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Calculation methods for flange connections according to EN1591
Chapter 1: Static connections
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Repair Advisors a division®
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2 EN1591 Method Repair Advisors a division®
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• Fluid pressure
• Mechanical resistance of the material of flanges, bolts and gaskets
• Bolt load stress
• Possible dispersion due to the flange assembly process
• Change of gasket stress due to deformation of the components
• Influence of piping tensions
• Effect of axial forces and external bending moments
• Effects of temperature difference between bolts and the flange ring
EN 1591 Parameters
Regulation EN1591: “Flanges and their joints – Design rules for gasketed circular flange connections (07/01/2003)” is the European reference law on the specific topic.
It is divided into two sections:
• EN 1591-1: Calculation method
• EN 1591-2: Gasket parameters
Preliminary notes
EN1591 sets leakage rates and mechanical resistance criteria for flanged connections.The behavior of the complete flanges-gasket-bolt system is considered both in assembly and working conditions.The calculation is based on the elastic analysis of the load/deformation relationships among every part of the flanged junction, corrected by the possible plastic behavior of the gasket.
Regulation EN1591:circular flange connections (07/01/2003)” is the European reference law on the
Preliminary notes
EN1591 Method 3 Repair Advisors a division®
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Calculation methods for gasketed circular flange connections
Taylor – Forge Method EN1591–1 Method
CALCULATION METHODS
The admissibility of the assembly for the calculation
conditions is determined
The assembly behavior during its lifetime is analyzed. The recommended tightening
is defined according to leakage rate
The assembly is statically determined, but the reactions
evolution can’t be known
The behavior of the complete flanges-bolts-gasket system is considered, and the reactions
evolution can be known
Procedure comparison
4 EN1591 Method Repair Advisors a division®
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Taylor - Forge Method
The admissibility of the assembly is determined by the flange stress values (Pic. 1), by the bolt section (Pic. 2) and by the gasket pressure value (m;Y) (Pic. 3).The evolution of the reaction can’t be known.
The force applied by the bolting remains constant at all steps of service
The load imposed on the gasket is the required one to provide seating
P
Σ shell
Σ int. gasket
Slide 4 alto a sinistra
F
F
Slide 4 alto a destra
Resisting section Allowable stress
Slide 4 basso a destra
sR
Radial stress
Longitudinal hub stress
Tangential stress
Slide 4 basso a sinistra
P
Balance of forces
Balance of deformations
Axisymmetric model
Laws of rheology
BI
B
BII
SI
S
SII
Sa
Ba
Slide 5 alto a sinistra Slide 5 alto a destra
Z
Z
Slide 5 basso a destra
Bilanciamento delle deformazioni
tra
Axial deformations at the gasket place
Axial deformations of the bolts
Slide 5 basso a sinistra
1.0E-07
1.0E-06
1.0E-05
1.0E-04
1.0E-03
1.0E-02
1.0E-01
1000 10000 100000
Gasket Stress (psi)
Gas
ket L
eak
(mba
r l/m
s)
Qmin (L0.000001)
Qmin (L0.00001)
Qmin (L0.0001)
Qmin (L0.001)
Qmin (L0.01)
Qmin (L0.1)
QSmin (L0.000001)
QSmin (L0.01)
CEN Constants definition - Leak vs Sg Idealized GraphFor 3 Loading and unloading cycles
Sg1 Sg2 Sg3
Slide 8 basso a destra
sH
sT
Ønocciolo
Ømedio
Øesterno
The force applied by the bolting remains constant at all steps of service
The load imposed on the gasket is the required one to provide seating
P
Σ shell
Σ int. gasket
Slide 4 alto a sinistra
F
F
Slide 4 alto a destra
Resisting section Allowable stress
Slide 4 basso a destra
sR
Radial stress
Longitudinal hub stress
Tangential stress
Slide 4 basso a sinistra
P
Balance of forces
Balance of deformations
Axisymmetric model
Laws of rheology
BI
B
BII
SI
S
SII
Sa
Ba
Slide 5 alto a sinistra Slide 5 alto a destra
Z
Z
Slide 5 basso a destra
Bilanciamento delle deformazioni
tra
Axial deformations at the gasket place
Axial deformations of the bolts
Slide 5 basso a sinistra
1.0E-07
1.0E-06
1.0E-05
1.0E-04
1.0E-03
1.0E-02
1.0E-01
1000 10000 100000
Gasket Stress (psi)
Gas
ket L
eak
(mba
r l/m
s)
Qmin (L0.000001)
Qmin (L0.00001)
Qmin (L0.0001)
Qmin (L0.001)
Qmin (L0.01)
Qmin (L0.1)
QSmin (L0.000001)
QSmin (L0.01)
CEN Constants definition - Leak vs Sg Idealized GraphFor 3 Loading and unloading cycles
Sg1 Sg2 Sg3
Slide 8 basso a destra
sH
sT
Ønocciolo
Ømedio
Øesterno
The force applied by the bolting remains constant at all steps of service
The load imposed on the gasket is the required one to provide seating
P
Σ shell
Σ int. gasket
Slide 4 alto a sinistra
F
F
Slide 4 alto a destra
Resisting section Allowable stress
Slide 4 basso a destra
sR
Radial stress
Longitudinal hub stress
Tangential stress
Slide 4 basso a sinistra
P
Balance of forces
Balance of deformations
Axisymmetric model
Laws of rheology
BI
B
BII
SI
S
SII
Sa
Ba
Slide 5 alto a sinistra Slide 5 alto a destra
Z
Z
Slide 5 basso a destra
Bilanciamento delle deformazioni
tra
Axial deformations at the gasket place
Axial deformations of the bolts
Slide 5 basso a sinistra
1.0E-07
1.0E-06
1.0E-05
1.0E-04
1.0E-03
1.0E-02
1.0E-01
1000 10000 100000
Gasket Stress (psi)
Gas
ket L
eak
(mba
r l/m
s)
Qmin (L0.000001)
Qmin (L0.00001)
Qmin (L0.0001)
Qmin (L0.001)
Qmin (L0.01)
Qmin (L0.1)
QSmin (L0.000001)
QSmin (L0.01)
CEN Constants definition - Leak vs Sg Idealized GraphFor 3 Loading and unloading cycles
Sg1 Sg2 Sg3
Slide 8 basso a destra
sH
sT
Ønocciolo
Ømedio
Øesterno
sH
sRsT
Radial stress
Longitudinal hub stress
Tangential stress
Pagina 3 Fig.1
1.0E-07
1.0E-06
1.0E-05
1.0E-04
1.0E-03
1.0E-02
1.0E-01
1000 10000 100000
Gasket Stress (psi)
Gas
ket L
eak
(mba
r l/m
s)
Qmin (L0.000001)
Qmin (L0.00001)
Qmin (L0.0001)
Qmin (L0.001)
Qmin (L0.01)
Qmin (L0.1)
QSmin (L0.000001)
QSmin (L0.01)
CEN Constants definition - Leak vs Sg Idealized GraphFor 3 Loading and unloading cycles
Sg1 Sg2 Sg3
Disegno 1 Disegno 2
Pagina 4 Fig.3
Øint flangia
Øext flangia
Øint g.ne
Øext g.ne
sp. g
.ne
Pic. 1
Pic. 2
Pic. 3
EN1591 Method 5 Repair Advisors a division®
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The force applied by the bolting remains constant at all steps of service
The load imposed on the gasket is the required one to provide seating
P
Σ shell
Σ int. gasket
Slide 4 alto a sinistra
F
F
Slide 4 alto a destra
Resisting section Allowable stress
Slide 4 basso a destra
sR
Radial stress
Longitudinal hub stress
Tangential stress
Slide 4 basso a sinistra
P
Balance of forces
Balance of deformations
Axisymmetric model
Laws of rheology
BI
B
BII
SI
S
SII
Sa
Ba
Slide 5 alto a sinistra Slide 5 alto a destra
Z
Z
Slide 5 basso a destra
Bilanciamento delle deformazioni
tra
Axial deformations at the gasket place
Axial deformations of the bolts
Slide 5 basso a sinistra
1.0E-07
1.0E-06
1.0E-05
1.0E-04
1.0E-03
1.0E-02
1.0E-01
1000 10000 100000
Gasket Stress (psi)
Gas
ket L
eak
(mba
r l/m
s)
Qmin (L0.000001)
Qmin (L0.00001)
Qmin (L0.0001)
Qmin (L0.001)
Qmin (L0.01)
Qmin (L0.1)
QSmin (L0.000001)
QSmin (L0.01)
CEN Constants definition - Leak vs Sg Idealized GraphFor 3 Loading and unloading cycles
Sg1 Sg2 Sg3
Slide 8 basso a destra
sH
sT
Ønocciolo
Ømedio
Øesterno
EN1591 Method
The force applied by the bolting remains constant at all steps of service
The load imposed on the gasket is the required one to provide seating
P
Σ shell
Σ int. gasket
Slide 4 alto a sinistra
F
F
Slide 4 alto a destra
Resisting section Allowable stress
Slide 4 basso a destra
sR
Radial stress
Longitudinal hub stress
Tangential stress
Slide 4 basso a sinistra
P
Balance of forces
Balance of deformations
Axisymmetric model
Laws of rheology
BI
B
BII
SI
S
SII
Sa
Ba
Slide 5 alto a sinistra Slide 5 alto a destra
Z
Z
Slide 5 basso a destra
Bilanciamento delle deformazioni
tra
Axial deformations at the gasket place
Axial deformations of the bolts
Slide 5 basso a sinistra
1.0E-07
1.0E-06
1.0E-05
1.0E-04
1.0E-03
1.0E-02
1.0E-01
1000 10000 100000
Gasket Stress (psi)
Gas
ket L
eak
(mba
r l/m
s)
Qmin (L0.000001)
Qmin (L0.00001)
Qmin (L0.0001)
Qmin (L0.001)
Qmin (L0.01)
Qmin (L0.1)
QSmin (L0.000001)
QSmin (L0.01)
CEN Constants definition - Leak vs Sg Idealized GraphFor 3 Loading and unloading cycles
Sg1 Sg2 Sg3
Slide 8 basso a destra
sH
sT
Ønocciolo
Ømedio
Øesterno
The force applied by the bolting remains constant at all steps of service
The load imposed on the gasket is the required one to provide seating
P
Σ shell
Σ int. gasket
Slide 4 alto a sinistra
F
F
Slide 4 alto a destra
Resisting section Allowable stress
Slide 4 basso a destra
sR
Radial stress
Longitudinal hub stress
Tangential stress
Slide 4 basso a sinistra
P
Balance of forces
Balance of deformations
Axisymmetric model
Laws of rheology
BI
B
BII
SI
S
SII
Sa
Ba
Slide 5 alto a sinistra Slide 5 alto a destra
Z
Z
Slide 5 basso a destra
Bilanciamento delle deformazioni
tra
Axial deformations at the gasket place
Axial deformations of the bolts
Slide 5 basso a sinistra
1.0E-07
1.0E-06
1.0E-05
1.0E-04
1.0E-03
1.0E-02
1.0E-01
1000 10000 100000
Gasket Stress (psi)
Gas
ket L
eak
(mba
r l/m
s)
Qmin (L0.000001)
Qmin (L0.00001)
Qmin (L0.0001)
Qmin (L0.001)
Qmin (L0.01)
Qmin (L0.1)
QSmin (L0.000001)
QSmin (L0.01)
CEN Constants definition - Leak vs Sg Idealized GraphFor 3 Loading and unloading cycles
Sg1 Sg2 Sg3
Slide 8 basso a destra
sH
sT
Ønocciolo
Ømedio
Øesterno
The force applied by the bolting remains constant at all steps of service
The load imposed on the gasket is the required one to provide seating
P
Σ shell
Σ int. gasket
Slide 4 alto a sinistra
F
F
Slide 4 alto a destra
Resisting section Allowable stress
Slide 4 basso a destra
sR
Radial stress
Longitudinal hub stress
Tangential stress
Slide 4 basso a sinistra
P
Balance of forces
Balance of deformations
Axisymmetric model
Laws of rheology
BI
B
BII
SI
S
SII
Sa
Ba
Slide 5 alto a sinistra Slide 5 alto a destra
Z
Z
Slide 5 basso a destra
Bilanciamento delle deformazioni
tra
Axial deformations at the gasket place
Axial deformations of the bolts
Slide 5 basso a sinistra
1.0E-07
1.0E-06
1.0E-05
1.0E-04
1.0E-03
1.0E-02
1.0E-01
1000 10000 100000
Gasket Stress (psi)
Gas
ket L
eak
(mba
r l/m
s)
Qmin (L0.000001)
Qmin (L0.00001)
Qmin (L0.0001)
Qmin (L0.001)
Qmin (L0.01)
Qmin (L0.1)
QSmin (L0.000001)
QSmin (L0.01)
CEN Constants definition - Leak vs Sg Idealized GraphFor 3 Loading and unloading cycles
Sg1 Sg2 Sg3
Slide 8 basso a destra
sH
sT
Ønocciolo
Ømedio
Øesterno
The bolts are treated in section
Torsion phenomenon at tightening is considered
The behavior of the assembly is determined by the leak-tightness values, based on the deformation of the flange during its lifetime (Pic. 1), of bolts (Pic. 2) and the deformations of the gasket in both tightening and operative conditions (Qmin (L), Qmax, QA, EG) (Pic. 3)
Deformation balance between
Pic. 1
Pic. 2
Pic. 3
sH
sRsT
Radial stress
Longitudinal hub stress
Tangential stress
Pagina 3 Fig.1
1.0E-07
1.0E-06
1.0E-05
1.0E-04
1.0E-03
1.0E-02
1.0E-01
1000 10000 100000
Gasket Stress (psi)
Gas
ket L
eak
(mba
r l/m
s)
Qmin (L0.000001)
Qmin (L0.00001)
Qmin (L0.0001)
Qmin (L0.001)
Qmin (L0.01)
Qmin (L0.1)
QSmin (L0.000001)
QSmin (L0.01)
CEN Constants definition - Leak vs Sg Idealized GraphFor 3 Loading and unloading cycles
Sg1 Sg2 Sg3
Disegno 1 Disegno 2
Pagina 4 Fig.3
Øint flangia
Øext flangia
Øint g.ne
Øext g.ne
sp. g
.ne
sH
sRsT
Radial stress
Longitudinal hub stress
Tangential stress
Pagina 3 Fig.1
1.0E-07
1.0E-06
1.0E-05
1.0E-04
1.0E-03
1.0E-02
1.0E-01
1000 10000 100000
Gasket Stress (psi)
Gas
ket L
eak
(mba
r l/m
s)
Qmin (L0.000001)
Qmin (L0.00001)
Qmin (L0.0001)
Qmin (L0.001)
Qmin (L0.01)
Qmin (L0.1)
QSmin (L0.000001)
QSmin (L0.01)
CEN Constants definition - Leak vs Sg Idealized GraphFor 3 Loading and unloading cycles
Sg1 Sg2 Sg3
Disegno 1 Disegno 2
Pagina 4 Fig.3
Øint flangia
Øext flangia
Øint g.ne
Øext g.ne
sp. g
.ne
6 EN1591 Method Repair Advisors a division®
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Due to the large number of parameters to consider, the mathematical calculation procedure is extremely complicated and difficult.
Thanks to a 20-year experience in the field, to a constant follow-up on regulations, and to the cooperation with the major companies and agencies of the industry,
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has developed a software aimed at analyzing at once all the necessary parameters according to EN1591.
EN1591 MethodCalculation example
EN1591 Method 7 Repair Advisors a division®
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Flanged connections control check
Excerpt of a calculation reportCalculation report
Condition Source Descriptionok Flange 1 (bF = 50,16 / eF = 18,20) ok = 2,76 >= 0,2ok Flange 1 (bF = 50,16 / eF = 18,20) = 2,76 <= 5,0ok Flange 1 cos(φS) = 0,87 >= 1/(1+0,01*ds/es) = 0,66ok Flange 2 (bF = 50,16 / eF = 18,20) = 2,76 >= 0,2ok Flange 2 (bF = 50,16 / eF = 18,20) = 2,76 <= 5,0ok Flange 2 cos(φS) = 0,87 >= 1/(1+0,01*ds/es) = 0,66ok assembly condition / Bolts FB0min = 267.026,00 >= FB0req = 35.221,80ok assembly condition / Bolts FB0req = 35.221,80 <= FB0max = 433.786,00ok assembly condition / Gasket ΦG = 0,05 <= 1
wrong assembly condition / Bolts ΦB = 2,25 <= 1.0ok assembly condition / Bolts FB0nom = 359.671,00 >= FB0req / (1 - ε)ok assembly condition / Joint FG0req = 35.221,80 >= FG0min = 35.221,80ok assembly condition / Flange 1 Ψmax = 0,09 < -1 or Ψmin = -0,09 > 1ok assembly condition / Flange 2 Ψmax = 0,09 < -1 or Ψmin = -0,09 > 1ok assembly condition / Flange 1 cM = 1,15 < 0ok assembly condition / Flange 2 cM = 1,15 < 0
wrong assembly condition / Flange 1 eF = 18,20 >= eFminA1 = 23,06wrong assembly condition / Flange 2 eF = 18,20 >= eFminA1 = 23,06
ok assembly condition / Flange 1 ΦF = 0,88 <= Φmax = 1,00
Name Value Unit DescriptioncS+’’ 0,79 -- (π/4)*(sqrt(1-0.75*(0.5*δQ+δR^2))+jS*(0.5*δR-0.75*δQ))cS-’’ 0,79 -- (π/4)*(sqrt(1-0.75*(0.5*δQ+δR^2))-jS*(0.5*δR-0.75*δQ))hG0’ 12,04 -- (d3e-dGe)/2hG0’’ 12,04 -- (d3e-dGe)/2
ΘFmaxE1’ 0,01 deg (ZF/EF)*{FG*hG+FQ*(hH-hP+hQ)+FR*(hH+hR)}ΘFmaxE1’’ 0,01 deg (ZF/EF)*{FG*hG+FQ*(hH-hP+hQ)+FR*(hH+hR)}ΘFminE1’ 0,01 deg (ZF/EF)*{FG*hG+FQ*(hH-hP+hQ)+FR*(hH+hR)}ΘFminE1’’ 0,01 deg (ZF/EF)*{FG*hG+FQ*(hH-hP+hQ)+FR*(hH+hR)}
FB0req 35,22 kN (53) = FG0req+FR0Mtnom 221,21 Nm (D.1) = kB*FB0nom/nB
MtBnom 113,23 Nm (D.8) = Mt.Bnom*(1+ε)MtBmax 136,56 Nm Mt.Bnom*(1+ε)eFminA1’ 23,06 mm pB*(((EGm*bGe)/(Ef*eG))*(pB/bF)*Sqrt(1-(ΦG0A1*bGt/bGe)^2)/10)^1/3eFminA1’’ 23,06 mm pB*(((EGm*bGe)/(Ef*eG))*(pB/bF)*Sqrt(1-(ΦG0A1*bGt/bGe)^2)/10)^1/3
ΦF’ 0,88 -- |FG*hG+FQ*(hH-hP)+FR*hH|/WF =ΦF’’ 0,88 -- |FG*hG+FQ*(hH-hP)+FR*hH|/WF =jM’ 1 -- sign{FG*hG+FQ*(hH-hP)+FR*hH}jM’’ 1 -- sign{FG*hG+FQ*(hH-hP)+FR*hH}kM’ 1 -- --kM’’ 1 -- --Ψopt’ 1 -- jM*(2*(eP/eF)-1)Ψopt’’ 1 -- jM*(2*(eP/eF)-1)Ψ0’ 0 -- ((fE*dE*eD*cos(φS))/(fF*2*bF*eF))*{(0.5*δQ+δR)+tan(φS)-δQ*2*(eP/dE)}Ψ0’’ 0 -- ((fE*dE*eD*cos(φS))/(fF*2*bF*eF))*{(0.5*δQ+δR)+tan(φS)-δQ*2*(eP/dE)}
Ψmax’ 0,09 -- Ψmax=((fE*dE*eD*cos(φS))/(fF*2*bF*eF)) *{(0.5*δQ+δR)+tan(S)-φQ*2*(eP/dE)+1*1*sqrt((eD*cM*cS*(1+1*1))/(dE*cos[3](δS))Ψmax’’ 0,09 -- Ψmax=((fE*dE*eD*cos(φS))/(fF*2*bF*eF)) *{(0.5*δQ+δR)+tan(S)-φQ*2*(eP/dE)+1*1*sqrt((eD*cM*cS*(1+1*1))/(dE*cos[3](δS))Ψmin’ -0,09 -- Ψ*min=((fE*dE*eD*cos(φS))/(fF*2*bF*eF))*{(0.5*δQ+δR)+tan(φS)-Q*2*(eP/dE)-1*1*sqrt((eD*cM*cS*(1-1*-1))/(dE*cos[3](δS)))Ψmin’’ -0,09 -- Ψ*min=((fE*dE*eD*cos(φS))/(fF*2*bF*eF))*{(0.5*δQ+δR)+tan(φS)-Q*2*(eP/dE)-1*1*sqrt((eD*cM*cS*(1-1*-1))/(dE*cos[3](δS)))ΨZ’ 0,09 -- --ΨZ’’ 0,09 -- --WF’ 5959,11 Nm (π/4)*{fF*2*bF*eF^2*(1+2*Ψopt*Ψz-Ψz^2)+fE*dE*eD^2*cM*jM*kM)WF’’ 5959,11 Nm (π/4)*{fF*2*bF*eF^2*(1+2*Ψopt*Ψz-Ψz^2)+fE*dE*eD^2*cM*jM*kM)
8 EN1591 Method Repair Advisors a division®
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EN1591 Method
Resistance criteria
GASKET Limitation of the compression
BOLTS Limitation of the traction
FLANGES Limitation of the rotation
SEATiNG CRiTERiA
LEAK-TiGhTNESS CRiTERiA
BOLT STRENGTh CRiTERiA
GASKET STRENGTh CRiTERiA
FLANGE STRENGTh CRiTERiA
Lower tightening limit
Upper tightening limit
}
}
EN1591 Method 9 Repair Advisors a division®
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EN1591 Method
Tightening recommendation
Upper tightening limit
Tightening device scatter
Lower tightening limit }Bolt tightening
[ ]
10 EN1591 Method Repair Advisors a division®
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EN1591 Method EN1591
THE ASSEMBLY BEHAvIoR DuRING ITS LIFETIME IS ANALYZED. THE RECoMMENDED TIGHTENING IS DEFINED ACCoRDING To LEAkAGE RATE
EN1591-1DESIGN RuLES FoR GASkETED CIRCuLAR
FLANGE CoNNECTIoNS
EvALuATIoN oF BoLTS’ INITIAL MINIMuM LoAD CAPACITY
EvALuATIoN oF THE INTERNAL FoRCES RESuLTING FRoM THE BoLT’S INITIAL
MINIMuM LoAD vALuE AND ANY oTHER LoAD CoNDITIoN (FuNCTIoN TEST)
MECHANICAL FEATuRESFLANGE
CHEMICAL AND PHYSICAL FEATuRES
GASKET
MECHANICAL FEATuRES
BOLTS
EN1591-2GASkET PARAMETERS
ANALYSIS oF THE FLANGE CouPLING
DEFINITIoN oF A LEAkAGE RATE
ANALYSIS oF THE FLANGED CoNNECTIoN’S uSE FEATuRES (FLuIDS, TEMPERATuRE, PRESSuRE)
DATA ouTPuT FRoM SoFTWARE
DATA PRoCESSING THRouGH CALCuLATIoN SoFTWARE
CHECk oF THE FLANGED CoNNECTIoN AND CouPLING BASED oN THE DETERMINED LEAkAGE RATE
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EN1591 Method 11 Repair Advisors a division®
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The method stated so far evaluates the degree of fugitive emissions per pollutant based on the fixed leakage rate (L).The
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® monitoring plan avails itself of the calculation outputs coming from EN1591.
This calculation method represents a valid alternative option, where possible, to other means of plant validation, such as:
• Specific tests
• EN1591 standard procedure
• usage of normalized flanged couplings
Advantages of the calculation method according to EN1591
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via del vetro, 13/15 - 30020 Marcon (vE) ITALY Tel. +39 041.4568562 Fax +39 041.5952900 - info@cfservice.eu www.cfservice.it
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