Keeping calm during an oil accident - Hansa Flex

Keeping calm during an oil accident - Hansa Flex

Issue 01/2009



Keeping calm during an oil accident

Safety measures for accidents involving hydraulic equipment














CoNteNt HYDrAULIkpresse 02/2009

operation of rental machinery


on construction sites

sustainable climate protection


begins at sea

haNsa‑FleX reference book:

„hydraulische leitungstechnik“14 14

the Xworld reaches sumatra

and the village of suak Nie



Materials made up of oil are


hazardous waste

03 editorial

04 iN-house produCtioN – New hose liNes eVerY MiNute

Hydraulic workshop container in practice

06 sCreeNiNG bY a proFessioNal

short delivery times make extreme demands

08 poiNtiNG the waY with the sea

Off shore wind farm in the German Bight

10 "this booK helps to FiNd better solutioNs"

An interview with: Helmut Wetteborn (Dipl.-Ing.)

11 booK oF the Year

"Hydraulische Leitungstechnik", published by HANsA-FLeX

12 traiNiNG seMiNar sChedule oF the iha

14 GoiNG bY the booK

Want to know more about hydraulic line engineering?

16 wheN the tsuNaMi CaMe

The fl ood desaster of Indonesia

18 Field report: tuNNel CoNstruCtioN

Getting down to work – unforgettable experience in the tunnel

19 haNsa-FleX braNChes

The wizards of münster

20 worK & liFe

Actively preventing backache

22 JuNGle, steppes, the silK road

XWOrLD Tour is heading north

24 KeepiNG Your CalM duriNG aN oil aCCideNt

safety measures during accidents with hydraulic equipment

26 Materials Made up oF oil

Improper disposal is a criminal off ence

27 steppiNG oN the Gas

German FLeXXpress fl eet set to expand in 2009

28 staNdards siMpliFY ColaboratioN

HANsA-FLeX leaves its mark on international standards (IsO)

30 CurreNt VaCaNCies withiN the haNsa-FleX Group

31 quiZ | FiGures & FaCts | preView


editor / publisher:

haNsa‑FleX hydraulik Gmbh

Zum panrepel 44 · 28307 bremen

phone: 0421 ‑ 48 90 70

telefax: 0421 ‑ 4 89 07 48

e‑Mail: info@hansa‑


Compilation: dietbert Keßler, enrico Kieschnick,

horst otto (papp werbeagentur)

layout: Jan‑Christoph Fritz, Nadine beneke

photos: Julia ahlers

print: berlin druck ·

responsible for contents: wolfgang rink

Frequency: bimonthly

subscribe to the hYdrauliKpresse on our website.

peFC/04‑31‑0976 iVw certified 1st quarter 2008

issue FebruarY 2009

15th volume

dear reader,

Impress Foreword

This coming march the VDBUm conference is being held in Braunlage and HANsA-FLeX will once

again be present at this convention (VDBUm = German Association of Construction machinery engineers

and master Craftsmen). During its seminar on hydraulic line engineering HANsA-FLeX will

be speaking to experts from the construction industry as well as machine technology and process

engineering specialists – reporting so to speak from practical experience for practical applications.

As a partner to the construction industry, HANsA-FLeX has always managed to impress with its

special concepts. One of these involves a fully equipped hydraulics workshop, a 20' container with

everything required to quickly produce spare hose lines, for example on a large building site. We

report about practical application on page 4.

As a hydraulics system partner we offer our customers effective support whether in terms of theory

or practice. On the occasion of the VDBUm conference the book published by HANsA-FLeX will be officially

presented to the general public: "Hydraulische Leitungstechnik" by Helmut Wetteborn (Dipl.-

Ing.). This book closes an important gap in scientific knowledge about the fluid technology and will

be personally introduced by the author to the experts gathered in Braunlage. In the publication he

has set particular store by its clear and comprehensive structure. Over 832 pages, this practical and

proficient reference book tells engineers and technicians everything they have ever wanted to know

about hydraulic line engineering, featuring numerous illustrations and diagrams for greater clarity.

This work, which has been lacking in the hydraulics sector for many years, is essential to anyone who

needs sound facts about line engineering and wants to play safe when planning, dimensioning and

dealing with hydraulic systems. Whether you are a designer, technician, fitter or still a student, this

practical manual will help everyone who is concerned with the safety and efficiency of hydraulic


In everyday practice we have noticed that many people who regularly deal with hydraulic systems

are not well informed about the proper procedures following an accident involving hydraulic oil. Yet

it is rather straightforward, and on page 24 we will tell you about the key facts.

International agreements are also becoming increasingly important in the world of hydraulics. On

page 28 you can find out how HANsA-FLeX, in an awareness of its own responsibility, takes part in

technical work groups of the International Organization for standardization (IsO) to ensure greater

compatibility worldwide and thus greater safety in the hydraulics sector.

the MaNaGeMeNt

dieter h. seidler, uwe buschmann, thomas armerding


asseMblY CONTAINer

In-house productIon

NeW HOse LINes eVerY mINUTe

The use of leased machinery is becoming increasingly important on building sites. Whether a crane or excavator is involved, contractors

rarely tie up their capital in new machinery if they are only going to need it on a single site.



Whenever building goes on in the east

Westphalia-Lippe region (southern Lower

saxony), a machine leased from Grotemeier

is almost always involved. This company has sold and

hired out construction machinery and equipment

for over 80 years, offering a complete programme

for structural and civil engineering contractors, road

works, bulk material handling technology for industry,

gardening, landscaping and agriculture.

This company not only specialises in the sale of construction

machinery, but also leasing, and is known

for its expert advice and cost-efficient solutions.

The range of equipment available for hire includes

more than 100 machines – vehicles and machinery

solely from reputable manufacturers of construction

machinery. Whatever customers need, it is available:

130 meter-ton building cranes, bulldozers, wheel

and telescopic loaders, hydraulic excavators and

special machines designed for instance for demolition

or tunnelling. Besides the standard equipment,

Grotemeier can also offer an extensive range of special

machinery: hydraulic hammers, drills, pliers for

pipe fitting, tree stump cutters, work platforms and

many other items. Grotemeier not only keeps 10,000

spare parts in stock for this construction machinery,

but also offers customers a wide range of services. 20

fitters alone are at the beck and call of customers –

including outside its official opening hours.

tiMe is MoNeY

speed and quality are Grotemeier's objectives. In the

building industry what counts is offering customers

fast, capable assistance. It was the company's service

philosophy that prompted it to set up its own

HANsA-FLeX hydraulics workshop. Workshop managers

Jörg miley and Frank sonntag had been looking

for a fundamentally new approach and then

found it in the shape of HANsA-FLeX's hydraulics

workshops. mD Uwe Grotemeier was likewise won

over by the idea of fitting out a container as a fully

equipped workshop. A swift review of this solution

was followed by the joint decision to incorporate

such a hydraulics workshop in the production processes

of the company.

The 20' container has been fitted out as a complete

hydraulics workshop and includes everything

needed for the speedy manufacture of spare hose

lines. Besides a set of basic equipment with standard

hydraulic hoses and pipes, fittings, connectors and

tools, the workshop also contains a hose press with

a fast-change system as well as a peeling machine

and a cutter. One major advantage of this hydraulics

workshop is that it can be stocked with the materials

specified by customers.

Once Grotemeier had decided to set up a hydraulics

workshop, the first step was to get together with Jörg

Heitlindemann from HANsA-FLeX's Bielefeld branch

to draw up a list of equipment for the container. They

worked out what components are needed by the customer,

and what hose lines have to be available and

in which numbers. The arrangements for the restocking

service were also agreed, with the Herford branch

being assigned the task of filling up the shelves at

regular intervals. No charge is made for the materials

in the container until a Grotemeier fitter removes a

hose line from the store.

Besides the machines needed to produce hose lines,

the container is also equipped with a delivery programme

geared to the customer's requirements.

This includes all hoses in nominal widths from

DN 6 - DN 25, fittings and screwed connections according

to various specifications. HANsA-FLeX also

supplies and stocks special hose lines with larger


properlY brieFed

Well organised shelving, hose reels, electrical connections,

optimum lighting and a non-slip floor all

go to make the container a productive workplace:

the technicians at this construction machinery company

now have all the hydraulic hose lines they need

at their fingertips. They no longer waste time waiting

for supplies or going out to pick up parts: Whenever

a new hose line is needed, it is quickly made up and

ready in a matter of minutes. something that of

course has a positive impact on costs – not to mention

the quality of service that Grotemeier can now

offer customers. As a service-oriented business, the

firm now has a winning argument vis-à-vis customers

in the guise of the hydraulics workshop.

The container workshop also comes in especially

handy for leased machinery: only the shortest of

downtimes is acceptable here. If a fault occurs in

a hydraulic line on site, the contractor hiring the

machine expects immediate help. Thanks to the

hydraulic workshop, the Grotemeier service vehicle

dispatched for such repairs will already have the required

item on board, so optimising the availability

of fitters and materials for the customer. As Grotemeier

operates to industrial standards, all hose lines

it manufactures are marked with a unique identification

number, something that may be important for a

warranty claim.

To ensure that Grotemeier's staff can make optimum

usage of the hydraulics workshop, they were already

briefed about hose production and operation of the

internal and external peeling machine and the hose

CONTAINer asseMblY

press during the preparatory phase. FLeXXpress

service technician Frank Hausmann was entrusted

with this task as the equipment used in the hydraulics

workshop is the same as the machines in the

FLeXXpress vehicles. Having worked as a service

technician for years, he was naturally able to instruct

Grotemeier's fitters not only about the standard skills

involved, but also offer many valuable tips from his

everyday practical experience.

equipped with all necessary tools and spare parts the

mobile hydraulic workshop unit offers the perfect solution to

manufacture custom‑made hose lines on‑site and in no time


Full serViCe DOppsTADT

screenIng by a professIonal

sHOrT DeLIVerY TImes preseNT TremeNDOUs CHALLeNGe

Waste utilisation and recycling are more important during times of shortage of raw materials.

For this purpose high-capacity reprocessing plants are required for an effi cient waste


In December 2008 a training course at Doppstadt

Calbe GmbH concluded with a joint dinner of suckling

pig, by invitation of HANsA-FLeX. IHA training

manager Ulrich Hielscher introduced the staff of

this waste processing machine manufacturer to the

subject of pipe connection technology and its special

features. Not only does this enhance the know-how

and expertise of Doppstadt's fitters, but it also fosters

the team spirit amongst the staff.

To convert waste into a secondary raw material and

return it to the cycle of materials, it has to be processed

efficiently, as well as being broken up in most

cases. This is carried out by screening the pre-sorted

shredded product into several flows of material,

so-called fractions. Doppstadt is a specialist for the

machines and equipment needed here. Originally

founded as an agricultural business in Velbert, Germany

in 1965, the company has meanwhile developed

into a partner for environmental engineering

with a worldwide reputation.

Today a workforce of 90 people based in Velbert

are responsible for the planning, design and manufacture

of plants and for developing shredding

technology for mobile and stationary applications

in the waste management industry. such machinery

can be used to process materials such as waste

timber, domestic refuse, commercial, industrial and

organic waste as well as excavated earth and mixed

construction rubble, turning it into combustible fuel

substitutes such as pellets. Doppstadt's screening

machines from the sm series form an essential link in

this processing chain. Used for screening and classifying

compost in residual waste treatment systems and

for landfill excavation, they are used to filter out the

pre-shredded material and separate out undesirable

hard substances such as nonferrous metals, stones or


compact synthetics. What remains is a dry, homogeneous

mass that is rich in energy. The energy content

and options available for use of the new material are

a partial substitute for fossil fuels such as coal or oil.

Doppstadt has now been designing and building

trommel screen machines for 20 years. The universal

sm 620 is a professional high-capacity system. In its

name the "6" stands for the machine length of six

metres, and the "20" for the drum diameter of two

metres. Its rotating screening drum can easily cope

with even the most problematic of materials. Different

screen/mesh panels can be used depending

on the material involved. After screening, the fine

fraction (particle size < 40 mm) is conveyed to the

biological section of a plant. A load-sensing system is

used to control the supply of material to the drum, so

ensuring optimum utilisation of the screening area

over 28 m2 in size.

every year some 100 trommel screens leave the production

line at Velbert, with each one being made to

order. such "on-demand production" is a speciality

of this manufacturer: the modular system allows the

basic machine to be brought into line with the specific

requirements of the individual customer thanks

the wide range of available options.

FoCus oN serViCe reiNForCed

bY FraMeworK aGreeMeNt

Doppstadt can complete such customised orders

in next to no time. For suppliers such as

HANsA-FLeX this of course means being geared to

short delivery times. For years the Doppstadt account

has been under the watchful eye of the Düsseldorf

branch, to be precise by Andreas radig of the field

team. The staff at Düsseldorf are responsible for sup-


Cose CollaboratioN: from left to right: (Field work,

haNsa‑FleX düsseldorf), Jörg leyhausen (technical

Manager, doppstadt), peter Funke (General Manager,



sM 620 proFi: approximately 100 all‑purpose screen drums are produced per annum.

plying the customer with whatever might be needed

for hydraulic line engineering: curved pipes, hose

lines, screw fittings and couplings. Complete sets

of ready-to-install curved pipes are supplied by the

schönebeck pipe bending centre. Incidentally, also

including a pre-assembled rail bearing numerous

connections. It is not just the conveyor belts that are

moved hydraulically on the sm 620, but also the rear

belt which folds down horizontally, so allowing it to

be used for sorting. The mighty screening drums are

also self-cleaning thanks to the inclusion of a hydraulically

controlled brush.

HANsA-FLeX has won the trust of customers by acting

as a reliable, competent and flexible partner. It

recently signed an framework agreement that outlines

the 2009 supply volumes, which in turn can

be utilised for the planning process. This guarantees

a fast response from the hydraulics service provider

even when delivery deadlines are very tight. Andreas

radig calls at this customer's works at least twice a

week, maintaining close contact with technical plant

manager Jörg Leyhausen and buyer sascha köster.

Both know that HANsA-FLeX always responds to

Doppstadt's needs right away, with all staff at the

branch pulling together when a deadline is imminent.

"Our recipe for success is a focus on service,"

comments Andreas radig, "for if the customer is successful,

we'll all be doing fine as well."

Besides being supplied with hydraulic line engineering

in the Oem sector, Doppstadt also relies

on HANsA-FLeX's skills and uniform product quality

when it comes to spare parts. As Doppstadt's

screening machines operate in tough conditions

all over the globe – there are 4,000 shredding and

screening systems in europe alone – it is important

for help to be available as soon as possible when re-

DOppsTADT Full serViCe

pairs are needed. Its dense network of branches lets

HANsA-FLeX show what it can do here, so ensuring

satisfaction for Doppstadt's customers.

KiCKiNG oFF Further


And team spirit is not just limited to working hours.

The Düsseldorf branch belongs to HANsA-FLeX's

Duisburg region, which has organised a football

tournament for customers and business partners

for years. These matches, which are held in krefeld's

Glockenspitz Hall of sG 76 Uerdingen, have proved

very popular. As a keen football fan, Andreas radig

is especially committed to the tournament and hit

upon the idea of inviting the amateur players from

Doppstadt to join in as one of twelve teams involved.

Considering his colleagues in Velbert are mad about

the game and pretty good at it, too.

The Doppstadt team has now taken part in the

tournament for years, and even won the last two.

But they'll have to be patient before they can hang

onto the challenge cup for good: relocation of the

Düsseldorf branch to a new building prevented the

competition from being held in 2008. The tasty meal

of suckling pig nevertheless had both sides teaming

up for further cooperation in future.


oFFshore teChNoloGY WIND eNerGY

poIntIng the way forward

wIth the sea


sustainable climate protection starts at sea. Germany is reducing its use of nuclear energy for power generation, planning to phase it out

altogether by the year 2020. Wind power can make a significant contribution to power generation in the future and help cut emissions of

greenhouse gases. A commercial provider is now planning to establish several offshore wind farms in the German Bight from 2009.

The company responsible for the design, construction

and operation of these wind parks is

the BArD Group, which has chosen Germany's

North sea as the site for eight farms in total, each

boasting 80 five-megawatt turbines. The firm was

founded in Bremen with a team of four staff in 2003.

With currently almost 600 people employed the

company is setting up for business with its first wind

farm in 2009: "BArD Offshore 1", based some 90 km

north-west of the island of Borkum and 120 km from

Helgoland, Germany's only "high-sea island". The

first batch of power to be produced by the wind park

will already be supplied to the national grid this summer.

The regenerative electricity from the individual

turbines will be accumulated on an energy platform

and converted to direct current to reduce losses dur-

ing transport. The electrical power will then be transmitted

to the national supply network via some 100

km of undersea and 80 km of land cables, ready for

distribution to consumers.

In October 2008 an identical pilot plant with a total

height of 152 metres was initially put into service

off the coast of Hooksiel on the North sea coast.

The plant has been specially designed for tough

offshore conditions. Like the other installations that

are planned, it stands on a so-called "Tripile", a sort

of tripod made of steel piping. These steel pipes are

topped by a cross-piece which supports the tower

and the generator gondola. Installation of the Tripile

takes place at sea using a special erection vessel

at depths of approx. 40 m. With a diameter of 4.20

metres at the base of the blade, the dimensions of

the rotor blades are quite breathtaking. These blades,

which are almost 60 m long and weigh in at nearly 29

tons, are manufactured using a special process. This

takes place at a high-tech production plant in emden,

where the blades are produced "directly at the

waterfront". A quick look at emden's harbour shows

current stock levels. Numerous blades lie ready to

be loaded onto the pontoons for transport: BArD is

already planning to install the first thirty of the gigantic

turbines at sea in 2009. Installation can even

take place in rough seas and heavy winds thanks to a

special jacking-up platform with an enormous builtin

crane. The turbine gondola alone weighs some 280

tons. The three-blade rotor measures approx. 122 m

in diameter and is positioned as usual on the wind-


ward side. The turbine delivers its rated output even

with just a light breeze and only needs to be shut

down in very stormy weather.

boNded blade bY blade

BArD has pushed back the boundaries in terms of rotor

blade dimensions. measuring six metres in hight

even when lying flat on the ground, the blades are

the size of a house. They are made of up to 64 layers

of fibre glass reinforced synthetic material based on

epoxy resin – a material that has proved its worth in

the manufacture of rotor blades for almost a quarter

of a century. The longitudinal spar flanges are also

made of fibre glass, so guaranteeing optimum rigidity.

All three-dimensional components and bracings

have a core of plastic foam. While the classical design

consists of an upper and lower shell, these blades

have three parts: a central section with the base of

the blade, as well as a leading and a trailing edge.

This avoids splicing at delicate sections of the blade,

i.e. the blade tip and trailing edge, which are known

trouble spots for conventional rotor blades.

This meant that BArD was entering new territory

with the design and development of blade production

in emden. It has built new laminating systems

60 and 48 m in length to manufacture the jumbosized

rotor blades. A machine delighting in the name

of Trailing-edge segment Bonder (TsB) is used to

bring together the segments which have been prepared

for the blades in a previous production process.

This device works like an oyster shell: the production

technicians join up all parts and make the part ready

for bonding. Once the adhesive has set, the two casting

moulds are gently prised apart again with hydraulic

control, and the component can then go off

for final assembly.

From the outset HANsA-FLeX's Industrial Installation

department in Oldenburg was responsible for the

TsB. Clemens Otte was in charge of all parameters

involving the complex hydraulic systems of the machine.

HANsA-FLeX dealt with control of the complete

hydraulics while handling electronic control of

the machine in cooperation with etw elektrotechnik

Wilhelmshaven. The electrical specifications for stationary

and remote control of the system were also

provided by Clemens Otte.

Besides offering engineering support, HANsA-FLeX

also supplied all components for the TsB, from the

hydraulic pumps through to valve blocks and hydraulic

cylinders, as well as the line engineering. Further,

HANsA-FLeX was responsible for assembly of the machine,

including commissioning. But until this could

take place, the HANsA-FLeX fitters had to install

1,500 metres of hydraulic pipes alone. The hydraulic

WIND eNerGY oFFshore teChNoloGY

GiaNt diMeNsioNs: the wea measures 152 meters in height and is constructed in the North sea, for the assembly of the

tower and its 60 meters long rotor blades entirely new procedures had to be established.

oil for the machine has also been selected with care:

the environmentally compatible panolin HLp sYNTH

32 will not cause pollution should the pipework

spring a leak. HANsA-FLeX is currently redesigning

the TsB according to its experience over the first few

years while conducting discussions with the customer

about making improvements to the 60-metre

production plant. They are working together on new

hydraulics solutions such as the installation of small

hydraulic cylinders to further optimise the closing


The future lies with offshore

wind energy

From January 2009 until 2015 operators will

be paid 15 cent per kilowatt hour for electricity

generated by o� shore wind turbines. This

is the timeframe envisaged by Germany's

Renewable Energies Act ('EEG'), which aims

to boost the share of regenerative energy in

the power supply system to 20 percent by

the year 2020. Today this � gure is still 15 percent.

By 2030 the German government wants

wind energy to account for 25 percent of the

power supply, with 15 percent to come from

o� shore wind farms.


literature »HYDrAULIsCHe LeITUNGsTeCHNIk«

"thIs book helps to fInd

better solutIons"


When it comes to communicating theoretical and practical information about hydraulic line engineering, "Hydraulische Leitungstechnik"

by engineer Helmut Wetteborn provides hydraulics specialists with a book that sets completely new standards in terms of its complex

subject matter and overall structure. HYDrAULIkpresse had the opportunity of speaking to the author:

with NuMerous publiCatioNs oN hYdrauliC eNGiNeeriNG graduate engineer and specialised consultant helmut wet‑

teborn from haNsa‑FleX offers an extensive range of seminars when it comes to hydraulic engineering.



mr Wetteborn, you have worked on this reference

book for a good two years. How did you come up with

the idea of writing a book?

helmut wetteborn:

During my many years of experience I have seen

that engineers developing hydraulic systems apply a

good deal of precision when the design and arrangement

of units and components is involved. This is

demonstrated by the detailing seen in construction

drawings or in associated documentation. However,

the diagrams of the hydraulic line engineering for

assembly often only contain very general indications

or end in hasty sketches. During installation

this unfortunately means that many details are left

to the fitter, who may or not be very experienced, or

to mere chance.

Nor does the relevant literature include much information

about hydraulic line engineering. even thick

books covering all aspects of oil hydraulics only devote

some two or three percent of their pages to this

subject. There are of course many papers and articles

that deal with individual aspects of line engineering

in detail. Laws, standards, provisions and trade association

regulations all contain information about

the correct design of line engineering according to

the requirements and its proper usage. But facts

about practicable application are generally thin on

the ground. The main thing lacking is a realisation

of the intricacies of hydraulic line engineering as a

basis for decision-making. The current state of affairs

is characterised by a theoretical approach to line engineering

that is not sufficiently complex and a wide

variation in the level of experience.


ook of the year


The practical manual "Hydraulische Leitungstechnik"

published by HANsA-FLeX is setting

new standards. Helmut Wetteborn (Dipl.-Ing)

has written a book that deals with the basic features

of hydraulic line engineering in a clear and easily understandable

manner. This publication is a must for

everyone who wants to make such line systems safer

and more economical as a functional part of stationary

or mobile hydraulics.

Offering a full range of fluid technology services, the

HANsA-FLeX Group also stands for efficient line engineering.

The literature in this sector generally treats

hydraulic line engineering as a side issue and is not


esseNtial literature including checklist and

practical examples. the reference guide provides

helpful suggestions on troubleshooting, the right

planning, construction and operation of hydraulic

engineering systems.

always up to date in technical terms. "This prompted

us to invest not inconsiderable resources in producing

a practical manual which presents the relevant

facts in an understandable way, so providing everyone

who wants to make hydraulic line systems safer

and more economical with a versatile instrument for

their planning, manufacture, installation and operation",

explains Uwe Buschmann, mD of HANsA-FLeX

Hydraulik GmbH.

Helmut Wetteborn (Dipl.-Ing.) is an author who has

years of practical experience and knowledge in the

demanding world of hydraulic pipe systems while

also being able to explain complex issues in a clear

»HYDrAULIsCHe LeITUNGsTeCHNIk« literature


How did you manage to complete such an enormous

832-page book in just two years?

helmut wetteborn:

Well, we didn't actually start from scratch. When

writing the book, I was above all helped by my unflagging

interest in hydraulics and my experience

as an instructor at the HANsA-FLeX training centre.

I was already aware of a whole range of problems,

and I have always been spurred on to find practical

solutions. All my life I've been keen to get to the bottom

of things. In addition, I have always been able to

bounce ideas off my colleagues at the training centre

and the Technical Department. This also involved individual


I'd now like to take the opportunity of expressing my

special thanks to mr peschka, the editor and layout

man at Tanner AG in Lindau. It is partly thanks to him

and his ideas that this book has turned out so clear

and comprehensible, and also thanks to our excellent

working relationship.


This manual is not just directed at practical experts.

Who else are you addressing here?

and comprehensive manner. This has been demonstrated

by the co-initiator of the HANsA-FLeX training

centre, not only at countless seminars involving

practical experts from HANsA-FLeX and customer

staff from 1999, but also at special lectures held at

technical universities. "For us Helmut Wetteborn is a

man who always takes an open-minded approach to

the latest problems and can be relied on to come up

with a solution. And he is invariably willing to learn

something new," comments Uwe Buschmann. "This

meant we had no difficulty in choosing engineer Helmut

Wetteborn as the author of this book."


literature »HYDrAULIsCHe LeITUNGsTeCHNIk«

helmut wetteborn:

Although it has been designed as a practical manual,

we have not neglected the engineering aspects that

provide its background. The book is thus aimed at

managers, safety engineers, Qualified persons, instructors

and designers. Another target group is buyers

and sales staff as well as students and trainees.

But it also addresses the people employed by the

manufacturer and users of line engineering, in addition

to fitters in workshops and on building sites.

Whatever the subject, we offer guidance for the appropriate

practical procedure.


We cannot help noticing that you stress safety issues

time and time again.

helmut wetteborn:

That's right – this is something that is necessary

here. In recent years technical progress in the field of

hydraulic systems has been developing at an amazing

rate, including on an international scale. The response

has been stricter laws, which are increasingly

delegating decision-making to manufacturers and

users. This development, which is above all characterised

by an increase in pressure levels, of course

also involves pipework and hose lines. Here too this

means greater responsibility.


One issue that is not widely known in this context is

given special emphasis in your book: personal liability

and negligence.

helmut wetteborn:

everyone has to realise that every action you take,

starting with planning and ending with operation,

involves responsibility. And this boils down to personal

liability in the event of damage. Today the use


Februar – März

of this technology is being increasingly governed by

laws, regulations and basic safety norms to protect

both man and the environment. I therefore advise

everyone to have a think about such issues. This is

why I have devoted the first chapter of the manual

to this problem. Ignorance is no defence if damage



proper design and safety – unlike other works

published in this field, your book does not stop at


helmut wetteborn:

That's true. It takes a detailed, and above all practical

approach to the subjects of line engineering and

safety, and the inspection and testing of hydraulic

lines, pipes and hoses. It also looks at certain laws of

physics. Here this work always fulfils its claim to offer

solutions and answers. It highlights unsatisfactory

work results, which can already be seen at the planplanning stage, as well as negligence during installation.

This manual will help to avoid mistakes during the

planning, manufacture and operation of hydraulic

line engineering and provides safety engineers and

Qualified persons with structured materials to reliably

organise systematic inspection. The checklists

and practical examples supply them with valuable

information, so equipping them for the responsible

tasks they have been assigned.


How would you recommend readers of

HYDrAULIkpresse use this manual?

helmut wetteborn:

The manual "Hydraulische Leitungstechnik" contains

information that will make the work of designers and

engineers easier. It repeatedly refers to the economic

efficiency of line systems and draws attention to

the risks involved. The contents list and index of key

words will help readers to find what they are looking

for, while the symbols used here indicate the nature

of the facts provided. The practical tips with their

personal approach are especially informative, not

only for designers and manufacturers, but also fitters

and operators. As the author of this book I would of

course be delighted to help readers with any queries

they might have.

quiCK aCCess: in the the index comprehensive knowledge

is just a keyword away.

Please note:

This book is only available in


02. – 06.02.2009 Grundlagen der Fluidtechnik Teil 2 Bereits ausgebucht! Dresden

19.02.2009 Grundlagen der Leitungstechnik Bremen

02.03.2009 Grundlagen der Dichtungstechnik Eisenberg

02. – 06.03.2009 Grundlagen der Fluidtechnik Teil 2 Bereits ausgebucht! Dresden

09. – 13.03.2009 Grundlagen der Fluidtechnik Teil 1 Dresden

10. –13.03.2009 Grundlagen der Schlauch- und Rohrverbindungtechnik Bo� zen/Höxter

19.03.2009 Grundlagen der Leitungstechnik Bremen

30.03. – 03.04.2009 Grundlagen der Fluidtechnik Teil 2 HYDRAULIKPRESSE HANsA-FLeX Dresden CUStomERS 02|2009 mAgAzIn

Für weitere Informationen wenden Sie sich bitte an Frau Anne Schmidt unter der Telefonnummer: +49 351 413 97-19 |




» beflügelndes

Wissen über

hydraulische leitungstechnik!

hydraulische leitungstechnik –

ein Praxishandbuch

von helmut Wetteborn

Die Planung, Herstellung und Montage hydraulischer Leitungstechnik beruhen

in hohem Maße auf praktischer Er fahrung. Dieses Handbuch bündelt zum

ersten Mal dieses Wissen und wendet sich an leitendes Perso nal, Sicherheitsingenieure,

Hersteller von Leitungstechnik und viele mehr.

Die rasante Verbreitung der hydraulischen Systeme in vielen stationären und

mobilen Einrichtungen, die die Mechanisierung und Automatisierung in der

Industrie mit sich bringt, führ t zu Einsätzen und Beanspruchungen, die hohe

kollektive Belastungen provozieren.

Die verantwortlich handelnden Personen benötigen ein praxisnahes Instrumenta

rium zur Beur teilung der Sicherheitslage, für die sichere Auslegung und

Gestaltung der Leitungstechnik und die Konstruktion anforderungsgerechter

Lösungen. Aber auch praxiserprobte Entscheidungshilfen für die wir tschaftliche

Umsetzung der Lösungen bei Montage und Inbetriebnahme sind gefragt.

„Wi s s e n k o m m t e r s t z u r Wi r k u n g, w e n n e s a n g e w e n d e t w i r d .“

G . B l o c h e r, Ta n n e r A G



literature »HYDrAULIsCHe LeITUNGsTeCHNIk«


by the book


The practical reference book "Hydraulische Leitungstechnik" contains answers to a whole range of questions involving line systems and

even includes specifi c suggestions and solutions. Nor does it merely remain theoretical, but takes readers by the hand, off ering them factual

assistance for practical applications. HYDrAULIkpresse will now take selected examples to illustrate what this actually means, so demonstrating

how useful this book can be in your everyday work.

Clearly structured over 832 pages, this publication

will not only fascinate readers with its subject

matter, but also includes numerous handy

hints. They will have no trouble in finding the topics

they are interested in thanks to the detailed contents

list and index of key words. special symbols are used

to indicate the meaning of each entry and ensure

faster access. A work with a focus on engineering that

takes readers by the hand with its direct approach,

addressing them personally with formulations such

as "Take note...", "Check...", "make sure…". The publication

is rounded off with photographs, diagrams

and graphics relating to specific cases as well as practical

calculations and handy checklists.

The information provided about the repair of hose

lines is a good example of how to deal with this recurring

problem. "professionals" will balk at these

words. And rightly so, as repairs to hydraulic or

repairs to hose liNes, as shown above, pose an extreme

safety hazard and are practically illegal.

pneumatic hose lines are practically ruled out by the

group norms DIN eN 982 and DIN eN 983 h governing

safety! engineer Helmut Wetteborn includes a picture

of a repaired hose line as a warning to readers.

"Anyone who lets himself get involved in such solutions

should be aware that he is acting illegally and

demonstrating gross negligence. The issue of personal

liability comes up here – and with any harm, could

even result in a jail sentence," remarks the author.

The book applies this question to the specific case of

pipework and warns readers about such negligence

– justifiably so. He explains in detail what a repair

may involve. An explanation that particularly applies

to service technicians: "They are the ones who

are frequently pressurised by the customer to come

up with a makeshift solution to solve the problem

quickly – a solution that may well not be legal".

Another example relating to hose mechanics should

be mentioned here: the failure to comply with the

minimum bending radius of a hose line. A picture

illustrates a mistake that is made every day when

hose lines are being assembled: the bending radius

selected is too tight. This error originates with the

engineer designing the layout of the hydraulic system.

It means that the hose line will fall short of its

expected service life, so resulting in sudden failure

with all associated consequences.

This manual now offers designers or fitters a practical

option for calculating the necessary connecting

dimensions of hose lines. The result is a specific line

hose MeChaNiCs is another important issue since a wrong

bending radius will considerably shorten the life span of the

hose line (1 = beginning of bending radius, l = 115 mm,


l = 190 mm).


length that meets their requirements as well as correct

positioning of the connections and proper usage

of the line. The correct installation of hose lines can

also be quickly checked during service inspections.

planners, manufacturers and operators of hydraulic

line systems will find useful suggestions for their everyday

work as well as handy information throughout

the book to make things clearer. For example, the

negative impact of design faults on the economic efficiency

of a hydraulic system. How you can break the

chain of events occurring here is demonstrated with

the example of such errors that affect the tempera-


ture conditions in a hydraulic system. It is generally

known that the optimum operating temperature lies

between 50-70 degrees Celsius. If the constructional

or external influences cause this temperature to increase,

a chain of events may be set off – to adverse

effect. If further action only addresses the symptoms

and does nothing about the causes, the operating

conditions of a machine or system will ultimately

deteriorate with excessive temperatures, so pushing

up the costs of maintenance and operation. The

author rounds off this topic in a clear and informative

manner by making case-specific temperature recommendations

for hydraulic fluids and lines.

taKiNG thiNGs Further

Going beyond such practical examples, the book also

takes things further by repeatedly delving into problems

which are not considered in sufficient detail. For

instance, there is the question why corrosion occurs

inside sealed hose lines or pipes which are stored

for lengthy periods. rust particles have an adverse

effect on hydraulic fluid as an energy transfer medium,

causing wear in the hydraulic system. readyto-install

hoses and pipes are normally sealed off

after manufacture, something that is actually often

stipulated by the customer.

This is perfectly plausible as the aim is to prevent

dust or dirt getting inside. But practice shows that

there is a factor here that is initially more or less ignored:



»A technical engineering book with case-related illustrations,

practical calculations and useful check lists.«

It is contained in the air, present in the form of humidity.

If we assume that there is an ambient temperature

of 30 degrees Celsius with a humidity level

of 60 percent when the pipe is sealed off, 18.24 g

condensation per m3 cubic content of the hose or

pipe will be given off at an installation location with

a temperature of approx. 21 degrees C. A thimble can

contain 2 g water. It thus becomes clear that sealing

off a hose or pipe traps a certain amount of condensation,

which can then develop its corrosive effect

uncontrolled. This is why Helmut Wetteborn recommends

leaving hose lines open when stored for long

periods and rinsing as necessary prior to installation.

This of course has to be agreed with the customer,

although it is only with specific figures that qualified

discussion will be possible.

Verdict: There are virtually no other publications that

present the complex issue of hydraulic line engineering

in such a clear, comprehensive and practical way

as this book.

Please note:

This book is only available in


»HYDrAULIsCHe LeITUNGsTeCHNIk« literature


Xworld sTAGe 22

when the tsunamI came

»Half of its inhabitants were killed by the gigantic wave and all of their houses were destroyed.

On arriving at a refugee camp the traumatised survivors from the village were met by miserable conditions.«

this is where the VillaGe oF suaK Nie was loCated before enormous freak waves completely destroyed the village on 26 december 2004. Now it is being rebuilt at a safe distance to

the sea – with the support of haNsa‑FleX.



It was the third biggest seismic event ever to be recorded - and it probably cost the lives of

more than 230,000 people: the seaquake that occurred off sumatra on Boxing Day 2004.

At around 8 am local time the earth was shaken

by a shock measuring 9.1 on the richter

scale. The energy released on this date was

equivalent to around half the UsA's annual energy

consumption. But it was not the quake so much that

did the damage, but the flood waves it caused: They

ravaged the coastal regions of the Bay of Bengal, the

Andaman sea and south Asia. One area that was particularly

badly affected was the Indonesian province

of Aceh on the island's west coast.

This province also includes the village of suak Nie,

which on the day the disaster struck was home to

258 people – until the moment the tsunami hit the

coastline. Half of its inhabitants were killed by the gigantic

wave, and all their houses were destroyed. On

arriving at a refugee camp, the traumatised survivors

from the village were met by miserable conditions.


ArD's radio Bremen and the aid organisation Terre

des Hommes launched an appeal for donations immediately

after the disaster to build a new village

for its former inhabitants. The aim was to construct

50 little homes, which were to be mostly put up by

the occupants themselves, at a cost of some 2,500

euros per house. The campaign also elicited donations

from the staff at HANsA-FLeX and the company

itself. The sum collected by the workforce was then

doubled and rounded up by the management so that

the housing project then benefited from a total of

18,000 euros.


remains committed

sTAGe 22 Xworld

On 10 January 2009 the XWORLD Tour reached

Suak Nie at around noon to � nd out how it had

been getting on rebuilding the village. Result: Although

a lot has happened in the meantime, there

is still plenty of work to do. Thomas Armerding,

who had accompanied stage 22 with colleagues

from HANSA-FLEX and the XWORLD project management

team, thus decided on the spot that

HANSA-FLEX would continue to support the villagers.

Although the village has been rebuilt by now – at a

safe distance to the sea – the infrastructure has by

no means been restored. Thomas Armerding: "It is

particularly important to o� er people a real perspective

again, which will enable the community

to support itself in the long run". True to its motto

"We are aware of our responsibility" HANSA-FLEX

will be providing the funds in order to build up a

rubber-� g plantation near Suak Nie. Rubber is an

important and much demanded commodity – and

not just for hydraulic hoses – which can provide a

basis to the people of Suak Nie to achieve self-suf-

� ciency. The project will be realised in cooperation

with Terre des Hommes" and HANSA-FLEX will donate

the required funds of €40.000. We will report

about this project in further detail in the next issue

of the Hydraulikpresse.

The people of Suak Nie have been delighted by

the news. Already upon their arrival the German

visitors were greeted with a festive welcome and

honoured with a religious ceremony for the support

o� ered thus far. Now the community of 17 Suak

Nie can look forward to a better future.


gettIng down to work


C. Daniele Badami has only been working for HANsA-FLeX in Ittigen / switzerland since 1 August 2008. And despite not having any experience

in this branch, he was allowed to join colleague peter Diedrich in the Gotthard Base Tunnel, partnering him during installation work on

the sedrun-Faido site in October. An unforgettable assignment for the 22-year-old. When it is completed in 2016, this 57 km rail tunnel will

be the longest tunnel in the world.

No idea what to eXpeCt: daniel bandami from

haNsa‑FleX ittigen got on the elevator to vsiti the

construction site 850 meters undeground.

To optimise the costs of building the Gotthard

Base Tunnel, extra starting points for driving,

so-called intermediate headings, have been

planned in addition to the north and south tunnel

mouths. Driving for both stretches of the tunnel towards

the north and south will take place from the

central sedrun section via two vertical shafts approx.

800 metres in depth. Work on the two vertical shafts

at sedrun will be carried out using an access gallery

some 1,000 metres in length. Both shafts will be used

for supply and disposal services during tunnel driving,

with the sedrun 1 shaft already being equipped

with a high-capacity conveying system. This was the

start of a unique experience for HANsA-FLeX colleague

C. Daniele Badami:

When he was asked beforehand whether he suffered

from claustrophobia or was afraid of heights,

he felt a bit nervous, "as I wasn't very sure what I'd

be letting myself in for, but I decided to take up the

challenge." The entrance to the tunnel for the sedrun

section is located at an altitude of 1,350 m above sea

level, with the future tracks, i.e. the actual site, being

based at 500 m asl. A difference in levels that calls for

a jumbo-sized lift.


When the lift plunged downwards on my first day on

site, covering the 850 metre height difference in a

single minute, all I could think was, Oh my God, what

have I let myself in for! Once we arrived at the bottom,

I was first struck by the heat and high humidity.

It's no mean feat working at +30°C and humidity

levels between 80 and 90%. You break out in a sweat

before you even lift a finger.

everyone who goes down for the first time is impressed

by the gigantic machines working underground.

The blasthole drilling machines, the skips,

excavators, the entire concreting logistics – every

piece of equipment had to be taken down, installed

and put into service – an awesome infrastructure

system. seeing all that with your own eyes is an unforgettable


Working underground is of course physically exhausting

- even if some people now think installing

a couple of hydraulic hoses in shuttering is a piece

of cake. Apart from the fact that several hundred

metres of hose line were involved here, I wouldn't

mind hearing what they'd say if they had themselves

worked underground here. You only have a realistic

idea of what's involved if you've actually spent time

in the tunnel.

Despite the high level of physical effort I found working

underground for three days an extremely positive

experience. For me this was a unique experience, and

I can only advise every hydraulics technician to sign

up for such a project if the opportunity presents itself.

You'll never forget something like this. The mere

thought that I did my bit in helping to build the longest

tunnel in the world and have stood where trains

will be hurtling through at 200 km/h is a fantastic


eXtreMe worKiNG CoNditioNs in

the Gotthardt‑tunnel at 850 metres

below sea level: +30°C, humidity above

80%, and all of the equipment has to be

carried to the depth of the mountain and

assembled on site.



eXCeptioNal deMaNds are placed on the hydraulic line

engineering by the special vehicles of signa Nova. to this

end prototypes have to be continuously developed and


The münsterland region, which has traditionally

tended to revolve around agriculture, is home

to some 1.6 million inhabitants. Its economy

is mainly characterised by small to medium-sized

enterprises. The münster branch was founded by

HANsA-FLeX 25 years ago. The staff cannot help but

notice the changes to industry underway in this region,

bringing in new customers with requirements

that are out of the ordinary. "That spurs us on to do

our very best," comments Andreas Bartsch, head of

the münster branch.

A team of seven plus trainees not only takes capable

charge of the spare parts business "at the counter

or in the field", but also offers fast help with the

FLeXXpress hydraulics service whenever necessary.

To ensure the full satisfaction of customers in their

region, the staff from münster cooperate closely

with the branches based in nearby salzbergen and

stadtlohn. In addition to its spare parts service, the

branch has also made a name for itself thanks to

HANsA-FLeX's performance as a partner in serial production

and is successfully doing business with Oems.

münster is dealing with customers with complex demands

more and more often. For example, so-called

kitting – i.e. the supply of complete hydraulic assembly

kits – is a requirement made on hydraulics service

providers that is becoming increasingly popular.

The company siga Nova Fahrzeugbau is taking

things a step further: the manufacturer plans to set


up its own HANsA-FLeX workshop in-house. As an

engineering company for special vehicles siga Nova

producers semitrailers for agricultural and forestry

applications, dump trucks and swap-body systems

– whether designed as one-off vehicles or in small

series. It is with such highly customised vehicles that

special demands are made on the hydraulic line engineering.

With HANsA-FLeX's fully fitted container

geared to siga Nova's specific requirements this

manufacturer now has a hydraulics workshop that

is equipped to produce hose lines with all machines.

The firm is able to make up and optimise samples

without wasting time. The münster branch ensures

that the container is regularly replenished with hose

materials, fittings and components designed for professional

line engineering. But that's not everything:

HANsA-FLeX also organises staff training for the engineering


wiNd oF ChaNGe

The branch is meanwhile now also doing business

with the wind power sector, which has brought the

wind of change to the münsterland economy. such

customers already rely on the staff at münster when

it comes to developing line engineering prototypes

for both onshore and offshore applications. When

working with HANsA-FLeX, the designers of the

new jumbo-sized turbines benefit from almost half

a century of experience in the line engineering sector.

Whether the proper installation of hose lines

mÜNsTer braNChes



of mÜnster


is involved or selection of the right hose material,

HANsA-FLeX can advise on the best solutions, produce

samples without further ado and assist with the

transition to serial production. "such contracts call

for our full attention," explains Andreas Bartsch. "We

pull out all the stops and work a little magic to make

sure we get the material to the customer on time."

And pulling out all the stops is also what the sorcerers

from münsterland have in mind for the HANsA-FLeX

football tournament to be held in Belgium in may –

even if this involves getting tough. Football fans from

HANsA-FLeX's branches in münster, salzbergen and

stadtlohn meet up once a month to play each other

in a sports hall – so having fun while working off the

stresses and strains of daily life.

the CoMplete CoNtaiNer worKshop is ideal for the

production of hose lines, from one‑off s to a small batch



worK aNd liFe preVeNTION



"Ouch!" The swift response to a stab of pain in the back or neck. everyone has experienced this at some time in their life. Backache is a com-

mon problem: 25 percent of europe's working population suffer from it. According to the health report issued by the German Association of

Company Health Insurance Funds, problems with the back are the most frequent reason given for inability to work.

Virtually everyone has to deal with backache at some

time in their life. Indeed, it would not be far wrong to

speak of an endemic disease here. Luckily, backache

is only temporary in almost 90 percent of cases and

soon disappears of its own accord. But the causes still

remain: lack of exercise, stresses and strains at work,

during leisure time or sport. Backache can also be

psychosomatic in nature, the result of stress. To avoid

back problems from the outset, it would of course be

simplest for people to try to improve their posture

and exercise patterns, so training the muscles and

ensuring a more balanced approach to life. Although

everyone knows about this, very few keep to these

basic rules.


wroNG posture whilst

sittiNG is one of the main

causes for serious back

problems (left). important

is the correct upright

position: the seat should be

high enough for the thighs

and calves to form a 90 de‑

gree angle while the entire

sole of the foot touches the

ground (right).




sport and plenty of exercise are naturally the most

effective ways of preventing such problems. If the

back muscles are just allowed to rest, they will waste

away, with the spinal discs becoming brittle and the

joints "rusting up". To sum up: The entire spine will

wither away without exercise, and backache may

be the result. Backache is generally brought about

by overdoing things physically on a long-term basis.

The most frequent causes are standing or sitting for

lengthy periods as well as poor posture, e.g. working

with the back hunched up or the upper back twisted.

Back problems are also encouraged by a failure to lift

or carry heavy weights properly, as well as remaining

sedentary for a long time, whether at the office, in a

car, construction vehicle, and possibly also in front of

the television later on.

At work you should take note of a few basic rules

that will help to keep your back in good shape. This

of course particularly applies to office workers. sitting

properly is important and has to be learned. The

right sitting position is the main thing here. The seat

of your chair should be high enough for the upper

and lower leg to form a right angle with your feet

planted firmly on the ground. You should arrange

work equipment such as your pC keyboard and monitor

so you are sitting in a relaxed position.

eXerCisiNG at the oFFiCe,

relaXiNG iN Your Car

It is however important to change your sitting position

often and to also work standing up if possible. If

this is out of the question, you should at least leave

your desk from time to time and treat yourself to

a brief stroll round the office. Or you can also keep

yourself active by occasionally taking a bit of exercise

at your desk – with little movements that nobody

will even notice.


Anyone who drives a lot for work also spends a good

deal of the day sitting down, for example, sales reps,

taxi drivers, service technicians or people who operate

construction machinery. You can prevent backache

here by sitting in the right position in a good-quality

seat that is individually adjustable. The basic rule for

a proper sitting position in the car is to put your seat

so it is as high as possible, with the backrest forming

an angle of approx. 110 degrees to the seat. You can

also look after your back while driving: always slide

as far as possible into the seat while still holding the

steering wheel with your arms at a slight angle and

operating the pedals with the legs slightly bent.

GettiNG a hold oN thiNGs –

but properlY

Anyone who frequently has to lift or carry heavy

loads at work should make sure they do this properly.

But you may well be asking yourself how you can go

wrong when lifting loads? Well, quite a lot actually.

Take a good look at yourself when lifting something.

You'll be making things easier on your back if you

move in as close as possible to the object you want to

lift, standing up straight with one leg positioned next

to the load. squat down keeping your back and spine

straight and grasp the item firmly with both hands.

While lifting, brace the muscles of the stomach and

pelvis and lift the object mainly with force from your

legs and little from your back – this will allow you

to stabilise your spine. Incidentally, you should hold

the load as close to you as possible, with the weight

evenly distributed over both arms. Do not twist during

lifting, and especially not when squatting down

as that is bad for the back! When you set down the

load, bend the hip and knee joints while keeping

the spine straight. Have you been doing all this right

when lifting weights?

preVeNTION worK aNd liFe

liFtiNG CorreCtlY is the basis for a healthy back: it is important

to lift with a straight back whilst ensuring that most of the lifting

strength and power comes from the legs (right) and not from the

back (left).

When lifting really heavy objects, you

should preferably use a barrow, lifting

truck or trolley. Why not ask a work colleague

for help? Wanting to do things by

yourself is the wrong approach here. And

another thing: Whenever you reach for an

object from your desk or in the workshop,

make sure you do not twist round or that it

is within arm's reach. If you cannot reach it,

stand up or take an extra step: a little more

exercise won't harm, and your back will be



Xworld sTAGe 22

Jungle, steppes, the sIlk road


The XWOrLD Tour has now passed the equator: In the middle of January it reached the Indonesian island of sumatra. During this stage of

the tour all eyes were on the village of suak Nie, which had been destroyed by the disastrous fl ood of 2004 and has been rebuilt with the

help of donations – including from HANsA-FLeX (see info box "When the tsunami came"). The convoy is now heading further north, crossing

China, mongolia and the endless steppes of russia to reach Finland.


From the beginning of march the trip to the middle

kingdom will follow the same route as taken

by stage 19 at the end of November 2008, but

in the opposite direction. It is however set to be no

less exciting: Dense jungle awaits the participants in

Thailand, who also have to cross the mekong in Laos.

To enter China they had to take a separate driving test

(you can find out more about the thrills and spills of

stage 19 on the Internet by visiting,

"Impressions of the stages").

stage 33, scheduled to begin at the end of may 2009,

will then take them right across the north of China

(all trips before this date have been sold out). The

XWOrLD Tour will take a spectacular route along

the Taklamakan desert and the Great Wall of China,

taking in classic stopping points on the old silk

road. Islamic mosques, Buddhist monasteries and


historic fortifications will offer a fascinating insight

into China's varied history. The stage will kick off in

khasgar. participants are advised to arrive a day early

so they can visit the famous sunday market on 31

may 2009.

Two weeks later the convoy of Land Cruisers will then

reach the Chinese capital of Beijing. From here stage

34, which is scheduled to begin in the middle of June,

will then lead through the Gobi desert to Ulan Bator

– the capital of mongolia. The participants of the

following tour will retrace their steps, stopping off

at other rarely visited destinations such as the Vulture's

Gorge or the khuislin-Naiman-Nuur National


stage 36 (scheduled to start in Beijing on 12 July

2009) is set to become a true voyage of discovery,

sTAGe 22 Xworld

revealing its secrets along the way: While it was only

the Imperial palace in China's capital that access was

being denied to, the name "The Forbidden City" once

applied to the entire town where this stage will finish:

Vladivostok. This city, whose name means "rule

the east", is home to the russian pacific Fleet and

was closed to outsiders until 1991. The XWOrLD Tour

will take an exciting route through Inner mongolia to

reach the city that is sometimes also known as russia's

"Liverpool of music". Here's a tip for anyone who

wants to extend their adventure-packed holiday:

Don't fly home but take the Trans-siberian railway.

The train journey lasts a good six days for the 9,288

km journey to moscow.



keepIng calm

durIng an oIl accIdent

Whenever there is an accident involving oil in a hydraulic system, it is essential to stay calm and take the appropriate action right away. But

proceed with caution: if hydraulic oil is not handled properly, this can be very harmful to health.

High-viscosity hydraulic oils are refined mineral

oils which have been given special properties

through additives. The use of such fluids calls

for care to ensure the safety of man and the environment.

This not only applies to the maintenance of

stationary and mobile hydraulics systems, but in particular

to the leakage of hydraulic oils with faults. The

laws governing the safe handling of hydraulic fluids

also contain rules for the procedure to be followed

by operators and everyone dealing with hydraulics


systems during incidents involving oil. In the interest

of health, anyone working on a hydraulics system

should avoid hydraulic fluid coming into contact with

the skin or inhaling it in spray form. If contact with

the skin cannot be ruled out for technical reasons,

help is available in the shape of special protective

equipment including gloves and goggles that are

resistant to such fluids. products designed to protect

and care for the skin should be applied in advance.

CautioN: iNJeCtioN oF oil

especially dangerous injuries will result if hydraulic

fluid gets under the skin. This may occur when highly

pressurised hydraulic oil spontaneously escapes at

fracture or leakage points and is forcibly injected

beneath the skin. You should seek medical aid immediately

whenever there is the slightest suspicion of

hydraulic oil having entered the body with an injury.

experience has shown that even the smallest injec-


tion oil may quickly destroy tissue and ultimately

make amputation of the affected part necessary. A

risk that you should always treat seriously! And this

not only applies to the use of hydraulic oil, but also to

all contact with lubricating grease and fuels.

Accidents can sometimes be prevented by donning

suitable protective gloves, for example made of

rubber, neoprene or nitrile latex. When checking for

leaks or troubleshooting, fitters should also wear a

helmet with visor to prevent any nasty surprises. But

take great care whenever dealing with hydraulic fluids

even if you are equipped with protective clothing.

make sure you always keep your distance from leaks:

another safety measure that should be borne in mind

by everyone dealing with hydraulic systems. But acting

carelessly with hydraulic oil not only presents a

risk to health, but also to the environment. Water

and the groundwater are especially sensitive to contamination

by oil. Just one drop of oil can pollute 100

litres of water. This should be above all remembered

when using mobile hydraulics on building sites.

preCautioNs iN the iNterest oF

the eNViroNMeNt

Your duty of care begins before setting up a site for

example by asking the local authorities which hydraulic

fluids they permit. The requirements of the

individual municipalities on the operator may well

differ here. Often only biodegradable hydraulic fluids

are licensed as operating resources on construction

sites from the outset. At all events when a mobile hydraulic

system is to be used in areas presenting a risk

for water. This means that before such an installation

can be put into service, the operator has to clarify all

environmental issues involving hydraulic oil with

the authorities. The body responsible in such cases

is generally the local water authority of the district

or municipality. This authority also specifies what

volume of lost hydraulic fluid must be reported with

accidents involving oil. such incidents are often not

notifiable if only tiny leaks have occurred – with this

generally only being the case for accidents involving

bio-oil. Bio-oils are normally classified as being less

hazardous to water than mineral oils, as 60 percent

or more will biodegrade naturally within four weeks

under certain conditions. But the same degree of


care is also required when handling hydraulic fluids

during servicing at plants and with defects. Company

regulations govern their usage here and must be observed

without fail.

everyone should know what immediate action needs

to be taken to prevent further damage being caused

by hydraulic oil. If the oil leak has not been caught

in a collection tray or trap and has already escaped

into the ground or a waste water installation, the rel-

»Just one drop of oil can

pollute 100 litres of water«

evant authority, police or fire brigade should be notified

"immediately" and informed about the quantity

of oil that has leaked into the environment. In such

cases "immediately" means that a person working

on the hydraulic system must contact the police or

the authorities as well as the manager responsible

at a company. An incident must also be reported

by service fitters. A specimen of the Länder installations

licensing ordinance states that reporting is

incumbent on anyone who "operates, fills or drains,

maintains, repairs, cleans, supervises or inspects an


Immediate action should be taken as appropriate to

contain environmental pollution to the greatest possible

extent with an accident involving oil. The point

of leakage should be sealed off at once, and steps

should be taken to prevent hydraulic fluid from getting

into the ground, surface water or the mains or

works drainage system. For example, drains should

be blocked off with cloths, and binding agents used

to absorb spilt hydraulic oil. Binders should therefore

always be readily available whenever hydraulics systems

are involved. It should likewise be ensured that

product descriptions and safety data sheets containing

information about the hydraulic fluids used are

to hand. This will allow specialists to offer systematic

help in the event of an emergency. With major incidents

involving oil the local or company fire brigade

or technical emergency services should step in after

immediate action has been taken to ward off any risk

to the environment or works facilities.


leaKed hYdrauliC oil is a danger to the environment and

physical health. therefore, any accident involving a hydraulic

oil spill has to be reported and binder for absorbing the oil

has to be handy at all times.


arbeit uNd lebeN ÖLeNTsOrGUNG

materIals made up of oIl


While servicing a machine, the operator of the plant replaces an old hydraulic hose line to be on the safe side. But how should he dispose

of it? simply throwing it away, possibly just leaving it in the pit or disposing of it by other improper means is a criminal off ence as working

materials containing oil are classifi ed as special waste.

Under no circumstances should you discard a

worn old hydraulic hose just any old where!

everyone operating hydraulic systems should

know this. Used hose lines and discarded hydraulic oil

have no place in our environment. The improper and

illegal disposal of oily materials is a crime against

nature and ultimately spoils the quality of life for


special waste therefore needs to be treated with

care. Disposal is governed by laws and regulations

such as the German Commercial and Industrial Waste

management Act. This states that used oil has to be

collected and handed over to a qualified disposal

company. Only this procedure guarantees that such

oil undergoes treatment and is available for recycling.

Or that afterwards it can be used as a fuel in

power stations, steelworks or cement factories. Until

disposal, it is essential to store waste oil properly to

make sure it cannot pollute the environment. Barrels

or containers used for storage should therefore be

carefully checked for leaks. It cannot be stressed often

enough that hydraulic oil that leaks into the earth

or groundwater is extremely harmful. It only takes

one drop of oil to pollute 100 litres of water! even if

only tiny leaks are involved, the costs of cleaning up

after such pollution with oil may be immense.

When hose lines are replaced, proper disposal is necessary

as well. Take care as they may still contain residues

of oil. Fittings should however be removed beforehand.

The scrap metal from fittings is subjected

to the tried and tested recycling process used in the

metal industry and is melted down into new steel.

HANsA-FLeX offers its customers a disposal service

»HANSA-FLEX supports customers

with its environmental disposal«

for such fittings – including certification. The old

hose material is prepared for subsequent recycling

according to the specifications of the relevant waste

disposal contractor – these may vary depending on

the region. For example, many companies only accept

hoses in certain lengths, making it necessary to

cut them to size beforehand. HANsA-FLeX supports

customers with its environmental disposal facility for

hose lines as this is part of its focus on service. every

branch is equipped to accept waste material and to

arrange for recycling in cooperation with specialist


HANsA-FLeX can however only offer this service in

return for an appropriate contribution towards costs:

environmentally friendly disposal of special waste

costs money, even when the customer has purchased

a new part. As working materials for hydraulics are

not covered by the extra charge made under Germany's

Dual refuse system, the costs of disposal

are not already included in the packaging costs for

the product, as with the "Green Dot". However,

HANsA-FLeX guarantees proper disposal of waste

materials in return. And HANsA-FLeX has more to

offer. The Fluid service training programme also includes

information about questions of disposal and

our responsibility for man and the environment.


steppIng on the gas

GermAN FLeXXpress FLeeT seT TO eXpAND IN 2009

serVICe FleXXpress

In 2009 HANsA-FLeX plans to add another 35 vehicles to the FLeXXpress fl eet in Germany. This means it will not only be improving availability

in the bigger cities, but also link up new regions to its FLeXXpress service.

The FLeXXpress fleet is made up of modern

service vans that have got what it takes. A set

of equipment that does not need an external

power source to function as well as everything required

for fast repairs and disassembly, as well as

the production and installation of hydraulic hose

lines. Besides the cutters, peelers and hose press on

board, the mobile workshops also contain a wide

range of spare parts including couplings, screw fittings,

adapters and pipe clamps to ensure that help

with hydraulics is quickly available everywhere at

any time.

HANsA-FLeX's rapid hydraulics service, which is

available throughout Germany 365 days a year, is

becoming increasingly popular among customers

when they need help on site right away. The growing

popularity of the service, combined with the increasing

complexity of the repairs involved, has made it

necessary to expand the network of vehicles in some

regions to prevent waiting periods from the outset or

to keep them as short as possible. As there is also a

the FelXXpress serViCe VehiCles are

equipped with all the necessary tools and ma‑

chinery for corrective maintenance works and

the assembly of hydraulic hose lines and are

thus able to assist at any time. More and more

vehicles are being kitted out with oil analysis

sets for a comprehensive fl uid‑service.

strong demand for the Fluid service now available

from FLeXXpress, other FLeXXpress vehicles are being

fitted out with the equipment needed to perform

or organise on-the-spot oil maintenance and analysis.

After all, contaminated oil is a frequent cause of

breakdowns. Our FLeXXpress Fluid service is the

easiest way to take proper care of your oil. The service

technicians from the mobile Fluid service are able to

install and maintain partial flow filter systems.

something else that ensures fast service is the Fpmobility

fleet management system that was launched

in April 2008. It is designed to optimise communications

between the company HQ and service vehicles.

An interactive table showing all vans and a map with

all HANsA-FLeX branches means that technicians can

be deployed more efficiently. mobile radio is used to

send a job to the next available fitter, so allowing the

customer to be given an exact time of arrival. Once

the work is finished, the fitter fills in the delivery

note with a digital pen that has meanwhile become a

standard item of equipment on all FLeXXpress vans.

While the delivery note is being completed by the

FLeXXpress technician, the data are simultaneously

transmitted to HQ, where the invoice is printed out

right away. A service that is proving popular among

customers: prompt billing ensures greater transparency

and lightens the workload at many branches.

since introduction of the digital pen it has already

been used to issue 28,000 delivery notes.

The 35 new "red Angels" now out and about on

Germany's road have naturally been kitted out with

another badge of service. This update to the 2009

vans signals from afar that the mobile hydraulics

service is already en route, bringing fast help from



teChNoloGY IsO sTANDArDs

standards sImplIfy



Whether bushings or wall plugs, envelopes or letterboxes, in Germany virtually everything has been standardised according to DIN, its

standardization institute. Although other industrial nations also have their own national organisations responsible for standardisation,

most – bar a few such as the UsA or Japan – do not have the status of our DIN norms. Given the increasing pace of international coopera-

tion between businesses and the worldwide trade in products, the harmonisation of industrial standards is of major importance, and with

it collaboration between national bodies.

Initially standardisation facilitated understanding

when technical issues were involved. At the same

time however, it was also a sign of agreement on

the lowest technical standard. standard specifications

were needed in the interests of uniformity and

safety for man and his environment. International

trade in goods and services

soon made it necessary

to harmonise the norms

existing worldwide to

encourage cooperation in

the world of technology.

many German standards

have been adopted during

this process. IsO is an acronym standing for the

"International Organization for standardization", the

institution responsible for coordinating standardisation

on an international scale. Its name comes from

the Greek "isos", which means "equal".

»Norms are however often put on a

par with the law: failure to comply

will be penalised by the market«

The Geneva-based International Organization for

standardization was founded in 1946 and is a voluntary

institution which is not governed by any treaty.

It draws up IsO standards, which are ready for adoption

by the member states without further change.

In the Federal republic of Germany they are known

as DIN IsO norms. The

resolutions passed by the

IsO do not have the status

of internationally binding

agreements. such norms

are however often put on a

par with the law: failure to

comply will be penalised

by the market. The IsO thus establishes international

standards that do away with barriers to trade. It thus

ensures that a whole lot of things in the world function

in more than just one country. members with

voting rights include virtually all national standardisation

institutes of the 89 states involved. There are


also other members just with observer and advisor

status. The IsO has some 200 technical committees or

work groups responsible for formulating and issuing

international standards: a process that takes place in

several stages. Two new standards are published every

day. Norms for furniture or for spectacle frames,

metric screw threads or a test method for measuring

the size of mesh in fishing nets.

The work groups meet once or twice a year. In the

last week of October 2008 south korea was the

venue for the annual meeting of Technical Committee

45 – rubber and rubber products, which is itself

divided into four subcommittees, attended by four

delegates from Germany.

Dr. Heinz and Dr. Warskulat

(evonik Degussa) and Dr.

Du Bois (Conti) contribute

their expertise in raw

materials and their testing,

while HANsA-FLeX

representative Axel Tammen

is responsible for hoses and hose testing. As an

expert he is in charge of the German and european

work group. This field, which is of vital significance to

HANsA-FLeX, is broken down into four work groups

– industrial hoses, automotive hoses, hydraulic hoses

and their testing. The meetings of TC 45 are attended

by a total of 45 representatives from China, Germany,

France, Great Britain, kenya, India, Indonesia, Italy,

Japan, malaysia, the Netherlands, sweden, Thailand,

the UsA and host country south korea. For

HANsA-FLeX Axel Tammen's presence at IsO meetings

is important to ensure it is actively involved in

the development of standards. "This is how we do

our bit to make hydraulics safer, more economical

and more efficient on an international scale," comments

Axel Tammen. "We are aware of our responsibility

and want to ensure that the safety of both

man and the environment is incorporated in such


struGGliNG For uNiForMitY

experts in TC 45 are currently working on 31 standards

concerning issues of relevance to HANsA-FLeX.

Here the hydraulics service provider can contribute

a wealth of practical experience acquired during

countless previous projects. This involves for example

the standards which describe hoses used by

HANsA-FLeX at IsO level, i.e.: IsO 1436 (wire-braidreinforced

hoses), IsO 3862 (spiral-wire reinforced

hoses), IsO 3949 (plastics hoses) and IsO 4079 (textile

reinforced hoses).


»The work of the subcommittee is

always a kind of wrestling between

the leading industrial nations«

It sometimes takes between three and five years

until a new standard is finally published due to the

periods of time allowed for objections. Work only

starts on a project when the technical committee responsible

has given the go-ahead. The experts then

get down to business. A team is currently dealing

with IsO 6803, the impulse test for hose lines, with

the draft version being initially discussed in the work

group. Any requests for changes are put forward and

incorporated before the draft is submitted to the IsO

committee. The draft is the subject of further discussion

and development at the next meeting, with

further action such as testing being decided at the

same time. A draft is sometimes withdrawn or put

on ice. This is what recently

happened with IsO

6945, which was meant

to lay down a uniform test

method for abrasion wear

behaviour. It transpired

that this method was unusable

and did not produce

any standard result. A new IsO norm is only approved

and published when all partners are happy with the


The work of the subcommittee is always a kind of

wrestling match between the leading industrial nations

Japan, UsA and Germany, who are aiming to

push through as many of their own norms as possible

internationally or coming up with compromises.

The 56th IsO meeting in korea dealt with possible

replacement of the measuring unit "bar" with "mpa,"

(i.e. megapascal, with 10 bar corresponding to 1

mpa). The work group managed to find a compromise

here, both units initially being listed in a table

for new standards. Axel Tammen however expects

"bar" to disappear sooner or later: unlike "bar", "mpa"

is an sI unit and thus forms part of the International

system of Units for measurement such as the metre,

kilo, second, ampere or kelvin.

"such negotiations are a kind of technological diplomacy

involving the forging of alliances and bartering,"

stresses Axel Tammen. Although a standard

does away with trade barriers, it is simultaneously

also a sort of technical "customs clearance" procedure,

when foreign companies have to modify their

products to comply with the norm. And this makes

it all the more important for HANsA-FLeX to have its

say in the work of these committees.

IsO sTANDArDs teChNoloGY

the teChNiCal CoMMittee 45 was held in south Korea at

the end of 2008. experts from 45 countries were deliberating

on important iso standards, amongst others various stand‑

ards from the field of hydraulics.

haNsa-FleX’s aXel taMMeN (left) took part as an expert

consultant and steered the sub‑committee on hoses and

testing. this topic was divided into the four task‑groups:

industrial hoses, automotive hoses, hydraulic hoses, and

their respective testing procedures. through its participation

haNsa‑FleX is able to make an active contribution to the

development of the standards.




"OUr empLOYees Are THe keY TO OUr sUCCess"

Export Controller

based at our HQ in Bremen.

Your responsibilities:

• Looking after customers

• Handling orders from our subsidiaries

• Off ering technical support to HANsA-FLeX sites based abroad

What we are looking for:

• A commercial qualifi cation with a basic understanding of technology

(preferably a background in wholesaling / exports) or a technical qualifi -

cation with commercial knowledge

• Initial experience in a similar role

• A good knowledge of the ms-Offi ce package

• Familiarity with sAp an advantage

• Above-average ability to cope with time pressures and stress

please send your application stating the salary you require to:

HANsA-FLeX Hydraulik GmbH | FAO mr rörig

Zum panrepel 44 | 28307 Bremen

Commercial/technical Coordinator

based at our Oyten branch.

Your responsibilities:

• providing technical advice, tel. selling, drawing up quotations/orders in sAp

• supporting the fi eld team, procurement, technical documentation, administrative


What we are looking for:

• Technical or commercial qualifi cation (background in wholesaling / exports,

mechanic with commercial skills, technical sales)

• product knowledge from fi ttings sector (connection technology)

• Ability to grasp technical problems and come up with reliable solutions

• Good skills in dealing with customers / team player

• knowledge of ms-Offi ce / ideally experience with sAp

• A good communicator who is also fl exible

please send your application stating the salary you require to:

HANsA-FLeX Hydraulik GmbH | FAO mr rörig

Zum panrepel 44 | 28307 Bremen

technical Service Coordinator


Further information regarding vacancies and opportunities within HANSA-FLEX you will fi nd at www.hansa-fl

for our branch in Bielefeld.

Your responsibilities:

• Advising customers about hydraulics and serving at the counter

• Dealing with incoming orders

• preparing hose lines / processing fi ttings

• picking goods for dispatch / monitoring stock levels

What we are looking for:

• A qualifi cation from the metalworking industry (mechanic, metalworker,

agricultural machinery mechanic)

• Ability to grasp technical problems and come up with reliable solutions

• Good skills in serving customers / team player / Class B (3) driving licence

• experience in looking after customers, ideally in the hydraulics sector

please send your application stating the salary you require to:

HANsA-FLeX Hydraulik GmbH | FAO mr rörig

Zum panrepel 44 | 28307 Bremen

Field team hydraulics mechanic

for our FLEXXPRESS rapid hydraulics service

for the Bremerhaven region (vacancy: 492).

Your responsibilities:

You are responsible for keeping downtimes involving customer equipment

to a minimum on site as well as for the maintenance, servicing and delivery

of new hydraulic lines and for looking after customers and increasing our

customer base.

What we are looking for:

• Techn. qualifi cation (mechanic for agricultural machinery, car mechanic)

• requirement: a knowledge of hydraulics in relation to mobile hydraulics

• experience in the fi eld of construction or agricultural machinery, work

platforms or commercial vehicles

• Ability to cope with time pressures and stress

• Driving licence (class C1 or C1e) / on-call duty

please send your application stating the salary you require to:

HANsA-FLeX Hydraulik GmbH | FAO mr rörig

Zum panrepel 44 | 28307 Bremen


wIn an Ipod touch


please send the answer in by email to or by post. please do not

forget to indicate your name and your postal

address. The deadline for entries is march 13th 2009.

One entry per participant will be considered for the

facts & fIgures



elst, Belgium 1989 20 years

Dresden, Germany 1994 15 years

Boffzen (sondermaschinenbau), Germany 1999 10 years

klagenfurt, Netherlands 2004 5 years


Würselen/Aachen, Germany 1994 15 years

spreenhagen, Germany 1994 15 years

Weingarten, Austria 1999 10 years

Zwolle, Germany 2004 5 years

Dubai, United Arab emirates 2004 5 years

rokiskis, Lithuania 2004 5 years

Alytus, Lithuania 2004 5 years


draw. Terms and conditions apply for legal recourse

and liability. A cash payment for the prize is not possible.

employees and members of HANsA-FLeX are

excluded from participating.

ipod touch, 8 GB (holds up to 1750 songs), 3.5-inch

(diagonal) widescreen multi-Touch display; earphones,

UsB cable, dock adapter, software iTunes for

mac & Windows; pC system requirements: UsB 2.0

port, Windows Vista or Windows Xp Home or professional

with service pack 3 or later, iTunes 8 or later;

mac system requirements: UsB 2.0 port, mac Os X

10.4.10 or later; iTunes 8 or later.

preVIew 04|2009





hYdrauliC liNe eNGiNeeriNG What's new about pipework elasticity

health & saFetY protection with goggles, gloves and equipment

haNsa-FleX solutioNs Customer benefit enhanced by customised concepts

iNdustrial serViCe HANsA-FLeX steps up industrial installation and FLeXXpress fleet

report FroM ZwiCKau Gudrun Dietrich banks on the expertise of the field team

Xworld adVeNture 2008/2009 From penang to Bangkok

saFe usaGe oF CleaNiNG aGeNts What instruction leaflets tell us

QUIZ | preVIeW FaCts & FiGures


What is the German title of the

HANsA-FLeX volume published this year?

A: Hydraulik im Überblick

B: Die Welt der Hydraulik

C: Hydraulische Leitungstechnik

aNswer editioN 12|2008

a: borough of Geisenfeld – winner: w. Fackler, wachendorf




224 127


HANsA-FLeX Hydraulik GmbH posener straße 20 94315 straubing




More magazines by this user
Similar magazines