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INDUSTRY WITH A TAILWINDThe world has ambitious plans for rapid development of wind energy – the opportunities behind a long-neglected onshore and off-shore energy source
AFTER THE WORST-CASE SCENARIOHow our radiation protection experts are supporting the people and industries of Japan
CISTERNS FOR TANZANIAEngineers without Borders help people help themselves
contactC U STO M E R M AG A Z I N E O F T Ü V R H E I N L A N DC U STO M E R M AG A Z I N E O F T Ü V R H E I N L A N D I S S U E 2 . 11I S S U E 2 . 11
Technology & Safety04 16 24 Markets & ExpertiseTrends & Innovation
Focus: Wind energy
Fresh air 04
How people can profit from the wind
High pressure 06
A sector between protective walls
and windmills
Assembly instructions 08How wind energy giants are
constructed
Head in the clouds 10An interview with Frank Witte on the
future of wind energy
High-wire act 12Why our engineers are crazy
about Alpha Ventus
Mission 16
How Dr. Jens Uwe Schmollack and his
team are supporting Japanese industries
Dragnet 20
How material inspector Dr. Jürgen
Dartmann detects hazardous material
defects
Herculean task 24
How Hellenic Petroleum is modernizing a
refinery with help from our international
experts
02
Inhalt
contact 2.11
SpotlightFacts and Figures 14
– New testing lab in Shanghai
– TÜV Rheinland corporate report
– Scrapping initiative
– Tracking fakes
Contents
Editorial
26African and German mayors discuss climate change and migration, an au pair
from Hungary looks after the neighbor’s children, your daughter goes to
school in Canada for a year, a call center in India handles your IT support
needs and the steak on your plate originated in Argentina – no area of modern
life can be seriously considered free from globalization.
In our business, project teams have long been reaching beyond national
boundaries, for example, to help build wind farms in the North Sea with com-
ponents from a dozen different countries. With our international expertise as
solution providers, we not only support wind turbine manufacturers in quality
assurance during production of individual elements, but also in the selection
of the right raw materials. This spares the companies and their staff costly
and risky remedial work in rough seas. To find out how this works, what ex-
traordinary people are involved, where the winds of change are taking the
energy market and much more, check out our lead story (pages 4 to 13). The
conversion of a Greek oil refinery is another prime example of how our ex-
perts’ know-how enables companies to draw on global supply chains to build
complex systems – dependably, economically and successfully (pages 24 and
25).
Being at the right place at the right time is not just our core competency, it’s
also something we take to heart – our experts are dedicated to helping people
and protecting them from risks. Find out about how our radiation protection
team in Japan (page 16) and Engineers without Borders in Tanzania (page 26)
are helping people help themselves.
SOLUTIONS WITHOUT BORDERS
People & Environment
Human rights 26
Why we support Engineers without
Borders in building cisterns in Tanzania
Values 29
A new quality of relationship between
car tuners and TÜV inspectors
Editorial Information 32
03contact 2.11
Cover picture:
Katja Flöther, Head of Sales for
wind energy at TÜV Rheinland.
Dr. Christoph Hack, Member of the Executive Board TÜV Rheinland AG
Trends & Innovation Wind energy04
contact 2.1104
WIND IN THE SAILS OF THE ENERGY INDUSTRY
Fresh summer breezes, frosty winter blizzards, increasingly frequent
and devastating hurricanes: wind has always been a mixed blessing for
mankind. Once harnessed to propel battleships and drive mills, today it
is a promising source of energy for the future. The share of wind energy
in worldwide electricity production mix is seeing a sharp upswing – as
attested by wind farms like Thanet near the mouth of the Thames and
the offshore wind power plant Baltic I, which EnBW commissioned in
2011. At a rated power of 48.3 megawatts, it meets the energy needs
of around 50,000 households. And our experts are supporting RWE
Innogy in an even bigger project: the wind farm Nordsee-Ost, where we
are overseeing construction, has six times that capacity or 295 MW. By
2012, REpower will erect 48 turbines with a rated power of around 6.15
MW each near the island of Heligoland. The 1.1 million MWh produced
annually will supply energy to as many as 300,000 households. Read
more in the following pages.
contact 2.11 05
PROTECTIVE WALLS AND WINDMILLSPeople have been harnessing the wind since the beginnings of civilization, but the history of electricity generation by wind is still young. What potential do the trade winds, monsoon, föhn, mistral, bora and scirocco have for meeting the world’s energy needs? What prospects exist in conjunction with other renewable energy sources?
All wind turbines worldwide have a total rated power of around 200 GW, sufficient to supply around 200 million households with clean electricity. China is today’s “Wind state No. 1” after over-taking the US in 2010. They are fol-lowed in the top ten by Germany, Spain and India, which today is virtually equal with Italy, France, Great Britain as well as Canada and Denmark.
WIND POWER NATIONS 2010
USA40,180 GW20,7 %
Canada4,009 GW2,1 %
Great Britain5,204 GW2,7 %
France5,660 GW2,9 %
Germany27,214 GW14,0 %
Denmark3,752 GW1,9 %
China42,287 GW21,8 %
India13,063 GW6,7 %
Italy5,797 GW3,0 %
Spain20,676 GW10,6 %
Other countries26 546 GW13,7 %
06 contact 2.11
As early as 5000 BC, the clever Egyptians
expanded their empire using sailing craft.
Windmills for grinding flour and grist were
not invented in Holland, but around 1750 BC
in Babylonia. Eight centuries later, mills with
vertical rotation axes and standing vanes,
blades or sails were a common feature of
the Persian landscape. Windmills did not
come to symbolize the Netherlands until
the 16th century, and Don Quixote has been
tilting in vain at the winged monsters upon
brave Rosinante since 1605. In 1887, the
Scottish electrical engineer James Blyth
became the first person to use wind power
to illuminate his holiday home. But this
technology was long considered expensive
and inefficient, even though the physicist
Albert Betz developed the theoretical basis
for the aerodynamics of rotors in Göttingen
around 30 years later. According to his
work, up to 59.3 percent of the available
energy can be converted to mechanical
power using aerodynamically optimized ro-
tors: Betz’ law, which remains true today.
With the intensified debate on energy is-
sues that began 20 years ago and today’s
increased public awareness of climate
change, wind power is seeing an upswing.
Wind turbines can be deployed on land and
at sea in all climate zones. According to
Greenpeace, wind energy has the potential
to generate one third of all electricity need-
ed by the middle of this century – resulting
in a considerable CO2 reduction. But no na-
tion is as heavily committed as Norway’s
smallest island: Utsira is home to 215 peo-
ple. The required energy is produced by two
state-of-the-art wind power generators,
whose output is stored by means of the
world´s first wind-hydrogen power plant.
Using electrolysis, excess energy is trans-
formed into hydrogen, which is then stored.
The resulting hydrogen fuel cell powers a
generator to supply Utsira residents with
electricity in calms and storms.
New technologies convert wind energy
into hydrogen
Harvard University has concluded that wind
energy would be sufficient not only to cover
the entire world energy requirement, but an
amount up to 40 times greater. But not ev-
eryone is a fan of this renewable energy
resource: for years, middle-class environ-
mental activists have been blocking what
they consider the “desecration of the land-
scape” and threats to birdlife, neighbors
complain of health issues caused by the so-
called infrasound of the rotor blades. Ame-
rican medical researchers have since dis-
proved this claim: at a distance of up to 300
meters, the noise level is between 40 and
50 dB(A) on average – quieter than many
workplaces. However, large-scale technolo-
gical solutions for storing surplus electricity
until the next peak period are still lacking. In
2009, the Fraunhofer Institute for Wind En-
ergy presented a technology for turning
electricity into natural gas: electricity is
used to produce hydrogen by electrolysis.
The hydrogen is then converted to methane
– the main component of natural gas – by
the addition of CO2. Energy produced in this
way could be fed into the existing natural
gas infrastructure, used to drive natural-gas
cars directly or processed further into gaso-
line or diesel. In mid-2011, a first hybrid
power plant for producing hydrogen from
wind energy is scheduled to go into opera-
tion in Berlin. This is the first pilot project to
link the energy sources wind, hydrogen and
biogas.
Wind is caused primarily by the differences in air pressure be-tween air masses on land (warmer) and at sea (cooler). The greater the difference between the air pressures, the greater the flow of the warmer air masses into the low-pressure region – and the stronger the wind. The wind speed is measured in km/h, the Beaufort scale indicates the strength from 2 (breeze) to 12 (hurricane).
HOW WIND IS CREATED
The offshore wind farm Thanet is 12 kilometers northeast of the mouth of the Thames. It com-prises 100 Vestas V90 wind tur-bines and is operated by Vattenfall UK. Each turbine has a rotor mea-suring 90 meters in diameter; the generators are rated for 3 MW each, for a total of around 300 MW rated power. The farm covers an area of around 35 square kilome-ters. In this region, the North Sea has a depth of 20 to 25 meters.
THE LARGEST WIND POWER PLANT
Wind energy Trends & Innovation
contact 2.11
Over the sea, the air cools and falls
Over the land, the air warms and rises
New air masses rush in
sea land
07
GLOBAL PUZZLEThe Nordsee-Ost (NSO) wind park of RWE Innogy is super-sized in every sense. We are monitoring the manufacture of individual components. The 34-meter-long tower segments are being assembled in Cuxhaven. An onsite report.
This puzzle is really a job for giants. That is
how Johann Grapengiesser views building
a wind turbine. The project head at TÜV
Rheinland and his team for monitoring the
production of the components for the NSO
wind farm near the island of Heligoland are
currently travelling all over Europe. The
frames for the nacelles and machines are
being welded in Germany and in the Czech
Republic by Excon. The transmissions are
being built by Winergy in Vörde, in Germany
near the Dutch border. The rotor blades are
coming from the Danish company LM Wind
Power in Lunderskov and Powerblades in
Today, the giant among wind turbines is the ENERCON E-126, with a rated power of 7.5 mega watts. The hub height is 135 meters, and the overall height is 198 meters – just 29 meters less than San Francisco’s famed Golden Gate Bridge. The rotor has a diameter of 127 meters, longer than a soccer field. On January 27, 2011, the system went online near Magdeburg. Un-der favorable wind conditions, it generates 14,000 MWh per year and supplies up to 15,000 people with clean electricity.
An inside view of a giant: Gundolf Wehr-meister inspects the surfaces and welds using a flashlight.
THE TALLEST AND MOST POWERFUL WIND TURBINE IN THE WORLD
Gundolf Wehrmeister, inspector for the NSO project, oversees construction of tower segments at the Ambau company facilities in Cuxhaven.
08 contact 2.11
Bremerhaven. They form fiberglass-plastic
laminates into rotor blades 62 meters long,
which are inspected according to a pre-
cisely defined testing process on comple-
tion.
Eyes and ears
Our engineers are involved virtually every-
where. RWE Innogy has contracted them
to monitor the specified test plans as third
party inspectors. “We are RWE’s eyes and
ears in the production. My team and I sup-
port the processes, detect faults, offer rec-
ommendations for corrections and identify
manufacturing deviations,” summarizes Jo-
hann Grapengiesser. As mediators between
the customer and suppliers, they moderate
the working relationship and make sure that
the contractually stipulated specifications
are met.
Safe at wind force 10
With this quality assurance during produc-
tion, RWE Innogy wants to avoid remedial
work on the high seas. Repairs under harsh
weather conditions are many times more
complicated and costly than directly in the
plants of the component manufacturers.
The harsh offshore deployment makes ex-
treme demands of the steel components of
the tower and nacelle; welds and corrosion
protection have to last for decades. The
non-destructive testing of each weld is car-
ried out after grinding and sand-blasting.
The coating of zinc or special resin-based
plastics in particular must protect the rust-
prone steel from aggressive sea salt for
many years.
Tower in transit
The tower segments are constructed at the
plant of Ambau Stahl- und Anlagenbau in
Cuxhaven. Each of these sections of the
final tower is 34.5 meters long and weighs
121.5 tons. They are welded together, com-
plete with all entire internal components,
including elevator fittings, cable ducts and
cables.
The individual elements are then trans-
ported by night to Bremerhaven as a heavy
load, where they are transferred to a special
ship. This vessel transports the preassem-
bled segments to their sites off Heligoland.
In spite of its length of over 100 meters and
a beam of 40 meters, this ship, designed
especially for NSO, can hold its position to
within centimeters using satellite signals in
water depths of up to 40 meters.
Freshly formed and welded, the tower sections await the next processing steps.
O
Wind energy Trends & Innovation
contact 2.11 09
INFORMATION
Johann Grapengiesser
+ 49 221 806-4385
+ 49 40 378 79 04-67
www.tuv.com
When it comes to employee qualifi-cation for the wind energy industry, the TÜV Rheinland Academy is the ideal partner. Together with the tech-nology-focused university TU Berlin, we recently developed a unique pro-gram for training managers at Ves-tas in deploying the new carbon fi-ber composite technology. Vestas is a global leader in the manufacture of offshore wind turbines and has been operating a rotor blade factory
A FRESH BREEZE FOR TRAINING
in Lauchhammer since 2002. The TÜV Rheinland Academy has a facil-ity in the immediate vicinity. “With our plastics competence center, we are an important provider of educa-tional services for renewable ener-gies,” explains director Rainer Er-bisch. Worldwide, TÜV Rheinland Academy prepares executives for new challenges, provides safety training and trains individuals in the use of new energy technology.
10
The world has ambitious plans for expanding wind power, and not only in China, India and the US. The European Union could cover 14 percent of its energy needs using wind energy by 2020. By 2030 the figure could even be as high as 28 per-cent, according to the European Wind Energy Association. We support global projects of virtually all major manufactur-ers. Frank Witte coordinates these global activities for us. He is expecting expansion in the areas of offshore wind farms.
“THERE’S STILL ROOM AT THE TOP”
contact 2.11
A strong updraft: the wind energy market grew by 36 gigawatts, around 22.5 percent, in 2010.
11contact 2.11
Wind energy Trends & Innovation
Where is the world wind energy busi-
ness heading through 2020?
By the end of 2010, over 194 gigawatts of
rated power had been installed all over the
world. That’s equivalent to around 20 medi-
um-sized nuclear power plants of the same
type as the still-operative Fukushima I-6
reactor. The Global Wind Energy Council
estimates that this capacity will double in
the next three to four years. Worldwide
forecasts say around 1000 gigawatts will be
installed by 2020. In 2010 alone, the global
industry grew by 22.5 percent.
Will wind energy replace atomic pow-
er?
Certainly not as fast as widely predicted.
This is due to the cost of atomic power,
which is enabling emerging nations to grow
economically. However, economies of scale
are making wind energy less and less ex-
pensive in series production. The larger the
systems and the more they are manufac-
tured on industrial scales, the less costly
wind power will be.
What’s driving this dynamic?
Researchers and actuaries knew long be-
fore Fukushima that humanity needs new
energy policies. Fossil fuels must be re-
duced due to their CO2 emissions, and the
risk assessment of atomic power has
changed. Wind energy still harbours enor-
mous efficiency potential – not least, for the
environment.
What’s next technologically?
The largest wind turbine today has a rated
power of 7.5 MW. Turbines with 20 MW
could be available by 2020. The tower and
nacelle height will increase from an average
100 meters today to up to 150 meters. Ex-
perts calculate that each meter of altitude
yields one percent more electricity produc-
tion. Internationally leading experts say
maximum rotor diameter can be increased
in the future from the current 120 to 200
meters. Particularly the introduction of car-
bonfiber plastic technology will make this
possible. And there is still a lot of potential
for increasing power production in the aero-
dynamics of the rotor blades. At present,
the average wind yield is around 30 percent.
So there is still a lot of development scope
until we hit the theoretical limit of Albert
Betz of 59.3 percent. Especially in the
coastal regions of Europe, the US and China
– where most people live – offshore wind
farms consisting of several hundred tur-
bines will be built.
Are the industrial production capacities
up to this task?
What we are observing globally with opera-
tors and their manufacturers is comparable
to the automotive industry in the 1980s.
Industrial mass production is advancing.
However, it has not yet reached the level of
conventional engine manufacturing. The
series production and quality assurance in
the offshore area still requires a great deal
of development work, particularly in corro-
sion protection.
A global companion of our wind energy projects: engineer (Dipl.-Ing.) Frank Witte.
12 contact 2.11
THE SPICE OF LIFEThe jobs of some engineers look more like high-wire acrobatics. Whether commissioning, regular inspec-tions or maintenance management – everything must be done way up in the air. And our experts enjoy their adventurous jobs even in force-6 winds.
Wind turbines consist of a rotor with hub and rotor blades that convert the wind energy into mechanical rota-tional motion. The rotor blades are similar to aircraft wings. The top sur-face is curved more than the bottom surface. The air flow over the rotor blades thus generates a higher pres-sure on the underside and a lower pressure on the upper side. This cre-ates lift forces that cause the rotor to turn. The rotor transfers its energy to a generator via a driveshaft and, in some configurations, a transmission. A rotating machine housing, the na-celle, allows the system to turn with the wind and accommodates the en-tire technology. The higher the tower, the higher the wind speed and the energy yield.
WIND TURBINES – TECHNICAL MASTERPIECES WITH PROBLEM ZONES
Not the most comfortable workplace: Frank Kunkel uses a winch and cable to rappel along a 150-meter-high Alpha Ventus tower. “Touring” is the professional term for this type of onsite inspection.
Rotor• Fatigue fractures• Cracking• Lightning strikes• Rotor blade adjuster
mechanism
Bearings and shafts• Shaft imbalance• Bearing damage
Transmission• Gears• Seals
Generator• Wire winding• Overheating• Ventilation system
Nacelle• Control technology• Mechanical wind
direction follower• Assembly crane
Tower• Ascension aids
(ladders, stairs, elevators)• Hoists, hoisting ropes, chains• Bolts and rivets• Stability• Platform (particularly offshore)
Wind energy Trends & Innovation
13
Eight o’clock on a pleasant morning in fall
2010 above the training wind turbine of Al-
pha Ventus in Cuxhaven. Right on the
beach, wind force 6 on the Beaufort scale
– that is: strong wind, rough sea with white-
caps. Entirely normal weather for the North
Sea. And for Frank Kunkel. He has already
put on his personal protective gear, and in
a few minutes our engineer will walk out
the door – of the helicopter D-HTMA, which
he took off in to complete his helicopter
rappelling course. Asked if he’s afraid, he
just smiles. “This is the spice of life for an
engineer,” says the enthusiastic diver and
sailor. He loves the sea and the weather.
The modern helicopter, two turbines with
650 hp each, is specially designed for off-
shore missions. Frank Kunkel is lowered to
the object he is to inspect via the outboard
hoist. He must pass this course in order to
be able to rescue himself or colleagues in
the event of a precarious situation on Alpha
Ventus. He has been lucky so far. He was
able to perform the commissioning inspec-
tion of the ascension aids for Eon, Vattenfall
and RWE, the owners of the first German
offshore wind farm, from a ship. The com-
missioning of an offshore wind turbine is
the final phase of a major contract that
got underway in 2008.
Frank Kunkel “toured” the
eight towers with their
giant rotors erected
by REpower and
Areva. The 5
Loves his work and trusts in good material: Frank Kunkel, the Alpha Ventus high-wire artist.
MW rated power of each unit will secure
the electrical supply of up to 6,000 homes.
Frank Kunkel was satisfied: the require-
ments of the machine directive and the
operational safety regulation had been me-
ticulously observed. Nothing stood in the
way of approval.
Everything from a single source
Whether offshore or onshore: Frank Kunkel
is one of our 12 engineers who scale wind
turbines in Germany. They help secure a
part of our energy supply. As an authorized
inspection agency, we are the solution pro-
vider for wind turbine operators. In addition
to the “first climb,” our experts inspect all
safety-relevant components in the required
two-year intervals: rotor blades, for in-
stance, are subject to enormous stresses.
Our engineers visually inspect the parts,
looking for signs of material fatigue or dam-
age due to lightning strikes or birds. Par-
ticularly ascension aids such as elevators
and ladders can become death traps for
maintenance personnel. As a consequence,
legislators the world over impose stringent
safety requirements on the operation of
wind turbines, the ascension aids and the
authorized inspection agency.
Not a job for desk jockeys. “The important
thing is to not be afraid and trust the mate-
rial,” says Frank Kunkel. The academically
trained mechanical engineer is not afraid of
heights, but respects the dangers he ex-
poses himself to. It takes him around two
hours to inspect a wind turbine, and he is
surefooted even 90 to 100 meters up.
“Good physical dexterity and fitness are es-
sential, otherwise you can’t do this job.” To
make sure they stay that way, our
wind-climbers regularly attend
seminars such as rescue at
heights, offshore and heli-
copter training.
contact 2.11
INFORMATION
Katja Flöther
+49 40 378 79 04-20
www.tuv.com/windenergie
Facts
contact 2.11
For more than 20 years now, TÜV Rheinland has maintained operations
in China. With around 2000 employees it is now our largest branch
company in Asia. To further expand our local capacity, we opened a new
branch office with integrated testing facilities in Shanghai, in April 2011.
The building, with an area of around 17,000 square meters, houses test
labs for numerous product groups. As one of the largest and most
modern testing complexes in Asia, it is aimed at manufacturers in the
consumer goods, mechanical engineering and solar energy sectors.
With our work in this test complex, we will be in an even better position
to ensure that our clients’ products meet the technical standards of their
respective destination countries. In Shanghai tests are carried out on
electrical safety, electromagnetic compatibility and everyday usability as
well as chemical analyses – all at the highest technical level. Our com-
pany maintains further large labs in Hong Kong, Guangdong and Shen-
zhen.
HIGHEST STAN-DARDS IN TESTING AND TECHNOLOGY
As one of the first companies in Germany, we have re-
leased an integrated annual, financial and sustainability
report. Under the title “Boundless,” the report provides
facts and figures about our business success in 2010 as
well as on corporate social responsibility as a part of our
corporate strategy. The report also contains background
information on innovative processes in the areas of mate-
rials testing, the establishment of new test centers
abroad and energy efficiency. The sustainability report
complies with the criteria of the independent Global Re-
porting Initiative, which once again gave it its highest re-
port rating of A+. For the first time, parts of the sustain-
ability report were audited by the auditing firm of PwC.
“As a neutral provider of testing services, we have a par-
ticular obligation toward the general public when it comes
to transparency and openness. With this new corporate
report, we are the global pioneer in our industry,” says
Aud Feller, Head of Communications at TÜV Rheinland
AG. The integrated corporate report is available as an in-
teractive online report, as well as in printed and PDF ver-
sions in German and English. More information at: www.
tuv.com/corporatereport
THREE IN ONE
and Figures
Focused clients’ target markets: our new branch office in Shang-hai features an integrated testing lab.
Compact: TÜV Rheinlandpublished his first integrated corporate report.
Information: Aud Feller, [email protected]: Ralf Scheller, [email protected]
UNTERNEHMENSBERICHT 2010
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CORPORATE REPORT 2010
14
Experts estimate that ten percent of all products sold
on the world market are counterfeits. According to
the German Anticounterfeiting Association (APM),
fakes cost the German economy alone 50 billion eu-
ros and up to 70,000 jobs – every year. And the trend
is increasing.
To counter this, TÜV Rheinland has developed a pa-
tented Product Authentication and Control System
(PACS). It allows unique marking of all products, in-
cluding pharmaceutical packages, batteries, textiles
and solar modules. During production, each individual
product is marked with a unique, randomly gene-
rated code. With this solution for tracking and tracing
shipments, products can be identified and monitored
along the entire supply chain. Even end consumers
can verify the authenticity of a product via the Inter-
net or mobile device. In addition to PACS, our service
portfolio for combating product piracy comprises on-
line monitoring, investigations, supply chain security
audits, patent, brand and design protection and IT
security.
The first Cologne Conference on Product Piracy and
Brand Protection will be held this year on October 6,
2011. More information at www.tuv.com/brm
TRACKING FAKES
contact 2.11 15
Information: Daniel Ritlewski,[email protected]
In mid-April, German customs seized 5,700 electric drills and 1,850 angle grind-
ers at the Port of Hamburg – products that bore unapproved test marks of TÜV
Rheinland or were in violation of trademark law. We had these products de-
stroyed to demonstrate our zero-tolerance policy toward brand piracy and test
mark counterfeiting. A giant construction machine crushed the boxes contain-
ing the products, rendering them unmarketable. The application for border sei-
zure was submitted to the intellectual-property authority (Zentralstelle für ge-
werblichen Rechtsschutz) of German customs and approved in 2010. Our aim
was to intensify action against the misuse of test marks and trademark vio-
lations. The main emphasis was on protecting the trusted GS Mark, and thus
consumer confidence. Through this proactive approach, we prevented danger-
ous products from ending up in private households. We initially bear the costs
ourselves because we cannot always recover damages from those who try to
market the products – but that will not deter us in our struggle against abuse of
test marks. At www.tuvdotcom.com, consumers and dealers can enter the ID
number of a product and find out whether it is entitled to bear a seal or test
mark.
COMBATING FAKE TEST MARKS
Information: Dr. Susanne Aretz, [email protected]
Scrapping fakes as a public spectacle: TÜV Rheinland cracks down on products with counterfeit test marks.
Original above, imitation below: TÜV Rheinland’s “Track & Trace” system helps in less obvious cases.
16 contact 2.11
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Technology & Safety Radiation protection16Seeking to bring order to chaos: a large number of experts work on a grid line connection to the offsite power grid, the Okuma line, at the Fukushima nuclear power plant.
MISSION: RADIATION PROTECTION
17contact 2.11
Shortly after twelve o’clock on Friday, March
11, 2011: Dr. Jens-Uwe Schmollack, one of
our radiation protection experts in Berlin,
hears the news about the devastating earth-
quake in Japan. The quake causes the cool-
ing systems of reactors at the nuclear
power facility Fukushima Daiichi to fail. “I
was shocked and extremely concerned,”
recalls Dr. Schmollack. He immediately gets
in touch with his colleagues in Berlin and
Cologne. They are all experts in the area of
nuclear technology and radiation protection,
and form a specialist network in an extreme-
ly short time. From then on, the team led by
Dr. Margot Horn, Head of the Radiation Pro-
tection Business Field in Germany, is in
constant contact with colleagues abroad
and in Japan as well. On the weekend after
the disaster, they try day and night to get an
accurate picture of the situation, estimate
possible consequences and give recom-
mendations. But the situation deteriorates
dramatically: explosions occur, releasing
radioactive materials. While many foreign-
ers leave the country as rapidly as possible,
Dr. Schmollack immediately embarks for
Following the nuclear disaster in Japan, our radiation protection experts are assisting local citizens and industry: they provide qualified information, take measurements, advise and help residents help them-selves. A look at the present and future of a nightmare.
Japan. “The first thing I did was get up to
date on the radiological situation at our
Japanese main office in Yokohama,” he
says. Yokohama is around 50 kilometers
south of Tokyo. Our experts help swiftly and
without red tape: using special measuring
equipment from Germany, some of which
Dr. Schmollack brought personally, they
conduct numerous radiation protection
measurements in the greater Tokyo region.
Our German specialists check schools and
playgrounds free of charge. Companies
based there also commission the testers to
measure their premises. The focus is on
both the dose rate, a measure of the exter-
nal radiation load, and the contamination of
objects, buildings or food, which is respon-
sible for the internal radiation load.
From cars to mother’s milk
In the first weeks after the nuclear incident,
our laboratories are working all-out. The
analyses commissioned by Japanese pri-
vate individuals and companies cover such
diverse specimens as soil samples, car
parts, mother’s milk and drinking water.
“We enjoy a high reputation in Japan. They
value our expertise and the care we put into
our work,” notes Dr. Schmollack. Because
the consequences of the nuclear disaster in
Japan will persist for years, we are sup-
porting the Japanese population and indus-
try over the long term. “We have received
a great number of inquiries from industry,”
Monitoring the radiation levels: radiation protection expert Dr. Jens-Uwe Schmollack checks vegetable crops in Japan.
18
affirms Bruno Kuckartz, Head of Division for
Energy Systems and Automation, “because
the radiological effects impact Japan’s en-
tire export market – particularly the automo-
tive industry.”
To secure sufficient capacity to handle the
numerous contracts, we are currently es-
tablishing a competence center with new
laboratories in Yokohama. We have already
invested considerably since March, for ex-
ample in state-of-the-art measurement
technology. Now we can both scan large
areas and conduct precise individual mea-
surements. “This enables us to measure
rapidly and precisely on a large scale. Above
all in manufacturing facilities, but also in
places such as ports, the measuring equip-
ment is a big help,” explains Dr. Schmol-
lack.
TÜV Rheinland wishes to support its clients
over the long term, beyond the current crisis
management. Anyone who considers how
many parts go into making a car will under-
stand that we cannot possibly check all
parts. Consequently, companies must inte-
grate measuring and monitoring in their
production processes. We advise them on
this and help them to procure and install
suitable equipment.
We would also like to train company staff
for the new tasks. “In addition, we want to
certify the monitoring with technical mea-
suring instruments,” says Bruno Kuckartz.
This will enable manufacturers to easily
18 contact 2.11
prove that their products are free of harmful
radiation.
No fear of imports
Important information for consumers: since
the accident, goods from Japan are being
closely monitored. According to experts,
concern of irradiated products is unjustified,
as measurements are conducted when the
products are exported from Japan and again
on importation in the destination country, for
twofold customer protection. While the
German government is planning to elimi-
nate nuclear power by 2022, the discussion
on alternative energy sources has just be-
gun in Japan. “With our many years of ex-
perience, we can support the dismantling of
nuclear facilities,” says Bruno Kuckartz. To
prepare for increasing demand, we are cur-
rently building up our team in the area of
nuclear technology and radiation protection
in Japan and around the world.
March 11, 2011, changed not only Japan but
the entire world. The consequences of this
disaster continue to impact the globalized
economy and do not stop at national bor-
ders. “The international ramifications show
that the existing regulatory system is inad-
equate. It concentrates on immediately
managing the incident, but not on the glo bal
dimension,” observes Dr. Schmollack. As of
the beginning of July 2011, he is back in
Berlin. He and his colleagues continue their
work for Japan undiminished.
A tool for experts to measure ionizing radiation: the scintillation counter.
19
Radiation protection Technology & Safety
contact 2.11
RADIOACTIVITY: MEASURING METHODS AND HEALTH RISKS
Radiation is measured in sieverts
(Sv): 1 sievert (Sv) = 1,000 mil-
lisieverts (mSv) = 1,000,000 micro-
sieverts (µSv)
Limit values vary internationally. In
Germany, the legal limit value for in-
dividuals in the general population is
1 mSv effective dose per year.
0.08 mSv is equivalent to the effec-
tive dose on a long-distance flight,
for instance, from Frankfurt to New
York.
For persons occupationally exposed
to radiation, the limit value in Ger-
many is 20 mSv effective dose per
year.
The system of limit values for nucle-
ar disasters is extremely complex.
250 mSv is considered the limit val-
ue for the persons exposed to radia-
tion in the course of eliminating the
accident damage on the premises of
the nuclear plant in Fukushima.
A single dose of 1000 mSv causes
radiation sickness, but is not neces-
sarily fatal. More than 6000 mSv
causes immediate radiation sickness,
which causes death within days if
not treated.
Following the releases at the Fuku-
shima nuclear power plant, dose
rates in the range of 12 mSv per
hour were measured in the vicinity
of the facility.
In Germany, objects, buildings and
floor surfaces are considered radio-
logically safe when the resulting
effective dose is equivalent to the
value of 10 µSv (0.01 mSv).
The disaster of Fukushima under-scores the hazards of nuclear power: effective radiation protection helps reduce risk.
INFORMATION
Dr. Jens-Uwe Schmollack
+49 30 7562-1567
www.tuv.com
DAMAGE CSI
2020 contact 2.11
21contact 2.11
An industrial building in northern Germany.
The roof structure needs renovation, and
workers use a lifting platform to raise them
to roof level along the building wall. When
they are about halfway up, a dull blast
echoes in the morning air – and the platform
suddenly drops out from under their feet.
The lifting platform abruptly tips over, so fast
that none of the workers can hold on. The
foreman immediately rushes to help his col-
leagues who have fallen to the ground. The
accident plays out in just a fraction of a sec-
ond, but condemns the accident victims to
weeks in hospital. It is subsequently found
that two steel bolts in a supporting member
had suddenly snapped. The lifting platform
simply collapsed.
Some time later, the broken steel bolts,
along with sections of piping and some
welded metal plates, land on the workbench
of Jürgen Dartmann in Cologne, Germany.
Our materials tester and damage analyst is
charged with finding out how this accident
could occur. Every year, he and his team
process around 200 commissions – a job
much like that of a crime scene investigator:
Fractures, holes, cracks – material damage on industrial equipment is always potentially dangerous. As relentless as any crime scene inves-tigator, damage analyst Dr. Jürgen Dartmann seeks to uncover the root causes until the culprit has been identified.
to prove beyond a reasonable doubt why a
specific event occurred on the basis of just
a few clues. Even insurance companies and
prosecutors depend on Dartmann’s judg-
ment. “Only we’re not concerned with mur-
der but with torn welds in factories or cor-
roded drinking water pipes,” says the
expert. Dartmann seeks to find the nature
and the cause of the damage, at least in
most cases – sometimes he also acts in a
preventative capacity to keep damage from
occurring in the first place.
Material inspection Technology & Safety
Prevention mission: Dr. Jürgen Dartmann inspects a bottling system at Cologne’s Reissdorf Brewery to prevent damage before it can happen.
Deep pits under electron bombardment
Dartmann frowns briefly while he regards
one of the steel bolts in his hand. His expe-
rienced eye detects a fine linear structure
on the fracture surface. A first clue? “Could
be a fatigue fracture,” Dartmann mumbles.
But suspicion is a long way from proof. That
is provided by the scanning electron micro-
scope. The principle: the fracture surface is
irradiated by electron beams in a special
chamber, producing a detailed image. This
can be displayed on a monitor – at a magni-
fication of up to 100,000 to 1. The result is
astonishing: the fine lines now look like
No escape: the three-point bend test shows at what stress level a metal begins to give and become deformed.
22
deep pits and appear to cluster at the edge
of the fracture surface. “The bolt received
a slight crack which gradually worked its
way into the interior,” Dartmann explains. It
is in fact a fatigue fracture. This can be rec-
ognized from the wavy lines which beat
against each other roughly under load.
But it is not enough to examine the fracture
surface from the outside alone. “We also
need to study the anatomy of the material,”
Dartmann says. Only a look inside can re-
veal why the fracture occurred. A hot clue
for the damage analyst: something may
have gone wrong in the casting of the bolt.
Possible errors and irregularities can be de-
tected even after the fact by means of de-
structive testing of the material.
A look inside
At a prominent location on the fracture sur-
face where the cracking began, Dartmann
and his colleague cut a tiny piece out of the
bolt. They grind, polish and treat the sample
with acid until they obtain a mirror-smooth
surface: a cross-section through the heart
of the material. Without this laborious prep-
aration, examination under an optical micro-
scope would show only a hilly landscape.
Now, however, a different picture emerges.
„There are shell-like flaws in the metal
structure and squeeze marks near the
edge,” Dartmann reports. In short: the bolt
material is not uniform. Grave errors were
made in its manufacture.
22 contact 2.11
Case closed? Not quite. Dartmann must still
“put the material through its paces.” For the
final series of tests, he has individual rods
machined from the bolt in the workshop.
Then the steel has to show what it’s made
of: the rods are torn apart, bent and attacked
with a hammer in a variety of test rigs. This
way, Dartmann determines the steel’s ten-
sile strength and hardness. This enables
him to judge whether the material was even
designed to be used for bolts in a supporting
member.
Risky combination
“Material fatigue failure in the form of crack-
ing,” is the damage analyst’s final verdict.
The surprise finding: the bolt was even as-
sembled incorrectly, as proven by a photo
from the accident site. The bolts were sim-
ply inserted into the supporting member
with no cladding and no lubricating effect.
“Metal under heavy loads rubbing against
metal, which also caused the squeeze
marks – a risky combination together with
the material defects we discovered,” Dart-
mann says. The manufacturer of the lifting
platform is thus proven to be at fault, clear-
ly and beyond all reasonable doubt, and
must pay damages. And Dartmann’s expert
opinion contains action recommendations
for ensuring that accidents like this one do
not happen again.
A smoking gun: a broken bolt is enough for Dr. Jürgen Dart-mann to discover the cause of the accident.
Damage cases from the lab: from a defective automo-tive catalytic converter and corroded pipes to a faulty heat exchanger.
Comprehensive detec-tive work: Dr. Jürgen Dartmann is interest-ed in the special material glass as well as the production systems in the Reiss-dorf Brewery.
23
INFORMATION
Dr. Jürgen Dartmann
+49 221 806-2404
www.tuv.com
Material inspection Technology & Safety
contact 2.11
COLOSSUS FOR GREECE
24 contact 2.11
Petroleum is a complex natural product. In
its crude state it consists of around 17,000
different substances in widely varying pro-
portions depending on its origin. Accord-
ingly, complex processes are required to
convert it into final products to fuel engines,
heat boilers or serve as raw material for the
plastic production. Whether gasoline, die-
sel, heating oil or other crude oil derivatives:
all of the products must have precisely de-
fined compositions and meet certain re-
quirements.
International megaproject
This is why refineries are actually huge
chemicals factories, where a wide range of
processes take place. The retrofitting and
modernization of an existing plant that Hel-
The refinery operator Hellenic Petroleum is converting its plant in the Greek town of Elefsina – a Herculean task that requires the efforts of manufactur-ers from several countries. We are making sure the components comply with the safety and environmental requirements.
Transport on 18 axles: this gasifica-tion unit is one of many compo-nents TÜV Rheinland is inspecting for Hellenic Petroleum.
Control center: George Paparidis Technical Director at TÜV Rheinland in Greece.
Markets & Expertise Hellenic Petroleum oil refi nery2424
25contact 2.11
lenic Petroleum is currently carrying out in
Elefsina near Athens is hardly less compli-
cated than building a new facility. Greece’s
largest oil processor, which accounts for
almost three quarters of the country’s total
refinery capacity at its three sites, is con-
ducting the complex conversion to concen-
trate on low-sulfur diesel. When it is com-
pleted, Hellenic Petroleum’s second-largest
plant will process various types of crude oil
at a capacity of up to 100,000 barrels of
fuel daily.
The new systems must fulfill technical re-
quirements in terms of function and cost-
effectiveness, while also complying with
Greek and European environmental and
safety regulations. In Elefsina, Hellenic Pe-
troleum is going even further. The company,
which made environmental protection an
integral part of its business activities more
than two decades ago, will not only produce
low-sulfur fuel in Elefsina, it will also meet
its own energy needs using the low-emis-
sion gases that emerge as a byproduct dur-
ing production process.
Our experts from TÜV Rheinland are making
sure in advance that all the requirements are
fulfilled, starting with the production of the
components and later when they are in-
stalled.
“To handle a project like this you need not
only a lot of experts from a wide range of
different technical disciplines, but also a
high degree of international coordination
and a willingness to cooperate,” says
George Paparidis, Technical Director at TÜV
Rheinland in Greece, “because many of the
components are manufactured abroad and
tested there before being transported to
Greece.”
These components have enormous dimen-
sions and complex internal technology. Sys-
tems supplied by Spanish manufacturers
include a 70-meter gas reactor scrubber and
a gasification unit measuring 13 meters in
diameter – just two of the many compo-
nents, each weighing 360 tons. Further
systems were supplied from Greece, Italy
and India. Our experts checked various
manufacturing plants onsite to ensure that
the refinery equipment met all require-
ments and regulations. “Our teams have
been travelling in various countries since
July 2009 for Hellenic Petroleum,” reports
Paparidis. “This involves experts from six of
our locations in Spain, and others from Italy
and Greece.” In months of work, their re-
sponsibilities included checking work pro-
cesses and technical documentation, as
well as, accompanying various tests. Greek
TÜV Rheinland experts will also be involved
in the final approval inspection in Elefsina.
“A megaproject like the conversion of the
refinery in Elefsina requires many different
skills: technical expertise in the widest range
of areas, international project management
and extensive capacities at different loca-
tions,” concludes Paparidis. “Here we can
take full advantage of our strengths as an
internationally operating testing company.”
INFORMATION
George Paparidis
+30 210 556-2130
www.tuv.com
Hotspot: In this furnace, coke particles are heated to temperatures up to 400 degrees centigrade.
Heavyweight: This 70-meter, 394-ton gas reactor scrubber is produced in Spain.
26 contact 2.11
People & Environment People & Environment Cisterns for TanzaniaCisterns for Tanzania26
WHERE THERE’S WATER THERE’S A WAY
27contact 2.11
The Baramba Girls’ Secondary School in
Ngara, Tanzania, needs 5000 liters of water
– every single day. It is needed for washing,
in the boarding school’s kitchen and in its
labs. The school is located in the Kagera
region on a high plateau, not far from the
border to Rwanda and Burundi.
The public water supply in this town of over
16,000 in the farthest northwest corner of
Tanzania covered only a small portion of the
needs and was always subject to inter-
ruptions for indefinite periods. Consequent-
ly, the water was pumped into tanks in the
valley and driven up by car. A lot of money
was spent on gasoline, and a lot of time was
lost in the process – time the students could
have put to better use.
But things are different now. “We can sup-
ply our own water,” reports school Principal
Isaias Baramba with a smile. This project,
with a total volume of 26,000 euros, was
made possible by the organization Engi-
neers without Borders and TÜV Rheinland:
with our financial support, the engineers
built six cisterns on the school grounds last
year. This secures a dependable water sup-
ply for the campus, where around 300 peo-
ple live – and thus the school’s inde-
pendence.
Around four billion people on the planet have no direct access to drinking water. Particularly in regions rocked by conflicts and mass influxes of refu-gees, such as Tanzania, water scarcity is a problem. TÜV Rheinland has now helped Engineers without Borders to build rainwater cisterns.
“The construction of cisterns is a common
technology in this region, because cisterns
are easy to maintain and repair,” explains
Tilman Straub, who heads the cistern proj-
ect. The engineer undertook his first visit to
Ngara to learn about the local conditions in
2008. “We work together with the local aid
organization Mavuno. That makes a lot of
things easier,” says Steffen Rolke, project
coordinator for the German section of Engi-
neers without Borders in Berlin.
Knowledge transfer forms the basis of the
project. “With the help of Mavuno, we
trained a construction team that can now
build cisterns without us,” reports Steffen
The cisterns on the grounds of the Baramba Girl’s Secondary School were built using low-cost materials that are readily avail-able in the region.
The Engineers without Borders passed on their know-how about building and maintaining cisterns to local helpers – enabling them to continue the project on their own.
Rolke. The tanks and rooftop systems were
designed to be constructed using low-cost,
readily available materials. Through training
and with the aid of pictographs, the users
learned how to maintain, repair and clean
the tanks. “We support Engineers without
Borders because they work sustainably and
provide hands-on help to others so they can
help themselves,” says Aiko Bode, our
Head of CSR and Sustainability.
In addition to the cistern project in Tanzania,
we are providing support for the construc-
tion of toilets in a girls’ school in Kenya and
for a bridge project in Rwanda. These basic
facilities make day-to-day life easier: the
bridge ensures that the village remains ac-
cessible in the rainy season, water tanks
help in the dry season and toilets improve
hygiene and privacy.
28 contact 2.11
Words of thanks adorn the tank
The organization Engineers without Borders
has recently been declared a “Selected Lo-
cation” in the German innovation competi-
tion “Germany – Land of Ideas” – a well-
deserved honor, especially considering the
courage and energy the volunteers working
on the project invest, often along with a
large part of their annual vacation. Founded
in 2003 by nine engineers and an econo-
mist, this charitable organization now has
over 1000 members in 24 regional groups.
The emphasis of its activities is on providing
technical assistance relating to water sup ply
and infrastructure in general in developing
nations. Particularly for those taking part for
the first time, missions like this demand a
strong spirit of adventure. “I sometimes
think the colleagues need a vacation more
than ever once we’re finished,” remarks
Steffen Rolke. On the other hand, he has
never known a participant to return from a
mission anything less than enthusiastic. The
joy of the staff and students of the Baramba
Girls’ Secondary School at the dedication
ceremony of the cisterns was also the grea-
test reward for Tilman Straub and his team.
A sign on one of the tanks commemorates
the support – the words of thanks were lov-
ingly applied using a paintbrush.
Access to water: a human right
The United Nations has declared access to
clean drinking water a human right. But its
provision in developing nations fails mainly
due to a lack of know-how in building and
maintaining simple systems, according to a
survey of managers of public waterworks in
the third world conducted by the Witten/
Herdecke University. Women and children
are most often responsible for collecting
water. The trip to the water source – which
may be used by livestock as well and thus
contaminated – often takes many hours.
Anyone wishing to support Engineers wit h-
out Borders in building more cisterns is
welcome to contact Steffen Rolke: steffen.
Memorialized: the school’s words of thanks to Engineers without Borders and TÜV Rheinland are painted by hand.
People & Environment Cisterns for Tanzania
INFORMATION
Aiko Bode
+49 221 806-2350
www.tuv.com
Steffen Rolke
steffen.rolke@ingenieure-
ohne-grenzen.org
+49 030 3252-9865
www.ingenieure-ohne-grenzen.org
Car Tuning People & Environment
29contact 2.11
FINE-TUNED DIALOG
Glittering chrome rims, a flashy paint job, a
throaty engine sound and a chassis so low-
slung that every pothole leaves a dent in the
body – tuning enthusiasts love to show off
their masterpieces at events. And the third
Tuning Night, which TÜV Rheinland once
again hosted in June 2011, was no excep-
tion: 600 lovingly tuned vehicles and around
1,300 dedicated car fans transformed the
testing center in Cologne’s Poll district into
an extravagant showroom. In small groups,
tuners and TÜV Rheinland inspectors talked
shop about aerodynamics, curve perform-
ance and engine power. Which car stereo
puts out the greatest volume? And where
can you get the best shock absorbers? Key
questions in the world of car tuning.
For years, motor vehicle inspection authorities were the natural enemies of car tuners. But in Germany at least, the two sides have found their way to a constructive dialog. A look at a very vibrant scene packed with individualists.
37 events in a single season
After a downturn during the global econom-
ic crisis, Germany’s tuning industry is back
on the fast track. The German Association
of Automotive Tuners VDAT expects sales
in 2011 to top €4.5 billion. This is driven not
merely by the fascination of technology, but
by the desire to be different, to stand out
from the masses. It’s about lifestyle. A
tuned car is unique, not just another mass-
produced consumer vehicle anybody can
drive. This aim is what unites the scene.
“I like the sense of community,” says Ghas-
san El-Daifi. “We’re all on the same wave-
length.” Since his first attempts to “tweak”
his moped, the 31-year-old Cologne native
has been captivated by the fascination of
Tuning Minister 2009: Ghassan
El-Daifi discovered a passion for
tuning in his youth. Today he’s a
development engineer.
tuning. He put his automotive engineering
studies on hold to strike out on his own as
a car tuner – and have time for events such
as the GTI meet at the Wörthersee in Aus-
tria or the Essen Motor Show, Europe’s
largest tradeshow of its kind. His record is
37 events attended – in a single season.
With his masterpiece, a VW Bora BiTurbo
with 518 hp, air suspension and a multicolor-
effect paint job, El-Daifi has already won
numerous prizes in the scene, including the
title “Tuning Minister 2009,” a competition
we launched on the Internet. Participants
created a program of their own – with
tongue-in-cheek remarks such as “Engine
noise is not noise pollution but an important
cultural good” – that was a big hit in the
online forum www.legmichtiefer.com. This
website is a part of our extensive commu-
nication initiative, which was launched in fall
2008 and has continued successfully ever
since. Here, tuning fans can create a profile,
upload photos, create groups – and most
importantly, ask our experts about modifica-
tions they want to make on their vehicles
before approval problems arise. The plat-
form exploits the full range of Web 2.0 me-
dia including Facebook, Twitter and You-
Tube. “We’re especially beefing up our
Facebook offering. Go take a look. We’re
thrilled every time a new fan clicks ‘Like,’”
explains Jost Schaper, Marketing Team
Head at TÜV Rheinland Mobility.
A direct line to the scene
We are deliberately presenting ourselves
more prominently at tuning meets and
shows – as well as organizing events such
as our popular Tuning Night in Cologne. And
the modifications keep getting more radical:
“Today, a car has to have a multimedia sys-
tem with at least 10 monitors to be consid-
contact 2.1130
ered special,” says El-Daifi,” “and that’s
nothing.” Our aim is to improve our contact
with the young amateur tuners and act as a
constructive partner. For far too long, tuners
and vehicle inspection authorities were like
oil and water. After all, our experts have to
refuse to approve vehicles for street use if
the car no longer meets the requirements
for vehicle safety or environmental protec-
tion due to modifications – a great disap-
pointment for the tuner who has invested
countless hours, heart and soul and above
all a great deal of money. The dialog is help-
ing. “Today, we inform users about the
usefulness and feasibility of the modifica-
tions in advance and don’t wait until the
amateur mechanic shows up for inspec-
tion,” explains Dr. Manfred Doerges, Execu-
tive Director of TÜV Rheinland Mobility.
The tuners are taking us up on our offer –
they are the ones who profit most, when
Full house at the testing center: more
than 1300 car fans turned out for the
Tuning Night in Cologne.
Kfz-Tuning Mensch & Umfeld
31contact 2.11
Te facipis autatinim zzriurem nis
nostrud magniam delit accum etu-
ero odolore eu facinci psuscin er-
Who’s got the power? Many car
tuners use the mobile testing
bench to find out exactly …
… how much horse power a tested
car has under the hood.
People & Environment Car Tuning
32 contact 2.11
their “babies” are approved. “Our detailed
in spections are not a form of harass-
ment, but rather important and useful,”
Dr. Doerges explains. Because cheap, low-
quality parts continue to show up on the
Internet – often with falsified technical com-
ponent reports. Inspectors take such parts
out of circulation to protect all road users.
Customizers who do not obtain proper ap-
proval for their modifications risk severe
penalties, and, in the event of an accident
with an illegally modified vehicle, hefty re-
imbursement claims from insurance com-
panies.
Good reasons for looking at vehicle inspec-
tion not as a bothersome obligation but a
useful opportunity. El-Daifi, who today
works as a development engineer at Ford,
thinks so too. And it’s not impossible that
he might someday switch sides – to an in-
spection service. “But of course,” adds El-
Daifi, “only to TÜV Rheinland.”
INFORMATION
Jost Schaper
+49 221 806-3558
www.tuv.com
Editorial InformationPublisher: TÜV Rheinland Aktiengesellschaft, Communication,
Am Grauen Stein, D-51105 Cologne
Phone: +49 221 806-4314 Editor: Aud Feller
Fax: +49 221 806-1760 Text: S+L Partners GmbH, Cologne
Internet: www.tuv.com Printing: Druckhaus Ley + Wiegandt, Wuppertal
Photos: Lothar Wels (Titel, pp. 6-11, 20-23); picture-alliance/dpa (pp. 2, 16, 18); TÜV Rheinland AG (pp. 2, 3, 12-13, 14, 1
5, 17, 19, 24-25, 29, 32); Ingenieure ohne Grenzen (pp. 3, 26-28); gettyimages/Stephan Wilkes (pp. 4-5); Thanet/Jamie
Cook (p. 7); photallery/Fotolia (p. 6); Enercon GmbH (p. 8); Ralf Bille (p. 11); Carl-Victor Dahmen (p. 15); picture-
alliance/abaca (p. 16); Lack-O‘Keen/Fotolia (p. 18, 19); Borbet Group (p. 29); Ludwig Heimrath (pp. 29-31); Reinhard
Witt (p. 32); artcop/Fotolia (p. 32); M.Gove/Fotolia (p. 32)
Id-No. 1112147www.bvdm-online.de
The greenhouse gas emissions resulting from the production of this brochure have been offset by investments in the Gold Standard climate protection project “Wind energy in Yuntdag“.
Open house day: visitors feast-
ed their eyes on around 600
lovingly customized vehicles.
