Flange Survey Services


Flange Survey Services

Cutting-edge laser instrumentation for measuring wind tower flanges.

As any wind professional knows, the towers supporting massive turbines are far more complicated than they might appear from the ground, requiring incredibly precise manufacturing techniques and practices. Made of rolled steel segments attached by flanges, these increasingly tall tubular structures demand flanges that meet very tight flatness and parallelism tolerances.

Manufacturing the flanges is difficult enough, but many have also found difficulty in accurately measuring the flatness or quality of the flange. Achieving geometrical correctness is made difficult by the manufacturing methods used. During the welding of the flange segments and storage of the sections, tension and/or stress can be induced. This stress can change the dimensional characteristics of the flange/segment, making it out-of-spec and therefore rejected. This condition then requires additional labour and machining to correct the problem, driving up costs and delaying the schedules. The ability to detect and ultimately correct these geometric features ensures a faster production schedule.

Laser Flange Measurement

Flanges are essentially joints, so they must be machined properly in order to avoid tension during or after coupling, and also to ensure water tightness of the coupling faces. Achieving geometrical correctness is made difficult due to the manufacturing method. During the welding of the flange segments together or during storing of the sections, tension and/or stress can be induced. The ability to detect and ultimately react to these dangers ensures a trouble-free service life. Traditionally older methods would mean that you had to rely on straight edges and feeler gauges to accurately measure flatness on flanges. This method is fine as long as the objects are smaller than the straight edge, but with segmented, chained, or overlapping measurements the problem of surface waviness arises. This created the need for modern measurement tools, methods, and techniques to be able to combat these problems in a fast and easy way. By using the Status Pro flange laser system, it became possible to measure the entire flange against a constant reference; an ultra-flat plane of laser light.

This is done by firstly mounting the laser directly on the flange allowing the laser beam rotation to effectively produce a laser plane. Using the laser receiver, we are able to measure the distance between the flange surface and the laser plane very accurately. By simply allowing the laser to rotate 360 degrees, this produces an ultra-flat plane of laser light. Using the hand handheld PC/Tablet and appropriate flange flatness software real-time results are provided. Again, using the hand-held tablet a measurement report in PDF format is produced, and the data can also be transferred as a CSV file into other types of software for further analysis if so desired. Consequently, evaluation of the raw data is possible with most programs and applications.

RSL are able to offer flange flatness verification using sub millimetre total stations and Status Pro measurement systems. Using the status Pro Flange system, we are able to accurately measure machined flatness to within 0.2mm.

This enables RSL to complete flange surveys of any size. Bolt hole diameters can also be surveyed for the following parameters to specified tolerances.

“RSL One have been the go-to company for professional dimensional surveying for all of our large complicated structures which have been manufactured over the past 27 years.  RSL pride themselves on service, quality and have a real can-do attitude and it’s been a pleasure working with the company and we look forward to enjoying further success between the two companies”. 

Bill Scott OBE
CEO, Wilton Universal Group

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