Inspections & Tests
To guarantee flawless quality, we conduct extensive tests and inspections before, during and after the procuction. Our testing personnel is trained according to DIN EN ISO 9712. Additionally, all the welding work is performed by welders holding a welding permit. Also our welding supervisors own the necessary qualifications.
Further is our internal testing personnel in possession of qualifications for most of the common test methods according to ISO and ASME standards. All other tests can be conducted with assistance of competent partners.
kompaflex employs a number of people with the following diplomas of the IIW (International Institut of Welding):
- Internationel Welding Specialist (IWS)
- International Welding Technologist (IWT)
- International Welding Engineer (IWE)
Our welding staff is qualified according DIN EN ISO 9606 and DIN EN ISO 14732. Our welder do have WPQ’s for TIG, MAG and PLASMA. We weld according our WPS’s, which are qualified with PQR’s according DIN EN ISO 15641-1. Because we have to do welding on big variety of materials, kompaflex possesses more than 100 PQR’s.
Testing Supervisior and Personnel
Our testing personnel is qualified according EN ISO 9712:
- The testing supervisor has a Level III qualification
- EN ISO 9712 Level II
- ASNT-TC-1A Level III
Water Pressure Test
For the water pressure test, the expansion joint is sealed tightly on both sides. The test is carried out at our factory by pressurizing with water up to the specified test pressure, whereby no liquid may escape (no pressure drop) or inadmissible deformation may occur. Pressure tests are carried out according to DGRL/PED AD HP 30 or ASME code.
To detect a leakage of the inner layer, the expansion joint is pressurized with compressed air. Nekal testing fluid (special soapy water) is applied. Bubbles made visible in this way indicate a leak. This is a standard test carried out in our factory for all our multi-ply expansion joints.
Helium Leak Test
All expansion joints can be subjected to a helium leak test. The following two test methods and leakage rates according to EN 1779 are standard at kompaflex:
- A1 Vacuum Integral test: Leakage rate 1.0E -10 mbar*l/s
- A3 Vacuum Local test: Leakage rate 1.0E -10 mbar*l/s
Higher leakage rate on request possible.
Visual Testing VT
Visual testing as a non-destructive test method has been standardized in DIN EN 13018 (General principles of visual testing). Welding seams are tested according to DIN EN ISO 17637. The kompaflex test personnel is qualified according to EN ISO 9712 and SNT-TC-1A Level 2 / Level III.
Dye Penetration Test PT
The dye penetration test is carried out in accordance with ISO 3452. The kompaflex test personnel is qualified according to EN ISO 9712 and ASNT-TC-1A Level 2 / Level III. Especially in the case of welds, irregularities on the surface can be detected. The dye penetration test is a surface crack inspection, which at first glance appears very simple, but it takes a lot of experience to apply it correctly.
Digital X-ray DR
komaflex has its own digital X-ray department of the latest generation. Digital X-ray technology offers numerous advantages over the analogue X-ray technology:
The images can be viewed and evaluated immediately after shooting on a monitor. Archiving in digital form ensures that the recordings are available in original quality even after many years.
The X-ray inspection is performed according to ISO 17636-2 and the ASME code.
Spring Rate Test
The spring rates calculated after a standard, has large tolerances of up to +/- 30%. For applications where the spring rate is a decisive criterion, it makes sense to determine the effective value in a spring rate test. kompaflex is able to experimentally determine the axial, lateral and angular spring rate in such a test.
Positive Material Identification Test
Determination of the chemical composition of materials. PMI (Positive Material Identification Test) tests, are essential for the traceability of materials. Material mix-ups can lead to considerable damage and must be absolutely excluded, especially in sensitive, safety-relevant areas. Therefore, kompaflex has a PMI device to verify the use of the correct material at any time as required.
Surface Roughness Test
The surface roughness of an object is determined by measuring a two- or three-dimensional profile of the surface. With our measuring device we can determine various roughness parameters, including the widespread Ra value.
Life Cycle Test
The service life of a expansion joint is determined in a life cycle test. For this purpose, the strokes defined in advance are driven until the bellows fail.
In a bursting test, water is used to increase the pressure until the expansion joint fails. In this specific case, the expansion joint has first failed due to in-plane instability.
With the help of micrographs, the material structure can be analysed more precisely.