6.2 Explosion protection

For flange connections in system parts and pipelines in which the formation of an
explosive atmosphere cannot be ruled out, either earthing straps or toothed washers
or serrated lock washers must be installed on at least one bolted connection for
potential equalization.
In addition, when installing these system components and pipelines outdoors, where
a lightning current passage cannot be ruled out, the connections and joints at flange
connections must be designed in such a way that no sparks occur. Suitable
connections are welded lugs or bolts or threaded holes in the flanges to
accommodate screws. Connections using clamps are only permissible if ignition
safety for lightning currents has been verified by tests.
The requirement to install the explosion protection device must be included in the
documentation of the requirements in accordance with section 4.

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6.3 Corrosion protection

To prevent bimetallic corrosion, the flange connection must be designed in such a
way that an electrically conductive connection or direct contact between the metals is
prevented by using insulators in the case of metal pairs with different electrochemical
potentials (e.g. in the case of black/white connections). All screw connections must
be insulated and the flange surfaces must be separated by an insulating sealing
surface.
The corrosion protection requirements must be included in the documentation of the
requirements in accordance with section 4. It must be ensured that the requirements
for corrosion protection do not conflict with the requirements for explosion protection
in accordance with section 6.2.

7 Documentation of the flange assembly

For flange connections of assembly classes 1 to 3, assembly records must be
completed in accordance with Appendix 1. Appendix 2, for example, can be used for
documentation.
For flange connections of assembly class 0, it is sufficient to check the assembly
personnel on the basis of inspections.

8 Quality assurance for flange assembly

Depending on the assembly class, the quality assurance measures are shown in Appendix 1.
The minimum scope for sampling and cross-checking includes the following points:
• Check that the assembly protocol is in order,
• Visual inspection of the assembled flange connection,
• Check the screw tightening torque or screw elongation,
• Check for the presence of equipotential bonding and/or splash protection, if
required.
Sampling and cross-checking must be carried out before the medium is applied.

This refers to
Random samplea random sample inspection by a second fitter, equally distributed
over all participating fitters;
Cross-check a counter-check to be carried out separately from the random check by
an independent qualified person who records each fitter involved.

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The independent person must have the necessary specialist knowledge to test flange
connections based on their professional training, professional experience and recent
professional activity. They must have the necessary reliability, have suitable testing
equipment and must not be subject to any instructions with regard to the test results.
They may be employees of the employer as well as of the specialist company or
another service provider.
If deviations from the specified requirements are detected in one of the random
samples listed above, the scope of the random sample should be extended to two
additional flange connections per rejected flange. For the flange connection at which
deviations have been detected, further measures must be defined, including re-
installation of the flange.
If the additional flange connections are tested without any findings, you can return to
the originally defined scope of testing.
However, if deviations are found in the additional flange connections, additional
flange connections must be tested. If deviations are found again, the scope of testing
must be extended again to include additional flange connections.
If flange connections with impermissible deviations are still detected within the
extended scope of testing, the scope of testing must be extended until all flange
connections (100% scope of testing) have been tested.

9 Qualification of the staff

Own staff
The flange connections may only be installed by qualified personnel. The employer
operating the system is responsible for instructing their own personnel.
In the case of relevant vocational training (industrial mechanic or comparable), it can
be a s s u m e d t h a t sufficient specialist knowledge is available. For flange
connections of assembly class 3, initial qualification in accordance with DIN EN 1591-
4 (G and V) is also required.
Organizational measures must be taken to ensure that all assembly classes retain
their specialist knowledge.
In the case of non-trade vocational training, instruction should be tailored to the
flange connections in question. This may be necessary, for example, for personnel
from the electrical and I&C departments for the assembly of measuring flanges. The
instruction should be based on the principles of the qualification steps for external
personnel in accordance with Appendix 1.

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 VGB-S-052-00-2020-06-DE

External personnel
If a specialist company is commissioned with the flange installation, it is responsible
for the qualification of the personnel. The specialist company should name the
personnel carrying out the work to the employer operating the system.
Proof of qualification should be provided in accordance with DIN EN 1591-4 [5] at the
levels shown in Appendix 1.

This refers to
Basic qualification level (G) in accordance with DIN EN 1591-4 Qualification level for safety
The ability to assemble flange connections using
manually operated torque wrenches;
Process-specific (V) according to DIN EN 1591-4 higher qualification level to
qualification level: Ensuring the ability to assemble
Flange connections using hydraulic clamping and
tightening tools as well as special flanges for
apparatus engineering.
The required qualification level must be obtained from a certified training provider.

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VGB-S-052-00-2020-06-DE

Appendix 1 - Measures for quality assurance

Qualification level
according to DIN Quality assurance
Assembl Pressurized systems
y class EN 1591-4
Assembly Sample size Cross-check
Own staff External personnel protocol 5 Scope
Systems with hazardous fluids
and ZÜS1 - subject to
3 inspection G3 + V 3 G3 + V 3 compelling 20 % 10 %
Natural gas installations
within the scope of the
DVGW regulations
Systems with hazardous fluids
and bP - subject to inspection2
System group 1 according to
VGB-R 507 (steam p > 40 bar
or in the creep range) -4 Mandatory
2 G3 + V 3 20 % 0%
from DN
Turbine-internal piping 100
according to VGB-S-503 (oil or
steam p > 40 bar or in the
creep range)

Systems with steam or

1 -4
G3 after after 0%
superheated water
determinatio determination
(p ≤ 40 bar)
n
-4
0 all other systems G3 - 0% 0%
1 Approved inspection body, for inspection limits see Annex 2 Section 4 BetrSichV
2 Person authorized to inspect, for inspection limits see Annex 2 Section 4 BetrSichV
3 see section 9
4 No special proof of qualification required for relevant vocational training
5 Make sure that the flange connection is clearly labeled

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 VGB-S-052-00-2020-06-DE

Appendix 2 - Assembly protocol

Logo Protocol for the assembly of a

flange connection
-Address-
1 Technical description of the system section:
Designation of system part: Location:
KKS/AKZ no.: Order number:
Reference to: Assembly class:
P&I diagram no.: 1 2 3
Isometric no.: Part of a sample Part of
Parts list no: the cross-check
2 Assembly protocol
Flange connection: Stock New
Flanges (type/material as specified):
Flange sealing surfaces (condition):
Flange alignment (gap/offset):
Clamped components (condition/position):
Screws/nuts
(type/material according to specification):
Screws/nuts (condition):
Gasket/s (type):
Gasket/s (condition):
Washers (completeness):
Expansion sleeves (condition):
Minimum thread protrusion:
Potential equalization (presence/type):
Insulating flange connection (completeness):
Splash guard available (e.g. Safe Ring®):
Tightening process:
Applied torque / elongation:
Special features:

Fitter: Installation company:

Date/ Signature:

3 Sample 4 Cross-check
Sample Cross-check
Visual inspections - requirements fulfilled: Yes no Visual inspections - requirements fulfilled: Yes no
Preload check - requirements fulfilled: Yes no Preload check - requirements fulfilled: Yes no

Remarks: Remarks:

2nd fitter/company: Auditor/company:

Date/Signature: Date/Signature:

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