Digital examination of flange connection fitters

Test bench (Image source: Weber Engineering GmbH & Co. KG)

A flange connection consists of several precisely coordinated components: flange, bolts, nuts, gasket, and washers together form a central element of many technical systems in the process industry. The professional assembly and subsequent testing of these connections are crucial to ensure the tightness, safety, and durability of the entire system. Even minor errors can have serious consequences.

Leaks, pressure losses, or even accidents involving hazardous substances are often caused by improper assembly or inadequate inspection of flange connections. Even small leaks lead to emissions that not only have a significant impact on the environment but can also endanger the health of employees. In addition, faulty connections cause high repair and maintenance costs and increase the risk of unexpected operational downtime.

Quality assurance through targeted testing

To meet these challenges, flange connection fitters undergo specific testing. The tests serve to check and verify both the theoretical knowledge and practical skills of the specialists. Weber has developed a modern test bench for this purpose, which objectively assesses the skills of the fitters with the aid of a central digital testing system. This system ensures a high degree of transparency and at the same time supports quality assurance. After passing the test, participants receive a certificate that officially confirms their qualification.

Flanges, bolts, nuts, gaskets, and washers together form a central element of many technical systems in the process industry. (Image source: AdobeStock / Yellow Boat)

The test bench designed by Weber comprises several stations, each of which places different demands on the test specimens. Among other things, one station is equipped with a manual torque wrench and a stationary torque measuring device to check the accuracy and handling during torque application. Other stations are designed as flange trees with different connection types, while other test stations are equipped with manholes or valve racks.

All stations are integrated into a central computer system that controls the tests, randomly selects the tasks, communicates with the inspectors' tablets, and automatically evaluates all results. Digital torque wrenches transmit their measurement data directly to the system in real time, thereby avoiding human transmission errors.

Procedure and evaluation of the examination process

The testing process itself follows a clearly defined procedure. First, the test subject's data is recorded, including their name, date of birth, and area of application. Next, an inspector and a test tablet are assigned, which serves as the interface between the inspector and the system throughout the entire test. The next step is to start the actual test. The central system transmits the test tasks to the tablet, whereupon the first task, the torque test with the manual torque wrench, begins.

This is followed by the assembly of a flange connection, the test station for which is determined at random. During the test, the inspector evaluates the work using digital checklists, supplemented by the automatically transmitted values from the torque wrench. Once all tasks have been completed, the system checks the results, issues a certificate, or notes a negative evaluation if the requirements have not been met.

The flange connection is partially inspected digitally. (Image source: AdobeStock / Business Image)

The evaluation system is clearly defined. Each test candidate starts with a base score of 25 points. Points are deducted for errors; if the score reaches zero or critical errors occur—such as a missing gasket or screw—the test is considered failed. Each test station has its own configurable checklist for objective evaluation of the assembly activities. The measured torque values are transmitted to the tablet via Bluetooth and automatically compared with the specified target values. The measurement is carried out in two steps: first after parallel tightening of the flange connection and finally after complete assembly.

Digital control and data analysis

The digital system that controls the entire test consists of two main components. The FlangeSkillControl test management program runs on the central computer system, while the FlangeSkillCheck application is used on the examiners' tablets. The management program handles the complete specification and configuration of the test environment, creates the test tasks, and transmits them to the tablets.

Once a task has been completed, the results are automatically transferred back to the system, evaluated, and then exported in the form of an individually configurable certificate. This certificate can be printed out locally or sent electronically by email, which greatly simplifies administrative follow-up work.

Overall, the test bench concept developed represents a modern, structured, and transparent method for evaluating flange connection fitters. The combination of digital testing processes, standardized procedures, and a centrally controlled system ensures a high degree of objectivity and traceability. This not only ensures the quality of the assembly work, but also sustainably enhances the safety and reliability of the entire industrial plant.