Radosław Sieczkowski, Phd - SPETECH^® Technical Director

Leveraging more than 35 years of experience in the pressure equipment industry, SPETECH^® provides an integrated approach to leak tightness management, aimed at reducing fugitive emissions, improving operational safety, and increasing the efficiency of industrial processes. The integrated SPETOCARE solution comprises a wide range of services that can be flexibly tailored to meet specific customer requirements.

For example, for one of our customers we implemented the SPETOCARE concept by providing the following services related to low-emission sealing systems:

• laboratory testing to determine gasket design parameters,
• engineering calculations verifying the mechanical integrity of bolted flange joints and compliance with the required tightness class,
• manufacture and supply of high-quality metallic gaskets.

Why an integrated SPETOCARE approach?

A practical example of the SPETOCARE concept is a project completed for our customer, an Italian manufacturer of process equipment.

The initial project scope included engineering calculations and the manufacture of large-diameter Ring Type Joint (RTJ) metallic gaskets. However, the actual operating conditions of the equipment - including pressure, temperature, operating characteristics of the installation, and the material specified for the gasket - made it necessary to extend the scope of SPETECH services to include dedicated laboratory testing and the determination of gasket design parameters in accordance with EN 13555.
It was found that no design parameters were available for RTJ gaskets corresponding to the specific requirements of the equipment being designed. Such data were essential for performing the required engineering calculations. The need to determine dedicated gasket design parameters is relatively common for RTJ gaskets and other metal-to-metal sealing systems, i.e. solid metallic gaskets installed between metallic flange faces. This is because metal-to-metal sealing systems have only recently become subject to engineering calculations that verify compliance with a specified tightness class. Previously, such sealing systems were generally considered inherently leak-tight and therefore required only mechanical strength calculations.

As environmental regulations governing fugitive emissions from industrial installations have become increasingly stringent, metal-to-metal sealing systems can no longer be assumed to provide adequate tightness by default. Today, every new application involving hazardous media - including those utilizing metal-to-metal sealing systems - requires verification of leak tightness by means of engineering calculations. Consequently, project-specific gasket design parameters must be determined under the actual operating conditions for which the gasket is intended.

Laboratory Testing

RTJ gasket specimens were manufactured from the material specified by the customer and subjected to laboratory testing simulating actual operating conditions, including service temperature, pressure, bolt preload (contact stress), as well as the operational characteristics of both the installation and the gasket, such as thermal and pressure cycling and gasket loading and unloading cycles.
The testing was performed by SPETECH^® Laboratory, which is independently recognized by the Polish Office of Technical Inspection (UDT) and TÜV Rheinland in accordance with ISO/IEC 17025. This approval confirms the laboratory's status as an independent testing facility.

Engineering Calculations

The gasket design parameters obtained during laboratory testing enabled engineering calculations of the bolted flange joint to be performed in accordance with EN 1591-1, taking into account the leakage class required for the specific installation. This represents the current engineering standard for new industrial projects subject to European regulations.

The completed calculations were submitted to the competent local technical inspection authority for review and approval of the flange-gasket assembly for the intended application.
It should be emphasized that the regulatory requirements concerning emission class calculations for metal-to-metal flange joints apply not only to new installations. These requirements are gradually being extended to existing facilities and will increasingly be implemented during maintenance shutdowns and refurbishment projects.

Gasket Manufacturing

Following approval of the engineering calculations and completion of the engineering consulting phase, production of the metallic gaskets commenced in accordance with the approved technical drawings. All manufacturing operations were carried out at SPETECH production facility. The finished products were supplied together with a complete set of EN 10204 Type 3.1 Inspection Certificates, confirming the quality characteristics of the manufactured components, as well as AD 2000-Merkblatt heat number transfer certificates ensuring full material traceability.

The project described above is an excellent example of the integrated SPETECH^® SPETOCARE approach, which delivers reliability and operational safety through the combined supply of engineering services and high-quality products from the recognized SPETECH^®4S provider.

Other elements of SPETOCARE system

The integrated SPETOCARE solution also includes:
•    specialist training covering gasket selection, installation and assembly supervision in accordance with EN 1591-4;
•    support for LDAR (Leak Detection and Repair) programmes, particularly during the "AR" (Repair) phase aimed at eliminating the root causes of excessive emissions;
•    on-site assembly supervision during gasket replacement or replacement of complete installation components in accordance with applicable standards, including EN 1591-4, ASME PCC-1, and ASME PCC-2.

SUMMARY

The integrated SPETOCARE solution offers a comprehensive range of services designed to solve leak tightness challenges in pressure equipment and piping systems. The scope of services may encompass the entire project lifecycle or selected stages only - from problem diagnosis and feasibility studies through engineering design, laboratory testing, personnel training, manufacturing, and finally installation supervision and operational support.

SPETECH^® is one of the very few companies in Europe that combines a team of highly qualified and experienced engineers with advanced testing equipment, comprehensive expertise in the relevant international standards and engineering procedures, as well as approvals and recognition from both Polish and international certification bodies. This unique combination enables SPETECH^® to deliver the full range of services described above while ensuring the highest level of technical competence and quality assurance.