HP_2007_10_EN

“That goes together”

2

“That goes together”Page 12

More power when serving the construction industry

HYDRAULIKPRESSE10/07

12

06

04

More power

when serving

the construction

industry

„That goes together“

Next door to the

customer

300th branch now open

XWORLD countdown

Put a tiger on your tank

Editorial 03

XWORLD countdown: Put a tiger on your tank 04

Next door to the customer – 300th branch now open 06

Light and stable – Die-cast components with maximum precision 08

In conversation with Frank Dahms – “Seeing change as an opportunity” 10

More power when serving the construction industry – “That goes together” 12

HANSA-FLEX‘s Oldenburg branch – “No can do just won‘t do” 15

Advising customers is a tough job – So the mixture‘s right 16

“fl uid award” for HANSA-FLEX – An award-winning article 18

How thick do you want it? Calculating pipe wall thicknesses correctly 19

Quiz, Seminars, Trade fairs 22

Literature, Figures & Facts, Preview 23

CONTENT | IMPRESS

Content

ISSUE OCTOBER 2007

13. JAHRGANG

Editor:

HANSA-FLEX Hydraulik GmbH

Zum Panrepel 44 · 28307 Bremen

Germany

Phone: 0421 - 48 90 70

Fax: 0421 - 4 89 07 48

E-mail: info@hansa-fl ex.com

www.hansa-fl ex.com

Compilation: Dietbert Keßler, Enrico Kieschnick,

Horst Otto (PAPP Werbeagentur)

Layout: Nadine Staciwa

Print: Berlin Druck · www.berlindruck.de

Responsible for contents: Wolfgang Rink

Frequency: Bimonthly

Subscribe to the on our website.

HYDRAULIKPRESSE02

The managing directors

Uwe Buschmann Thomas Armerding

Dear reader,

We are aware of our responsibility. For this reason we are concerned about the safety, both in practice and

theory, of everyone who works on and with hydraulic systems. We are therefore happy to pass our expertise

to our customers, for example by means of articles in journals.

Such articles containing sound knowledge are appreciated by readers. Only recently the readers of the ma-

gazine „Fluid“ paid tribute to an article written by an author from HANSA-FLEX. This illustrated article dealt

with safety and the requirements on fl uid systems in the fi elds of connection technology and line enginee-

ring. HANSA-FLEX always takes account of the risks involved and the safety provisions in this sector, carefully

complying with the regulations, standards and laws applying to hydraulic lines in order to guarantee the

safety of the equipment and above all, of the people working with such systems. We therefore see it as

our obligation to make every eff ort to ensure the necessary safety for our customers when dealing with

hydraulics. One more reason to extend the HANSA-FLEX Training Centre. The plans are coming on well, and

in 2008 we will already be able to off er our customers many new training courses in addition to the existing

programme.

Customer proximity and a focus on service remain the recipe for success at our company. You can fi nd out on

page 6 how customers benefi t from such engagement. Here we present the 300th branch of HANSA-FLEX.

It has recently been opened at a site belonging to one of our long-standing customers and concentrates

on off ering optimum support to an OEM customer who makes consistent usage of our hydraulic systems

provider concept.

In the meantime we are already initially considering whether this concept could also be implemented with

the construction machinery specialist Könicke from Garbsen. This company likewise consistently pursues

the concept of customer proximity. On page 12 you can read how both companies jointly enhance customer

benefi t with extensive and exemplary service.

FOREWORD

Editorial

HYDRAULIKPRESSEISSUE OCTOBER 2007

03

XWORLD

A Sumatra tiger decorates the sides of the jungle-

green Toyota Land Cruiser, promising exciting ad-

ventures. For weeks the vehicles in the XWORLD Tour

have been causing a stir on Europe‘s roads, where

they are undergoing intensive testing. High demands

will be made on these cars with their bright colours

and eye-catching motifs during this adventure tour.

To reach the breathtaking destinations of the

XWORLD Tour the vehicles will have to cover over

150,000 kilometres on their way right through Eu-

rope and Asia. The route leads through deserts, jun-

gles and high mountains. The cars will have to cope

with streams and small rivers as well as unmade-up

roads, rubble and snow. A challenge for both man

and machine.

To manage all that without breaking down safe and

reliable vehicles are needed. HANSA-FLEX did not

choose the easy way out when selecting the cars

and scrutinised several options. Together with the

travel agency pro+motion organising the event

numerous off -road vehicles were inspected and put

to the test. After careful road testing with vehicles

of diff erent makes, the choice fell on the Toyota

Land Cruiser. The decisive factor was the advanta-

geous global package on off er.

Opting for service

These Toyotas are characterised by their robust and

reliable design while still off ering a comfortable

ride; this is important as after all, the people tak-

ing part in XWORLD will be spending a lot of time

in the cars. The Land Cruiser is ideally suited to the

requirements of XWORLD. The Japanese manufac-

turer has acquired over 50 years of experience with

this model on the toughest terrain in the world.

But how does a near-series Toyota Land Cruiser

become an XWORLD vehicle equipped to deal with

anything?

By fi tting the 173 hp car featuring permanent four-

wheel drive with all conceivable extra features: This

was the task of the specialists from the Hamburg

company Off road-Manufaktur. They fi rst of all

raised the chassis and optimised the underride pro-

tection. A special “snorkel” allows the car to drive

through water without the engine choking. The

vehicles were also equipped with a fresh air fi lter

system, parking heater and a trailer hitch. Power-

ful extra headlights turned night to day, and cable

winches were even fi tted to ensure that the cars can

drag themselves out of any mud.

The vehicles took additional supplies of water and

fuel with them on additional roof racks as well as

spare wheels. The interior was also fi tted out to

cope with such a journey: radio sets, GPS naviga-

tion, a compass and an altimeter have all been

installed. An effi cient air-conditioning system en-

sures that participants will always feel comfortable

on board whether they are negotiating high moun-

tains, crossing the desert or making a stop at the

North Cape. On the tour each team consists of two

people per vehicle. The two of them are responsible

for their car, navigating the Toyota themselves and

loading/unloading equipment.

Two experienced tour guides are accompanying the

convoy in an escort vehicle. Important equipment

such as tents, spades, pickaxes, ropes and similar

items will be conveyed in this Toyota Hilux Double

Cab including a hardtop for the cargo area. This

means they will be equipped for all eventualities.

Can‘t be missed

After the six cars had been delivered, the next step

was to give them a makeover. After all, the idea

was for them to attract attention to the XWORLD

Tour from afar through an unmistakable look. The

designers from Papp Werbeagentur knuckled down

to this task and with HANSA-FLEX‘s Marketing de-

partment came up with the striking XWORLD logo

in a character style that smacks of adventure and

curiosity about the world.

The striking paintwork of the cars picks up motifs

from the highlights of the tour: images of a sunset

and the Sumatra tiger mentioned above, the Gobi

Desert, the Great Wall of China and the Himalayas.

These motifs were carefully printed onto foils by a

special printing fi rm and then laminated onto the

cars painted in diff erent colours by experienced

vehicle decorators from the company Intax in Old-

enburg. The cars, which have been cruising Europe‘s

roads on test drives for months, cause a real sensa-

tion in the traffi c wherever they go.

The preparations for the start of the XWORLD Tour

are currently also underway. When the vehicles set

XWORLD countdown: Put a tiger on your tank

HYDRAULIKPRESSE4ISSUE OCTOBER 2007

XWORLD

off from Bremen‘s market place in March 2008, the

start itself will be an experience for everyone taking

part. The fi rst stage is from Bremen to Istanbul. The

group of vehicles will be making for destinations

which are rarely visited in convoy.

All stages will off er unique experiences. The com-

prehensive catalogue for the XWORLD Tour describ-

ing all 43 stages in detail complete with pictures is

now available. It can be ordered from www.xworld.

cc or the Hotline +49 – (0)661 – 4 40 77 27 70. If

you would like to book the stage of your dreams,

you shouldn‘t wait any longer - many others will be

attracted by the adventure of the XWORLD Tour.

Setting off on an adventureYou will suddenly fi nd yourself right in the middle of

an adventure just by leafi ng through the catalogue.

Spectacular photos and detailed descriptions of each

stage will allow your imagination to run away with

you. Just the very fi rst stage of the XWORLD Tour will

make your dreams come true. To be more precise,

dreams of the Balkans. From Bremen the route leads

on an amazing journey through the Alps via Berlin,

Dresden and Neuschwanstein Castle. The beauties of

Slovenia and Croatia will be revealed to you as you

cruise high above the Adriatic. Continuing on a brea-

thtaking route to Istanbul you will see the mysteries

of the Balkans. You will cross from one continent to

the other at the Bosporus, and the fi rst stage will end

in Asia with a visit to Turkey‘s enormous metropolis

of Istanbul.

HYDRAULIKPRESSE 5ISSUE OCTOBER 2007

BRANCHES

“Being on good terms with the neighbours” has been

the motto at HANSA Maschinenbau in Selsingen,

where the 300th HANSA-FLEX branch opened in

September. There is an admirable concept behind this

impressive fi gure: with this branch HANSA-FLEX has

immediate proximity to the customer. The company

premises are now located in the newly constructed

hall of our customer HANSA Maschinenbau, a manu-

facturer of municipal vehicles and mobile excavators

for cemeteries. A close connection, only divided by a

door.

It was Reiner Plöger who came up with the idea.

For 15 years he has looked after the customer

HANSA Maschinenbau for HANSA-FLEX as a pre-

ferred supplier for hydraulic coupling elements.

A business relationship that is characterised by

absolute trust. When Reiner Plöger learned of the

restructuring planned at HANSA – the existing

production facilities of Nieder-Ochtenhausen and

Selsingen were to be concentrated at a new build-

ing at Selsingen – he spoke to the managing part-

ner Hinrich Prüß, suggesting setting up a branch at

the site of the customer HANSA Maschinenbau. A

joint concept was worked out, ensuring effi cient

support for this customer. The idea led to HANSA-

FLEX‘s 300th branch. Here HANSA-FLEX provides its

customer with whatever the company needs in line

engineering for hydraulics, cooling systems and

engines. Working hand in hand with the Dresden-

Weixdorf plant, it supplies hose lines, curved pipes

and special fi ttings.

The foundation stone for today‘s company HANSA

Maschinenbau was laid by August Prüß in 1950,

when it was set up as a repair workshop for agri-

cultural machinery in Zeven. He soon concentrated

on the construction of dump trucks for excavation

work. It was these dump trucks – which today are

now only known to the older generation, having

been ousted from the building site long ago by the

wheel loader – that gave birth to the company‘s

current manufacturing programme of municipal

vehicles and excavators for cemeteries. In the 1960s

the trend of using mechanical help for work proc-

esses was also adopted by cemeteries for activities

such as grave digging and moving earth.

As the paths at graveyards are narrow, the chassis

of the dump truck with its track width of 120 cen-

timetres proved to be a good basis for such work.

HANSA then gradually adapted the bodies of these

vehicles to their new role and now off ers modern

cemetery excavators, which with their dipper and

ditch digging shovels, earth drills, mowing buckets

and other attachments help cemeteries to perform

their work at lower cost. This also applies to the mu-

nicipal and multipurpose vehicles manufactured by

HANSA, which have become indispensable aids at

local authority sites thanks to a wide range of at-

tachments. Sophisticated hydraulic systems deliver

power combined with fi ngertip control for winter

spreader trucks and snowploughs, high-pressure

cleaning equipment and suction sweepers as well

as loading cranes and dumpers.

Ergonomically designed driver‘s cabs ensure maxi-

mum comfort for the operator in his work. HANSA

naturally also sets an example in complying with

the requirements of environmental protection. The

engines of the current series of machines are now

being converted to the Euro 3 and Euro 4 category,

thus fully satisfying all stipulations in terms of fi ne

particulate emissions.

Two men on hand to help

Whenever a new machine is developed at HANSA or

the design of existing vehicle modifi ed, the compa-

ny is glad to avail itself of HANSA-FLEX‘s expertise.

In the past a FLEXXPRESS service vehicle was dis-

patched to provide customer support, for example

by supplying samples of hose lines. A task which

is now taken over by the on-site branch in close

cooperation with the customer‘s 70 employees. It

may well happen that a sample for a curved pipe is

provisionally welded together to give HANSA-FLEX

an idea of how the part should ultimately look. The

specialists for fi ttings and special pipes in Dresden-

Weixdorf then use this to develop a technical solu-

tion for serial production. Two men are responsible

for looking after the customer at HANSA-FLEX‘s

300th branch: Holger Magura, who has been em-

ployed at HANSA-FLEX for many years, is joined by

Marco Peters, who recently qualifi ed as a mechani-

cal engineering technician with HANSA and has

also undergone specifi c training for his new role at

the branch.

Next door to the customer300th branch now open


BRANCHES

Project “Future”

Such close cooperation allows HANSA to greatly

optimise its cost structure: freight costs no longer

apply, there is no need to keep pipes and pipe fi t-

tings in stock, and costs for storing screwed connec-

tions become a thing of the past. But the concept

does not stop here. There is to be a change in the

“groundwork” performed by HANSA-FLEX, mov-

ing to just-in-time supply, so that HANSA-FLEX

takes over the responsibility for ensuring that the

production processes for cemetery excavators and

municipal vehicles go smoothly. The customer

keeps parts lists for each special vehicle, which from

now on include fi ttings technology. In future

HANSA-FLEX will supply fully prepared assembly

kits to the installation points, where they can be

installed without further ado. All components

are arranged in a carefully structured manner

on assembly cars. This means that the fi tter

immediately has the part to hand ready

to install without having to look for it.

For HANSA this minimises assembly

times, so culminating in a signifi -

cant cost saving in the course of

the year. And when it comes

to cost management at the

HANSA-FLEX branch, there

are also positive results

thanks to the part-

nership between

the two compa-

nies and the

i m p r o v e d

options when planning key stock-keeping fi gures.

Hinrich Prüß puts his full trust in this concept.

Work is already underway on jointly optimising

these processes. Reiner Plöger too is convinced

that both partners will greatly benefi t here as “the

daily proximity to our customer makes cooperation

easier. And allows us to see with our own eyes

where there is potential for improvement and come

up with suggestions for new technological solu-

tions.”

Although the focus of work at the new branch is

ensuring effi cient support for the customer HANSA

Maschinenbau,

other clients in the region already eagerly await

HANSA-FLEX, also hoping for a faster hydraulics

service. Customers based at Zeven, Buxtehude

to Stade have already indicated their interest in

working more closely with the new branch of

HANSA-FLEX.

However, whether the concept of an in-house

branch can be realised with other customers is yet

to be seen. At all events, Thomas Armerding, Man-

aging Director of HANSA-FLEX Hydraulik GmbH,

sees the opening of this 300th branch as “an exam-

ple of close cooperation and partnership with the

customer that is worth copying”.


DIE-CAST

In aircraft and automotive engineering every gramme

counts. For this reason this sector requires extremely

lightweight parts that off er high stability at the same

time. A good example here is the Airbus A380, which

uses ready-to-install precision die-cast components

made of aluminium.

Such parts are manufactured using the aluminium

die-casting process and have become indispensa-

ble in many branches thanks to their low weight,

high precision and minimised reworking costs. One

major supplier of pre-assembled aluminium die-

cast parts and components for the automotive and

aeronautics industry is the ae group in Gerstungen.

With a workforce of 1,700, the company has pro-

duction going round-the-clock at seven sites all

over the world. Leading brand manufacturers en-

trust the ae group with the manufacture of engine

blocks, undercarriage parts and transmission hous-

ings. Depending on each problem, the develop-

ment departments of customers and the ae group

specialists tailor these parts to serial production on

the ae group‘s assembly lines.

The aeronautics industry has also relied for years

on the precise quality level of die-cast parts from

the ae group. Examples of such parts are feet and

armrests for aircraft seating. The seat foot made of

die-cast aluminium is the successor to a version in

steel and as such satisfi es the high demands made

on component ductility. The armrest supersedes a

sheet-metal design, which used to be riveted to-

gether from 15 individual components. The new

armrest now consists of two semi-shells made of

die-cast aluminium, which are joined using the

electron-beam welding process.

These two innovative components have allowed

both weight and costs to be minimised. At the

same time there are other benefi ts such as stiff ness,

self-damping, greater scope of design, fi reproofi ng,

nontoxicity and unlimited recycling of components.

The welded seam of the armrest is subject to very

high requirements in terms of design. For example,

some 10 grammes of weight are saved per armrest

compared with the previous solution made of sheet

metal. When it comes to the feet used for the seat-

ing modules, the weight saving is far greater.

The ae group has succeeded in optimising the cast-

ing process so as to fully satisfy the strength char-

acteristics required. The demanding specifi cations

for Parts Subject to Special Archiving in the aircraft

engineering and vehicle construction sectors call

for a high level of ductility. Once achieved, there are

no longer any limits in terms of design.

The level of precision for the die-cast parts calls for

special expertise in mould and die production as

well as an understanding of the behaviour of such

cast materials. The casting equipment is based on

sophisticated technology: the hot liquid material

must penetrate all cavities of the mould to prevent

shrink holes in the cast parts. Shrink holes are un-

desirable voids inside a workpiece and are caused

by shrinkage in volume when a liquid metal sets.

For this reason, the metal is fi rst introduced to the

mould at a temperature of around 760 degrees Cen-

tigrade, with the mould being preheated to approx.

160 - 200 degrees Centigrade and cooled to prevent

stresses in the material. This process depends on

the dimensions and type of mould. After the mould

has been fi lled, the material is compressed with a

pressure between approx. 800 and 1200 bar and

forced into all cracks. This ensures that every detail

of a component is accurately moulded. It also rep-

resents a key benefi t as such aluminium die-cast

parts are now suitable for welding thanks to an in-

novative manufacturing solution from the ae group

and can be subjected to heat treatment.

werden.

Ensuring the ability to act

Casting moulds are exposed to very high tempera-

tures. This makes special demands on hydraulic

components and hose lines. This is why the ae group

uses temperature-resistant metal corrugated hoses

for the supply of the cooling / heating medium us-

ing thermal oil. The aggressive media involved in

the production process are best handled with metal

hoses made of stainless steel, which are stocked in

a range of dimensions at a consignment warehouse

set up by HANSA-FLEX for the ae group. This means

that the ae group is immediately able to act when-

Light and stableDie-cast components with maximum precision


DIE-CAST

ever replacements are required at short notice but

does not itself incur any storage costs.

As a supplier to the automotive industry, the ae

group cannot aff ord any delivery failures from

unscheduled machine downtimes. Given that the

assembly lines of car manufacturers are as tightly

scheduled as the assembly times for the A380, all

ae production plants operate round the clock, so

ensuring absolute delivery reliability.

The ae group has its own plant maintenance de-

partment responsible for troublefree production.

As its staff are on duty non-stop, the ae group is

assisted in its maintenance work by services from

the HANSA-FLEX organisation, which looks after

all of the company‘s sites. With the exception of

Poland, cooperation is coordinated by the branch

at Niederaula, where Manfred Wichers is in charge

of the customer. He joined HANSA-FLEX over 18

years ago and is therefore familiar with every de-

tail of the requirements made by the ae group. He

contacts this customer three times a week to check

that the ae group is getting prompt service. Here

he focuses on predictive maintenance by ensuring

that the various departments are supplied with

operating resources, so avoiding unscheduled stop-

pages. Hydraulic components such as valves and

hydraulic cylinders are always quickly available, as

well as a wide range of hydraulic hose lines. Where

hose lines are concerned, it has to be ensured that

a water-glycol mixture is used instead of hydraulic

oil with the aluminium die-casting machinery to

prevent fi res occurring in the event of any leakage.

This is important as hydraulic oil can catch fi re at

the temperatures involved.

Fast assembly of furnace

The staff employed at the ae group‘s maintenance

department are normally busy with routine op-

erations. However, whenever special assignments

are involved, they are supported in their work

by complete industrial installation teams from

HANSA-FLEX. At the site in Untersuhl a melting

and holding furnace had to be built from scratch

for the LaGrange plant at Georgia / USA. In addi-

tion, the Untersuhl site was to be fully modifi ed to

handle aluminium. Both projects were successfully

completed by Manfred Wichers with his colleagues

from HANSA-FLEX‘s industrial installation teams.

Beforehand he liaised closely with ae‘s works

managers to establish which components needed

to be procured. He was responsible for ensuring

the punctual availability of new units, hose lines,

pipe and screwed connections, which were all or-

dered in close agreement with Tobias Zindel from

the ae group‘s central purchasing department. The

furnace was assembled according to schedule and

without any problems. It was delivered to the USA

and commissioned there on time.

The ae group has meanwhile performed global

introduction of the X-CODE at its production plants

to ensure greater reliability for the procurement

of spare hose lines of identical design. This cuts

the time required for supply to a minimum. “This

means leaner ordering processes, forcing down the

rate of incorrect orders towards zero and above all,

cutting costs through delivery at short notice with

telephone ordering,” says Tobias Zindel, emphasis-

ing the benefi ts of X-CODE for his company.

Pressure medium: mixture of water-glycol

No hydraulic fl uid is suitable for every application.

Specifi c requirements are made on fl uids in hydrau-

lic installations to ensure that systems operate as

smoothly and as economically as possible. A mixture

of water-glycol is used with the aluminium die-

casting machines of the ae group. The hydraulic me-

dium known as HFC (water-glycol) consists 40% of

water and 60% of glycol and is a fl uid that is not easily

fl ammable. HFC is mainly used as a fl uid in hydraulic

systems at production plants working with very high

temperatures as well as under warm or hot operating

conditions.


IN CONVERSATION

Frank Dahms has gone through all levels of the compa-

ny at HANSA-FLEX, from apprentice to regional man-

ager. He started his career at HANSA-FLEX in August

1991, when he joined the company‘s HQ in Bremen

as a trainee for wholesale and foreign trade. After

completing his apprenticeship, he transferred to

HANSA-FLEX‘s branch at Wörnitz in Bavaria, where

he was initially employed at part of the offi ce team

before progressing to active sales in the fi eld. At

the same time he successfully completed a course

in business administration at night school. Hav-

ing meanwhile been promoted to branch manager,

Frank Dahms was put in charge of

HANSA-FLEX‘s two plants in Nuremberg.

In January 1999 he took over responsi-

bility for the Nuremberg Group, now

comprising the branches of Nuremberg,

Nuremberg-North, Schwandorf, Schwa-

bach and Bayreuth as well as three

FLEXXPRESS vehicles interlinked with

the plants. In the context of interna-

tional development of the HANSA-FLEX

Group he also provided support to the

plant in Australia for a time. As a region-

al manager Frank Dahms is currently re-

sponsible for the further development of

HANSA-FLEX. He explained to HYDRAU-

LIKPRESSE how exactly this will take

place:

: The re-

gional manager structure as a control

instrument of Management - who

benefi ts from this structure?

Frank Dahms: This decentralised

structure with its short decision-mak-

ing processes not only benefi ts the

customer but also our corporate and

communications culture. As a regional

manager I can take over responsibil-

ity here for the future development of

HANSA-FLEX. My thinking and action is

geared to sales, and I like the challenge

of working out and implementing new

concepts - this gives me motivation.

Whenever I am looking for a solution to customer

requirements, I can fi nd it here: Someone in the

HANSA-FLEX Group is already working on the prob-

lem. It is only a matter of evaluating the experi-

ences acquired and applying them to the demands

of your own customers.

: The manufacturers of

agricultural machinery will also soon benefi t from

HANSA-FLEX‘s focus on service?

Frank Dahms: At the meeting of regional manag-

ers it was decided to attend Hanover‘s Agritech-

nica in November for the fi rst time. A feature of

the trend in mechanical engineering is emerging

in the agricultural machinery sector: Germany is

exporting agricultural machinery to numerous East

European countries on a large scale. This machinery

owes much of its productivity to hydraulic systems,

which greatly facilitate the work of agricultural

enterprises although such quality products “Made

in Germany” of course also call for a correspond-

ing level of service. For HANSA-FLEX this above

all means: fi rstly supporting the OEM in building

machines and secondly, ensuring a high quality

standard for the spare part business and naturally

the ability to deliver without delay. Other regional

managers have had experiences similar to mine.

: The Nuremberg Group

has enjoyed positive experience with the sowing

machine manufacturer Horsch, who wants to step

up its cooperation with our company.

Frank Dahms: The company opened a new pro-

duction plant in Ronneburg near Gera on 01.01.07.

HANSA-FLEX supplies it with complete assembly

kits, which not only include HANSA-FLEX products

but also components from other suppliers - for

example, nuts and bolts which were previously de-

livered to the warehouse by other manufacturers.

Now everything comes together at HANSA-FLEX.

We supply assembly kits, also containing these

parts which have carefully organised according to

the installation situation. Here we are cooperat-

ing with the existing suppliers. There has been no

change in the product quality parameters from

the relationship between Horsch and the relevant

supplier. We have jointly developed and optimised

the assembly kits with specialists from Horsch

to ensure that this service will now go smoothly.

Horsch no longer incurs storage costs, and the exact

subassembly required is always to hand. This means

the fi tter has everything ready for installation at his

workstation.

In conversation with Frank Dahms“Seeing change as an opportunity”


IN CONVERSATION

: OEM customers thus

approach HANSA-FLEX with complex problems?

Frank Dahms: They are increasingly involving us

in preliminary planning for new machines or in

cost-reduction programmes. When reviewing a

machine design recently, we were able to optimise

the pipe layout and confi guration, with screwed

joints being replaced by 90-degree hose fi ttings.

This allowed us to minimise the cost of assembly

work and use cheaper components, something that

piece by piece results in an improved cost structure

in serial production. Here we are also able to avoid

any leakage at the points of connection, so actively

doing away with cost traps. It goes without saying

that HANSA-FLEX aids these processes by providing

samples promptly and preparing components for

serial production.

: A focus on service as the

secret of success?

Frank Dahms: Customers expect special benefi t.

We are ready to deliver this. Today it‘s no longer suf-

fi cient to just “dump crates on the delivery ramp”.

We integrate our services in the production chains

of manufacturers and off er high-performance

concepts. For example, the Nuremberg Group

supports the company Hamm Walzen with a serv-

ice for which a hall has been specially set up for

HANSA-FLEX at the company‘s site. There

HANSA-FLEX staff are responsible for preparing

all hose lines exactly as on the parts list and then

arranging them on special transport cars so that

they are ready to hand for the fi tter at just the right

time.

: Are you continuing to

develop the systems supplier concept?

Frank Dahms: Without a doubt - nonetheless,

the spare parts business for hydraulic connecting

elements has brought HANSA-FLEX recognition and

success for 40 years. It remains an important main-

stay of our operations and a key to growth. I greatly

attribute the success of the Nuremberg Group – and

I‘d like to stress this – to the commitment shown by

its staff ! And this is why we are planning the assign-

ment of new staff to new tasks. For special products

we need specialists in our group to reinforce our ex-

pertise and ensure greater customer proximity. We

have now trained staff to specifi cally push the sale

of hydraulic components and construction services

for units. These staff also visit customers directly in

agreement with the managers responsible for the

fi eld team. This has already proved a successful

move in the case of cylinder repairs.

: HANSA-FLEX is report-

ing growth in double fi gures. How can you guaran-

tee that customers will benefi t from this?

Frank Dahms: The X-LOGO project is reviewing

all current processes to ensure HANSA-FLEX satis-

fi es the requirements of this dynamic growth. This

will ultimately also include the introduction of SAP,

a software program that is used by 65 percent of

small and medium-sized enterprises. This will make

it even easier for us to connect with our customers

in future; SAP will bring us greater transparency.

The introduction of SAP will however mean change

for our branches, involving new work processes

which have to be taken on board by all staff . We will

thus be managing this process in cooperation and

partnership with all employees, organising training

courses to ensure that on 1 January 2008 SAP will

get off to a successful start at our branches.


CONSTRUCTION MACHINERY

A “New Power” off ensive was kicked off by Bau-

maschinen Könicke at NORDBAU 2007, which was

held at Neumünster in September and attracted

75,000 visitors. As a service-provider the company

Könicke from Garbsen has been an acknowledged

partner to the building industry for over 50 years

and distributes the complete range of the construc-

tion machinery manufacturer Volvo in the north of

Germany.

Volvo construction machinery is known for its

performance. At the fair the company presented

Volvo‘s new mighty wheel loader L350F, an inno-

vative vehicle which is already pointing to coming

trends in the construction machinery sector. Radi-

cally improved axles, upgraded transmission and

a greater tipping load open up new dimensions in

productivity. Besides wheel loaders, Könicke also

exhibited dumpers, compacts and new excavators

from Volvo‘s C-Series. The construction vehicles

made by this Swedish company, which are highly

regarded in the branch, are both effi cient and ro-

bust in operation and are characterised by an excel-

lent cost-benefi t ratio.

To ensure that customers for these machines can

use all features off ered by such modern machinery

in their everyday work, Könicke is now providing

support in the form of its “New Power” off ensive.

This for example includes driver training

courses, which have been very

successful. With some 1000

participants attending its

courses every year, Könicke

demonstrates a

high level of engagement in terms of safety, so

making it a key player when it comes to training

construction machinery operators. By taking part

in driver training programmes, Könicke‘s customers

not only safeguard themselves from risks of liabil-

ity but at the same time ensure greater safety and

more effi cient usage of their vehicles.

And Könicke is also applying the extended service

promise of its “New Power” off ensive to its service

fi tters. Construction machine operators are care-

fully prepared for all tasks involving hydraulics by

the instructors at HANSA-FLEX‘s training centre.

Whether new or second-hand –

HANSA-FLEX provides the link

Besides new machinery the company from Garbsen

also distributes reconditioned second-hand equip-

ment and modern rental machines. Whether new

or old, all vehicles are supplied by Könicke not only

in the standard version but also specially adapted

to customer requirements, for example equipped

with attachments such as grabs, hammers or

buckets. Könicke off ers the full range of options for

equipment and upgrading. The necessary (re)fi t-

ting of machines with quick couplings is supported

by HANSA-FLEX as well as for hoses and piping.

Könicke also relies on HANSA FLEX‘s expertise when

reconditioning used machines and maintaining the

hydraulics of its rental

equipment.

For example, hydraulic cylinders can be repaired at

short notice at the specialist centre of competence

in Königshofen. Sealing kits are swiftly ordered

from Eisenberg when required. HANSA-FLEX has

an extensive range of standard items to off er. The

company can also manufacture new non-standard

seals thanks to a well-assorted stock of primary

materials.

The specialist centre of competence for hydraulic

components at Dresden-Weixdorf has proved its

worth where cooperation is concerned. Könicke‘s

installation points can be supplied with spare parts

such as valves, hydraulic cylinders, measuring de-

vices etc. from a range of over 4,500 diff erent hy-

draulic components.

Particularly high expectations are involved when

Könicke‘s rental equipment is concerned. These

machines were used for example when the runway

at Leipzig airport was resurfaced section by section

virtually overnight. Here full trust was placed in the

reliability of the equipment as any delay was out of

the question: All work had to be completed by the

time the fi rst aircraft was scheduled to take off the

following day.

In Könicke‘s sales region of North Germany Volvo

construction machinery is available for hire at ten

locations. This not only shortens the journey to

More power when serving the construction industry“That goes together”


CONSTRUCTION MACHINERY

the building site but also saves contractors a return

trip as Könicke operates a so-called One-Way Sys-

tem for its rental machinery. This means a machine

can be picked up at one branch and dropped off at

another.

Customer proximity as a recipe

for success

With an individual full-service package Könicke

ensures optimum performance for construction

machinery combined with minimum downtimes.

This package extends from a professional advice

service as regards all queries about usage through

continuous maintenance to the provision of practi-

cal assistance and training.

Könicke thus does not abandon its clients once they

have its equipment and is consistently developing

its proximity to the customer. Over 300 staff are on

hand to off er help – sometimes round the clock –

throughout the region at any time. It is a fast re-

sponse, fl exibility and quality that count here. To

ensure this Könicke strives for proximity to the cus-

tomer, maintaining numerous branches in its sales

region and constantly expanding this network.

This service-provider is an ideal complement to

HANSA-FLEX, as the hydraulics company from

Bremen also relies on a dense network of sites and

is never far from the customer thanks to its mobile

FLEXXPRESS service vehicles. This also applies to

Könicke‘s customers: no matter where a rental ma-

chine for example is in use, a FLEXXPRESS service

vehicle can be dispatched there to ensure a fast

hydraulics service.

This successful cooperation is coordinated by

HANSA-FLEX‘s regional manager Thomas Hellmann.

Marcell Ollesch, Managing Director at Könicke,

greatly appreciates the cooperative relationship of

trust with HANSA-FLEX that has proved its worth

over many years. As he put it, “Our machines have

to work, and that‘s why HANSA-FLEX is the right

partner for us, guaranteeing the ability to deliver,

quality, engagement and a focus on service!”.

The cooperation between Könicke‘s regional fi t-

ters and HANSA-FLEX is especially advantageous.

The mobile fi tters are effi ciently supported by

HANSA-FLEX‘s dense network of branches. When-

ever they need a hydraulic spare part, it is quickly

available from one of HANSA-FLEX‘s sites nearby.

At the same time they are always certain of getting

tested quality parts they can rely on. “That goes

together very well,” was the verdict of Marcell Ol-

lesch, who is already looking ahead. He is currently

considering whether to station special containers

with spare parts for construction machinery for

his regional fi tters at the branches of HANSA-FLEX

based in Könicke‘s sales region.

But this is just one of the many ideas which can

be used to step up the successful cooperation be-

tween the two service-providers. It is currently

under discussion whether the FLEXXPRESS service

technicians in the region of North Germany should

be trained by Könicke to deal with Volvo‘s current

range of construction machinery. This means they

could work on the equipment at any time without

the machine operator being present. And the shop-

in-shop concept already successfully practised by

HANSA-FLEX with other customers is the subject of

future plans. All considerations revolve around one

objective: to provide even more eff ective support

to the customers of the construction machinery

specialist.


ADVERT

HANSA-FLEX International

As one of the leading system providers for fl uid technology the German industrial enterprise HANSA-FLEX is a reliable and profi cient partner for high-performance companies worldwide.

With new emerging markets in Lin-gang south of Shanghai HANSA-FLEX contributes its share in the vast de-velopment of this new metropolis.As from 2008 you have the exclusive possibility to rent halls with sizes between 200 and 5000 sqm for your business from the German company HANSA-FLEX.

Benefi t from the adavantages of a sopho-sticated transport connection in Lingang and the vicinity to a modern airport in Pudong.

For further information on our special rent off er please contact:

Germany, Bremen:Thomas Armerdingt.armerding@hansa-fl ex.com

China, Shanghai:Wang Fangwang.fang@hansa-fl ex.com

GERMANY

HANSA-FLEX‘s Oldenburg branch“No can do just won‘t do”

“Full House” was the cry when HANSA-FLEX‘s Olden-

burg branch staged an open day to celebrate 20 years

of existence at the beginning of September 2007.

Founded on 1 November 1987 and boasting 23 staff ,

it is now one of the Group‘s major branches and has

meanwhile acquired an impressive number of regular

customers.

Branch manager Jens Bruhn primarily attributes

this success to the high motivation of his staff and

the resulting level of customer satisfaction. “No

can do just won‘t do” is the motto of the Olden-

burg branch. No customer is allowed to leave the

branch without a solution to his problem. “And

even if it‘s just a telephone number where he can

fi nd help for a specifi c dilemma.” Something, says

Jens Bruhn, that is acknowledged by customers in

the long term. Such little tips foster relations based

on partnership that even lead to the branch being

involved in the activities of OEMs as a supplier for

fl uid technology. This was the case for example

with a manufacturer of municipal equipment based

in Wildeshausen. But major OEMs in the sectors of

construction machinery and industrial locomotive

engineering are also linked with the Oldenburg

branch. Something that is unusual for a region that

tends to be characterised by small and medium-

sized enterprises and where the provision of spare

parts is the key topic of conversion at the counter. To

ensure that customers receive expert advice at the

shop or on the telephone before a sale is made eve-

ry employee should attend training, where possible

twice a year. Since 2006 service from the Oldenburg

branch has included the close involvement of a

FLEXXPRESS vehicle. This guarantees fast help both

day and night thanks to a high level of commitment

whenever hydraulics repairs are required.

Progressing in big steps

Industrial installations on the other hand are

generally projects that are planned a long time

ahead. After HANSA-FLEX had submitted a number

of quotes for performing industrial installations

on behalf of customers, its engagement in this

sector opened up a new fi eld of business: indus-

trial installation. This expertise has come about

through cooperation with HANSA-FLEX‘s special-

ist centres of competence such as cylinder repairs

at Königshofen or the Schönebeck pipe bending

centre. Initially Clemens Otte was responsible at

HANSA-FLEX‘s branch for looking after customers

in need of hydraulic components or cylinders. He

soon started receiving enquiries, asking whether he

couldn‘t also arrange for the associated installation

work to be performed. Orders for installation were

consequently accepted and handled by the branch.

The trust placed in HANSA-FLEX‘s skills in this sec-

tor grew – industrial installation at Oldenburg

meanwhile started operating in the market as an

independent HANSA-FLEX business. Strategic use is

made of this industrial service in cooperation with

the Bremen Group, where Reiner Plöger is a key

player in terms of development. This relieves the

FLEXXPRESS vehicles based in the region of dealing

with long-term installation projects as they are de-

signed to provide fast help.

For the future, HANSA-FLEX‘s Oldenburg branch

is planning on training its own staff and currently

employs two apprentices in the commercial sector

and warehouse logistics. There Oliver Steenberth

has accepted HANSA-FLEX‘s off er and will train to

become a qualifi ed hydraulics technician in Dres-

den. This training profi le has been developed by

HANSA-FLEX itself to overcome the shortage of

qualifi ed staff for hydraulics. Oliver Steenberth is

one of the fi rst fi ve youngsters to take part in this

course, which ends in an examination taken before

a chamber of commerce.


ASPHALT MINING PLANTS

Anyone wanting equipment for roadworks with bi-

tumen goes to Benninghoven. This company, whose

exhibition stand was recently a key attraction for

customers at the BAUMA in Munich, is a leading

manufacturer of asphalt mixing plants both in Ger-

many and abroad.

Benninghoven was founded by Otto Benninghoven

at Hilden, Germany in 1910 and originally built gear

wheels and special-purpose machinery. At the be-

ginning of the 1950s the company diversifi ed into

the fi eld of industrial combustion technology and

then broke into the asphalt industry at the start of

the 1960s. Its fi rst products included burners, dry-

ing drums, bitumen systems and mastic asphalt

equipment. The ever-growing demand for Ben-

ninghoven‘s quality products forced the company

to step up production in 1970 when a modern new

production plant was built at Mülheim/Mosel.

Another major expansion then followed at Wit-

tlich in1990 when a new plant equipped with the

latest production technology was commissioned.

Today the Benninghoven Group carries out manu-

facturing at both sites. For almost a hundred years

the operations of this Group have been character-

ised by tradition and a pioneering spirit as well as

trend-setting technology and a highly qualifi ed

workforce. This guarantees constant innovation

and orientation to the needs of the customer. Over

600 employees work to uphold the good reputation

of Benninghoven products throughout the world.

Benninghoven specialises in transportable and

mobile asphalt mixing plants. Such systems, which

are designed in container form and are almost little

asphalt factories of their own – are mainly used on

large building sites and off er a mixing capacity of

up to 320 tonnes/hour. Bitumen is used as water-

proofi ng for buildings and in road construction as

a binding agent between mineral materials, known

as asphalt.

The high production level of Benninghoven tech-

nology is clearly demonstrated by the Concept

Type TBA equipment series. Although this plant is

designed for stationary operation, it can also be

quickly relocated elsewhere. These transportable

bitumen and asphalt mixing systems are made up

of modular elements, so they can be easily trans-

ported by sea, rail or road. On arrival at the instal-

lation site, they are quickly assembled as every

individual section of the plant is already equipped

with cables and pipework so the system is immedi-

ately ready for operation. Incidentally, such mixing

plants can also be set up without fi xed foundations

and off er optimum conditions for inspection and

maintenance thanks to generously dimensioned

walkway platforms to all sections. The entire sys-

tem is controlled using the latest computer and

process technology.

Here today, gone tomorrow

To ensure the fl exible and effi cient supply of as-

phalt and bitumen to small or mobile roadworks,

Benninghoven manufactures so-called roadmobile

mixing plants. These can be dismantled in a matter

of days and set up at another site ready for operation

as they are mounted on a chassis frame. This does

away with high costs for cranes and transport. The

mobile bitumen mixing plants can even be shipped

complete in a cargo plane. All pipes are prefabri-

cated on the systems supplied with blending und

batch mixing units and can be used at another site

at any time thanks to fl exible connections. These

plants off er a capacity of up to 200 tonnes/hour

and are designed for set-up by the customer with-

out help using his own staff . But Benninghoven‘s

portfolio also includes smaller very compact high-

mobility plants of the Batch Mobile type, which can

operate at a rate of 80 tonnes/hour.

When using hose lines, it must be borne in mind

that asphalt boilers are sometimes subject to tre-

mendously high temperatures. For over 20 years

Benninghoven has relied on HANSA-FLEX for the

hydraulic systems and piping of its asphalt mixing

Advising customers is a tough jobSo the mixture’s right


ASPHALT MINING PLANTS

plants. As a systems partner the hydraulic service-

provider has watched its customer become a key

international player in the course of their coopera-

tion, providing active support here so that over the

years a high level of trust has built up in the hydrau-

lics expertise of HANSA-FLEX.

Wolfgang Caspers from HANSA-FLEX‘s branch at

Wittlich has looked after this customer from the

outset. He is the man the technicians at Benning-

hoven turn to when a change in the existing hydrau-

lics system is planned or an entirely new machine is

to be developed. From the start the manufacturer

takes advantage of the latest systems know-how

off ered by HANSA-FLEX to come up with optimum

technical solutions.

This is of great benefi t to Benninghoven‘s Devel-

opment department: the early involvement of the

hydraulics experts from HANSA-FLEX help to avoid

cost traps which might have an adverse eff ect on

subsequent serial production.

Convincing industrial design

The joint search for the best solution in the hydrau-

lics sector does not just stop at providing advice but

is a pretty tough job as Benninghoven‘s product

developers require hands-on assistance. Calling for

Wolfgang Caspers to clamber about with the sam-

ple hose lines in installations which may already

be the size of a multi-storey building. He deter-

mines the fi nal dimensions on the spot, measures

the angles of curvature for the fi ttings and works

out the optimum routing and fi xing options for

hose lines and hydraulic pipes, including in terms

of their visual appearance. These data are used to

quickly put together samples and test them on the

pilot systems. Modifi cations are made and tried out

without delay until the optimum technical solution

has been found.

But the idea is not just for the plants to comply with

state-of-the-art technology but to also uphold

Benninghoven‘s claim of being a future-oriented

company thanks to modern design. Benninghoven

sets great store by ensuring that all plants look aes-

thetically appealing and blend in with their envi-

ronment thanks to their individual colour scheme.

For this manufacturer good industrial design is a

matter of course. This not only calls for a modular

concept but also optimum design for the routing

and fi xing options for hydraulic pipes and hose

lines. Sometimes success may depend on the visual

appearance of a plant in this fi ercely competitive

market.

Wolfgang Caspers is always on the lookout for the

right solutions to satisfy all the requirements made

by this customer on bitumen mixing plants. Com-

mitment that impresses Hermann Becker, purchas-

ing manager at Benninghoven. “We are after serv-

ice-providers who off er optimum support when it

comes to cutting costs and boosting performance.

Thanks to the engagement shown by Mr Caspers

we always fi nd ways off ering advantageous solu-

tions for fl uid technology,” comments Hermann

Becker, delighted with the long-term cooperation

with HANSA-FLEX.


TRAINING CENTER

“fl uid award” for HANSA-FLEXAn award-winning article

The renowned journal “fl uid” asked its readers to

chose the best articles published in recent years and

so select the “Product of the Decade”. 16 articles

which had attracted the greatest Interest among

readers were shortlisted for the fl uid award. Here

an impressive second place went to an article from

HANSA-FLEX, in which Helmut Wetteborn wrote

about the regulations and risks involving hydraulic

hoses.

The journal “fl uid” has a fi rst-class reputation in

the hydraulics sector. The article from HANSA-

FLEX deals with connection technology and line

engineering and explains using a presentation

made by Helmut Wetteborn how legal provisions

aff ect practical application and what circum-

stances are in particular relevant for the user. The

award of “Product of the Decade” demonstrates

that such practical relevance was greatly appreci-

ated by readers. With 20 percent of the votes the

article entitled “Nur kein Risiko eingehen – Vor-

schriften und Richtlinien für Hydraulikschläuche“

beat others to second place. At a ceremony held

on 6 September 2007 Managing Director Thomas

Armerding and Helmut Wetteborn were presented

with the award in the form of a sculpture as well

as a prize certifi cate at the publishing house Verlag

moderne industrie. This award is something that

HANSA-FLEX can rightly be proud of and pays trib-

ute to the company‘s eff orts in focusing attention

on hydraulics to ensure safety for line engineering.

In the award-winning article Helmut Wetteborn

not only discusses the risks involved in hydraulic

line engineering but also draws attention to vari-

ous rules and regulations. Line engineering is sub-

ject to the occupational health and safety laws, the

equipment and product safety act and the indus-

trial safety regulations. In other words, there are a

number of regulations, standards and laws which

need to be strictly observed where hydraulic line

engineering is concerned. A lack of proper care may

constitute negligence here. This applies to both the

installation and the operation of hydraulic systems.

HANSA-FLEX is aware of the responsibility incum-

bent on the company and actively passes on this

knowledge to its customers - after all, it‘s no mean

feat fi nding one‘s way about the maze of rules and

regulations. For this reason there is a strong em-

phasis on the aspect of safety in the courses held at

HANSA-FLEX‘s training centre.

DIN EN 982 as the focus of

attention

In his article Helmut Wetteborn looks closely at DIN

EN 982, which describes the safety requirements on

fl uid systems. This basic safety standard obliges the

manufacturers of fl uid systems to perform risk as-

sessment as well as their suppliers and operators.

Here, comments Wetteborn, it is important to use

the list of risks which covers the entire life cycle of

a machine, from design to the modifi cation of new

plants. This standard describes measures which can

be used to avoid hazards. A lack of information does

not help in the event of a loss; a lack of knowledge

may however result in negligence.

The article includes practical tips for considering

line engineering more carefully without using radi-

cal measures. Sometimes there are often very sim-

ple low-cost options that are adequate to ensure

safe design, manufacture and installation of line

systems.

And Helmut Wetteborn is delighted that the “fl uid

award“ has paid tribute to HANSA-FLEX‘s eff orts of

raising the awareness of customers for safety in the

fi elds of connection technology and line engineer-

ing, so ensuring the effi cient and safe application of

fl uid technology.

“fl uid” chief editor Mr. R. Schenk, advert management Mrs. G. Claus, Mr. H. Wetteborn and Mr. T. Armerding


TRAINING CENTER

There are a number of options available when cal-

culating pipe wall thicknesses. Each one produces

diff erent results. HANSA-FLEX off ers transparency to

make sure there is no uncertainty in practical applica-

tion when it is a question of calculating and building

pipework. Helmut Wetteborn, author of the manual

entitled “Hydraulische Leitungstechnik” currently un-

der preparation and an acknowledged expert in this

fi eld, told HYDRAULIKPRESSE what needs to be taken

into account when calculating pipe wall thicknesses.

Hydraulic pipes are ideally suited to low-loss trans-

mission of hydraulic force. Such components can be

incorporated in the machine or equipment system

according to the requirements, are safe and provide

for the use of all modern connection technologies.

Piping can be selected according to technical de-

livery specifi cations. The dimensions are standard-

ised, and tried and tested materials ensure reliable

operation.

But what knowledge is required for the design and

dimensioning of hydraulic pipes? “Limits and con-

ditions of usage as well as rigid pipe walls can be a

delicate matter and entail risks if they are not given

a design that is technically correct and economi-

cally necessary,” explains Helmut Wetteborn.

Once the required sectional area of fl ow has been

calculated, the next priority is to determine the wall

thickness. This depends on the actual pressure of

the hydraulic fl uid and the operating temperature.

Fig.1 Pipework system

The actual pressure is the total of the operating

pressure and any additional pressure such as peak

pressure and pressure peak (see also DIN 24312

“Pressure – Quantities – Terms”). The actual pres-

sure is a variable that depends on the work load of

the machine or equipment.

The operating temperature level causes reductions

in pressure which for example at all events amount

to 11.5% with stainless steel pipes in the tempera-

ture range between 50 °C and 100 °C. A steel pipe

does not show such negative behaviour in this tem-

perature range.

If fundamental infl uences such as pressure or tem-

perature are not taken into account suffi ciently

when calculating the wall thickness, this will inevi-

tably lead to burst pipes through overloading of the

hydraulic piping.

Fig. 2 Burst pipe

Properly curved

Pipework systems do not just consist of straight

pipes. The spatial conditions, position of the con-

nections and using the natural elasticity of the pipe

means that pipes do not run in straight lines. What

requirements result here?

Bending pipes weakens the thickness of the pipe

wall by stretching the outer fi bres of the pipe mate-

rial, something that needs to be counteracted here.

We therefore make a wall thickness allowance. This

can be calculated and depends on the bending ra-

dius of the pipe.

Depending on the tools used for bending and the

skill of the fi tter, the pipe will become more or less

oval in shape at its bend This is known as being

out-of-round in technical terms and should not

exceed the permissible limits. This circumstance

also aff ects the pipe‘s resistance to pressure. Such a

quality defect is often not realised and is underesti-

mated, with cracked pipes being the result.

In many cases repair welding is carried out to make

the pipe serviceable again. This is however not per-

mitted as DIN EN 13480-4 states that no welded

repairs are allowed.

In this case the safety aspect according to DIN EN

982 is disregarded:

• Components must be reliable

• Components must withstand the maximum

pressure

• Components may only be used within specifi ed

limit values.

Fig. 4 Pipe bending - out-of-round

How thick do you want it?Calculating pipe wall thicknesses correctly

Fig. 3 Hydraulic pipes


TRAINING CENTER

Wall thickness details

• Necessary wall thickness

• Compression and dilation of bending

• According to DIN EN 13480 or EDIN 2413

Tube wall “s“, internal pressure

according to EDIN 2413

or DIN ISO 10763

Bend radius R Prerequisites :

altered wall thickness through

bending, allowable out-of-round-

ness: < 10% in the bend

Out-of-roundness [%]

according to DIN EN 13480-4

or EDIN 2413

Hydrostatic test -

Test pressure calculated

according to EDIN 2413

Outer diameter

D

d

• Selection “Minimum wall thickness for plain tube” according to DIN ISO 10763

• Compared to DIN 2413 “Steel tubes”, load grade I and III (standard withdrawn)

• Calculated according to EDIN 2413 “Seamless steel pipes for fl uctuating stresses, bases of

calculation for tubes/ bent tubes”

* Load grade I = Dead load up to 120°C

* Load grade III = Cyclic loading up to 120°C

** Range of stress = Calculated pressure, shortfall of wall thickness by 12%

Dimensions DIN ISO 10763 DIN 2413 * EDIN2413**

I III

PR 12-1,5 259 353 305 302

PR 16-2 259 353 305 302

PR 22-2,5 232 320 280 275

PR 25-2,5 201 282 249 245

PR 30-3 201 282 249 245

PR 42-3 139 201 182 180

Calculation wall thicknessInternal pressure according to DIN ISO 10763, DIN 2413 (withdrawn) and EDIN 2413, calculated

pressue [bar], comparative value for material 1.0255 (St 37.4).

This results in objectives for designing hydraulic

pipes according to the requirements. The top prior-

ity here is the responsibility and safety laid down

by law.

The following applies to a pipe:

• Inside pipe diameter to be calculated according

to the fl ow ratios

• Thickness of the pipe wall to be calculated as a

function of the actual pressure, operating tempe

rature, bend and degree of out-of-round

• Thermal expansion of pipe to be taken into

account

• Mounting of pipe or pipe systems to be in line with

requirements.

Calculation / determination of the pipe wall thick-

ness can be carried out according to a number of

standards:

• EDIN 2413 “Nahtlose Stahlrohre für schwellende

Beanspruchung” (relating to seamless steel pipes

for fl uctuating stresses)

• DIN ISO 10763 “Nahtlose und geschweißte Präzi-

sionsstahlrohre” (relating to seamless and welded

precision steel pipes)

• DIN EN 13480-3 “Metallic industrial piping”

• DIN 2445-2 “Nahtlose Rohre für schwellende

Beanspruchungen” (relating to seamless pipes for

fl uctuating stresses)

• DIN 20066; Table 1 “Übersicht der Schläuche und

Zuordnung der Rohre” (relating to an overview of

hoses and allocation of pipes)

The dilemma of standards

These numerous options for calculation unfortu-

nately lead to diff erent results for the same pipe

under identical conditions: an impossible situation

for the responsible design of wall thicknesses. Fig. 4

shows examples for the calculation of permissible

design pressures. It reveals wide variation, some-

thing that is unacceptable in practice.So-called

“good technical engineering” and practical expe-

rience are what is needed here. This will ensure a

viable result when used in agreement with the ap-

plicable standards DIN ISO 10763 or EDIN 2413.The


TRAINING CENTER

prerequisite here is always that the wall thickness

for the straight pipe is fi rst calculated or taken from

relevant tables. In all cases the straight pipe forms

the basis for selection according to the pressure

parameters.

The following thus applies:

• Application of DIN ISO 10763 when the client

specifi cally wants his pipework system to be

designed with a 4-fold safety factor in relation

to the internal pressure

• Application of EDIN 2413 under consideration of

the typical fl uctuating load caused by the

internal pressure with a safety factor identifi ed

by the strength characteristic.

Both calculation approaches come to results that

are valid under the above conditions and ensure

safe hydraulic pipework. This applies both to steel

and stainless steel pipes. The infl uence of the pipe

bend and the property of out-of-round is deter-

mined by further calculations. The necessary in-

crease in pipe thickness is calculated in line with

actual practice using alternative methods accord-

ing to DIN 13480-3. Here the bending radius of the

pipe is taken into account, however for example

not a 90° or 180° bend (see Fig. 7). This calculation

method thus includes reserves which are advisable

as pipes are subjected to enormous stresses, for ex-

ample by:

• external forces such as fi tting, thermal expansion,

vibrations

• dynamic eff ects of hydraulic fl uid

• changes in pressure and temperature

The property of out-of-round is more than just a

visual fl aw at the pipe bend! “In practical terms this

impairs the transverse stiff ness of the pipe cross-

section with fatal consequences for pipe strength

- for this reason, there is a permissible level of out-

of-round,” states Helmut Wetteborn. This value is

specifi ed in percent. The permissible level of < 10%

is simultaneously also a quality feature for the pipe

bend.

Fig. 8 shows realistic examples for pipes from the

standard pipe material 1.0255 = St 37.4. The pipe

section on the left shows an out-of-round value

of 7.08%, which is still permissible. The section on

the right however shows an out-of-round value of

16.7% and therefore may not be used for fi tting.

Pipe bends should therefore be examined with a

critical eye.

Conclusion

There are reliable calculation options to ensure

responsible dimensioning and thus the safe opera-

tion of hydraulic pipework. The current standards

represent state-of-the-art technology and must be

taken in account without fail. Want to know more?

Then contact the Technology department or Helmut

Wetteborn at the training centre.

Calculation of allowance for bending according to DIN EN 13480-3, chart “Minimum wall

thickness for bending” (abstract)

Bend radius Minimum wall thickness before bending

Standard method Alternative method

R = 1,5 · D 1,15 · s 1,25 · s

R = 2 · D (variable) 1,10 · s 1,20 · s

R = 3 · D 1,06 · s 1,13 · s

s = requested minimum wall thickness for plain tubes

Calculation wall thickness

Fig. 7 Wall thickness allowances for bending


Mail your entries to ma@hansa-fl ex.com or post them to HANSA-FLEX Hydraulik

GmbH, Marketing Department, Zum Panrepel 44, 28307 Bremen, Germany .

Please include your name and address. Entry deadline: 19th November 2007.

Only one entry per participant. Any recourse to legal action and any liability

shall be excluded to the extent permitted by law. The prize may not be paid

out in cash.

Quiz

QUIZ | SEMINARS | TRADE FAIRS

Correct answer issue 08/07:

Stage 30 (Lhasa - Kathmandu)

Win an iPod nano!

Just answer the question correctly and an iPod nano 8

GB could be yours!iPod Nano, 8 GB (up to 2000 tracks), colour:

black or silver; incl. earbud headphones,

USB 2.0 cable, dock adapter, Software

iTunes for Mac & Windows; requirements

PC: USB 2.0, Windows XP Home or Professi-

onal Service Pack 2 (or newer), iTunes 7.4;

requirements Mac: USB 2.0, MAC OS X 10.4.8

or newer; (actual product may diff er from

displayed image)

10.10. - 13.10. PTC Asia 2007 Shanghai, China

18.10. - 23.10. VIIF 2007 Hanoi, Vietnam

23.10. - 26.10. Interdrive 2007 Moscow, Russia

05.11. - 10.11. FIHAV La Habana, Cuba

07.11. - 10.11. suisse transport Bern, Switzerland

11.11. - 17.11. Agritechnica Hannover

25.11. - 29.11. BIG 5 PMV 2007 Dubai, UAE

27.11. - 30.11. International Industrial Forum Kiev, Ukraina

27.11. - 30.11. Marintec China 2007 Shanghai, China

Trade fair announcements

11.10. Grundlagen der Leitungstechnik Bremen

15.10. – 19.10. Grundlagen der Fluidtechnik Teil 1 Dresden-Weixdorf

23.10. – 26.10. Grundlagen der Fluidtechnik Teil 3 WXD


12.11. Grundlagen der Dichtungstechnik Eisenberg


15.11. Grundlagen der Leitungstechnik Bremen


For further information please contact Mrs. Silvana Schubert (Schulungszentrum Weixdorf): +49 - 3 51 - 41 39 719.

Training seminar schedule October – Dezember 2007 IN GERMAN ONLY

Winner issue 08/07: E. Gabriel, Munich

What is the name of the Indonesian village that in

2004 was destroyed entirely by the Tsunami fl ood

disaster and which was rebuilt with the fi nancial aid

of HANSA-FLEX and which is also stage during the

XWORLD Tour in 2009?

A: Sidikalang

B: Suak Nie

C: Bukittinggi


Read in the following issue:

Copy deadline: 3rd December 2007

LITERATURE | FIGURES & FACTS | PREVIEW

Preview

23

XWORLD adventure 2008/2009 100 days to go!

Conveyor technique How modern conveyor technique can optimise warehousing

In conversation Diethelm Kappe, regional manager

Terex Dortmund A brand new HANSA-FLEX service concept

Training center Proper utilisation of hydraulic fl uids

HANSA-FLEX branches Czech Republic

12/07

Schulungsbuch „Fluidtechnik“ | 25,00 EUR **

by Wolf-Rüdiger Schmidt, Helmut Wetteborn, Ulrich Hielscher

2nd edition | 292 pages | internal publication: HANSA-FLEX

DIN-Taschenbuch 174 | approx. 90,50 EUR *

Schlauchleitungen für die Fluidtechnik

4th edition | 472 pages | Verlag: Beuth | ISBN: 3410145451

Flüssiges Gold | approx. 25,00 EUR *

by Klaus Lange

93 pages | Published by: Hüthig | ISBN: 3778530259

Hydraulik | 59,95 EUR ***

by Dieter Will, Norbert Gebhardt, Hubert Ströhl

2nd edition | 373 p. | Published by: Springer | ISBN: 3540343229

** Training manual available at your nearest HANSA-FLEX branch

Recommended reading

Figures & Facts

172

86

GermanyTotal

305

158

Openings

*** Available at the HANSA-FLEX training center * Available in all bookstores

October 2007: HANSA-FLEX Hamburg-Billbrockdeich: 25 years, HANSA-FLEX Prague: 10 years,

November 2007: HANSA-FLEX Oldenburg: 20 years, HANSA-FLEX Arsten: 10 years, HANSA-FLEX Budapest: 10 years,

HANSA-FLEX Bucharest: 10 years, HANSA-FLEX Vogelsdorf: 10 years

September

HANSA-FLEX Hydraulik GmbH Kölner Str. 183 50226 Frechen Germany

October

HANSA-FLEX Hydraulik GmbH Am Mittleren Moos 13 86167 Augsburg Germany

HANSA-FLEX Hidraulinės Jungtys UAB Gamyklos g.33 89110 Mazeikiai Lithuania

HANSA-FLEX Hidraulika Bitenu iela 14 5101 Aizkraukle Latvia

November

HANSA-FLEX Hydraulik GmbH Hag 5 6410 Telfs Austria

Anniversary

HYDRAULIKPRESSEISSUE OCTOBER 2007

HP_2007_10_EN

Documents

Transcript of HP_2007_10_EN