The Technical Instructions on Air Quality Control (TA Luft) set limits for immissions and emissions of pollutants. It is the "First General Administrative Regulation on the Federal Immission Control Act" of the German Federal Government. The TA Luft is intended to protect humans and the environment from pollution caused by installations. Among other things, it specifies calculation regulations for air pollutants and thus ensures uniform, legal regulation of immissions and emissions from industrial plants throughout Germany.
In this context, the limit values of new plants to be licensed must already correspond to the state of the art already at the time of commissioning. Operators of existing installations are obliged to adapt emission protection to the state of the art within certain transitional periods. The regulations have already been amended several times. The amendments are intended to take into account the respective further developed state of emission control and filter technology. The upcoming new TA Luft also aims to adapt emission protection in Germany to European legislation. With the entry into force of the new version of the TA Luft the emission limits for technical installations will be tightened by the Federal Government. In addition, operators of installations that have not yet been regulated must be prepared for their inclusion in the TA Luft.
The most important changes - and how ERIKS supports the industry
The amendment of the TA Luft tightens the requirements for technical installations that require an immission control permit. A total of around 50,000 installations are affected by the revision. These include waste treatment plants, factories in the chemical industry and metal production, as well as cement plants and large plants in the food industry.
- Transition period of 4-5 years
- Massive tightening for plant operators
- Many of the standard flange connections no longer meet the future requirements.
- Plant operators under obligation: mathematical proof of tightness
- A fundamental change is the responsibility:
- Previously, only manufacturers of gaskets were obliged to provide proof of tightness in accordance with TA Luft.
- In future, operators alone will be responsible for ensuring that their systems comply with the limit values of TA Luft.
Three challenges and our solutions:
TA Luft verification for flange connections and valves
In the future, plant operators will have to provide the TA Luft verification for their flange connections by means of a mathematical proof of tightness (according to EN 1591-1) with the associated gasket characteristics (according to EN 13555). This then also applies to metallic RTJ and lens gaskets. If flange connections cannot be calculated according to EN 1591-1, e.g. plastic or enamel flanges, a component test must be carried out as an alternative to prove the tightness. The most important innovations - with regard to static gaskets - are mentioned in section "22.214.171.124 Flange connections": Operators of installations may only use "technically tight flange connections". For the selection and design of gaskets of technically tight flanged joints, the new TA Luft stipulates the tightness class L0.01 with a specific leakage rate of less than 0.01%. leakage rate of less than 0.01 mbar l/s m with the test medium helium. ERIKS supports customers here with a TA Luft-compliant product range from soft materials to semi-metallic to metallic gaskets, as well as with tests/calculations on the state of the art and characteristic according to EN 13555.
ERIKS is a manufacturer of gaskets and valves for TA Luft requirements
- Development, production and delivery of customised gaskets as well as own brand and well known A-brand valves
- Compliant with the requirements of TA Luft
- Supply of full service package of flanged valves with matching gaskets for piping and calculations in accordance with latest TA Luft requirements for proof of tightness
- Comb profile, RTJ, spiral wound, graphite, soft material, rubber steel, metal and PTFE gaskets
First Challenge: Calculated proof of tightness according to DIN EN 1591-1
For flange connections with metal gaskets, e.g. ring-joint or lens gaskets, the procedure of guideline VDI 2290 shall be applied accordingly, provided that suitable gasket parameters are available. VDI 2290 supplements the TA Luft and defines the criteria of a technically tight flange connection for liquid and gaseous media. Each installation situation must be checked individually. The calculation must be made according to DIN EN 1591-1. The respective gasket parameters must also be determined according to DIN EN 13555, e.g. parameters for the required or permissible surface pressure, creep relaxation factors, etc. ERIKS provides comprehensive support to plant operators in the mathematical verification of leak tightness in accordance with DIN EN 1591-1 and in accordance with the TA Luft specifications.
ERIKS solution: Calculation of the proof of tightness according to DIN EN 1591-1
- Own AMTEC test bench for determining characteristic values according to EN13555
- Calculation of the strength of the flanges and design of tightening torques
- Proof of tightness according to DIN EN 1591-1
- Documentation of the calculations for the TÜV
- Determination of the sealing behaviour according to VDI 2440/2200
Second Challenge: Component test for non-calculable flanges
If a mathematical verification according to EN 1591-1 is not feasible, the proof of tightness of the flange incl. assembly is to be provided in the future by means of a component test according to the new TA Luft. TA Luft, the flange and assembly must in future be subjected to a component test. This means laboratory tests with leakage class L0.01/leakage rate of 0.01 mbar l/s m under real operating conditions (e.g. real operating pressures and temperatures) - likewise a significant significant tightening compared to the old TA Luft, as this must now be carried out for all non-metallic flanges.
ERIKS solution: Support for component tests
- Joint solution finding for non-calculable flanges
- Proof of tightness for all non-metallic flanges
- Proof of tightness already determined for e.g. glass lined flanges
Third Challenge: Installation by trained personnel according to DIN EN 1591-4
According to the new TA Luft, the flanges available after the above-mentioned proof of tightness may only be installed by demonstrably qualified fitters (according to DIN EN 1591-4). DIN EN 1591-4 specifies exact training contents at various training levels. Every fitter must be trained and tested at the so-called basic qualification level. In addition, installation instructions, testing, maintenance and quality control specifications must be documented in writing in accordance with VDI Guideline 2290. ERIKS competently accompanies plant operators through flange assembly monitoring and training in accordance with DIN EN 1591-4.
ERIKS solution: Training and on-site installation supervision
- Certified training of installation personnel according to EN 1591-4
- Assembly supervision by qualified personnel
- Documentation of the assembly and handover protocols
- Coordination of supervision with the customer
General contact ERIKS Group Head Office
3511 LK Utrecht
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