DIN EN 1591-4 en-US
DIN EN 1591-4 en-US
DIN EN 1591-4 en-US
DIN EN 1591-4
DIN Standards Committee for Piping and Steam Boiler Systems (NARD)
DIN German Institute for Standardization e. V. - No part of this publication may be reproduced in Price group 11
any form or by any means without permission of DIN Deutsches Institut für Normung e. V.,
Berlin.
www.din.de É
Exclusive sale of the standards by Beuth Verlag GmbH, 10772 www.beuth.de
Berlin 1954055
DIN EN 1591-4:2013-12
National foreword
This document (EN 1591-4:2013) has been prepared by Technical Committee CEN/TC 74 "Flanges and their joints", the
secretariat of which is held by DIN (Germany).
The working committee NA 082-00-16 AA "Flanges and their connections" in the Standards Committee for Piping and
Steam Boiler Systems (NARD) is responsible for German participation.
Changes
a) Change in the status of the document from a pre-standard (technical specification) to a standard;
c) the title has been changed, the reference to the Pressure Equipment Directive has been removed;
f) the content on the qualification of the trainer (section 4) and the assessor (section 5), on personnel
trained through work-based learning (section 6) and on the training location (section 7) has been revised;
g) Section 8 "Curricula for training" has been completely revised, in particular tables 1 to 11 on the training
topics have been introduced;
h) In 10.2, the assessment procedures for the assessment of competence have been revised;
j) In section 11, the requirements for competence management (documentation) have been revised;
k) information on the period of validity of the certificate has been included in section 12;
Previous issues
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EUROPEAN EN 1591-4
STANDARD
EUROPEAN August 2013
STANDARD NORME
EUROPÉENNE
German version
CEN members are required to comply with the CEN/CENELEC Internal Regulations which lay down the conditions under which this European
Standard is to be given the status of a national standard without any amendment. Up-to-date lists of these national standards with their
bibliographical references are available on request from the CEN-CENELEC Management Center or from any CEN member.
This European Standard exists in three official versions (English, French, German). A version in another language made by a CEN
member on its own responsibility by translation into its national language and notified to the Management Center has the same status as
the official versions.
CEN members are the national standards institutes of Austria, Belgium, Bulgaria, Croatia, Cyprus, the Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, the Netherlands, Norway,
Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom.
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reserved by
© 2013 CEN All rights of exploitation, in whatever form and by whatever process,are
CEN national members worldwide.
Ref. no. EN 1591-4:2013 D
DIN EN 1591-4:2013-12
DIN EN 1591-4:2013-12
EN 1591-4:2013 (D)
Contents Page
Foreword .............................................................................................................................................................3
Introduction.........................................................................................................................................................4
1 Scope of application..............................................................................................................................5
2 Normative references............................................................................................................................5
3 Terms......................................................................................................................................................5
4 Qualification of the trainer....................................................................................................................6
5 Qualification of the assessor ...............................................................................................................6
6 Staff trained through work-based learning.........................................................................................7
7 Training location....................................................................................................................................7
8 Curricula for the training ......................................................................................................................7
8.1 Content of the curricula ........................................................................................................................7
8.2 Qualification level ..................................................................................................................................8
8.2.1 General information...............................................................................................................................8
8.2.2 Basic qualification level ........................................................................................................................9
8.2.3 Tightening the connection with hydraulically operated clamping tools........................................10
8.2.4 Hydraulic torque-controlled tightening of the connection................................................................11
8.2.5 Heat exchangers and pressure vessels ............................................................................................12
8.2.6 Flanges made from brittle materials..................................................................................................12
8.2.7 Determining the bolt force after assembly .......................................................................................13
8.2.8 Compact flanges..................................................................................................................................13
8.2.9 Clamp connector .................................................................................................................................14
8.2.10 Special connections ............................................................................................................................14
8.2.11 Screw connections for pipe fittings with small bore .......................................................................15
8.3 Responsible engineer .........................................................................................................................15
8.4 Technical management .......................................................................................................................15
9 Effectiveness of the training ..............................................................................................................16
10 Assessment of capability ...................................................................................................................16
10.1 General information.............................................................................................................................16
10.2 Valuation procedure ............................................................................................................................16
10.2.1 Theoretical questionnaire ...................................................................................................................16
10.2.2 Practical assessment ..........................................................................................................................16
10.3 Certificate .............................................................................................................................................16
11 Competence management ..................................................................................................................17
11.1 Documentation by the manufacturer, operator or system builder .................................................17
11.2 Documentation by the assessor ........................................................................................................17
11.3 Information to be provided by the qualified person.........................................................................17
12 Period of validity of the certificate.....................................................................................................17
12.1 First certificate .....................................................................................................................................17
12.2 Extension .............................................................................................................................................17
References ........................................................................................................................................................18
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DIN EN 1591-4:2013-12
EN 1591-4:2013 (D)
Foreword
This document (EN 1591-4:2013) has been prepared by Technical Committee CEN/TC 74 "Flanges and their
joints", the secretariat of which is held by DIN.
This European Standard must be given the status of a national standard, either by publication of an identical
text or by endorsement by February 2014, and any conflicting national standards must be withdrawn by
February 2014.
Attention is drawn to the possibility that some elements of this document may infringe patent rights. CEN
[and/or CENELEC] are not responsible for identifying some or all of the patent rights involved.
The detailed changes made when converting the CEN/TS 1591-4:2007 guide to EN 1591-4:2013, a European
standard containing requirements, are too numerous to list in detail. It is recommended that users of CEN/TS
1591-4:2007 study EN 1591-4:2013 in its entirety to understand the differences between the two documents.
⎯ EN 1591-1, Flanges and their joints - Rules for the design of flanged joints with circular flanges and
gaskets - Part 1: Calculation method
⎯ EN 1591-2, Flanges and their joints - Rules for the design of flanged joints with circular flanges and
gaskets - Part 2: Gasket characteristics
⎯ CEN/TS 1591-3, Flanges and their joints - Rules for the design of flanged joints with circular flanges and
gaskets - Part 3: Calculation method for flanged joints with gaskets in force shunt connection
⎯ EN 1591-4, Flanges and their joints - Part 4: Qualification of personnel for the assembly of bolted joints in
pressurized systems in critical service
⎯ CEN/TR 1591-5, Flanges and their joints - Rules for the design of flanged joints with circular flanges and
gasket - Part 5: Calculation method for joints with full face gasket
According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to adopt this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland, Turkey and United Kingdom.
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DIN EN 1591-4:2013-12
EN 1591-4:2013 (D)
Introduction
The competence of bolting installers is a key factor in the safe operation of a pressurized system containing
bolted joints and in achieving the maximum performance of that bolted joint. Rules for the design of bolted
joints in pressurized systems, such as EN 1591-1, require the controlled tightening of bolts. This requires
qualified bolting fitters to ensure that the necessary specific bolt force tolerances can be met and, where
applicable, the specific tightness requirements can be achieved.
Training and qualification, experience and knowledge are often confused with each other. Training is no
guarantee of proficiency, and experience is no guarantee of knowledge and understanding. To achieve
proficiency, both training and experience are required, as well as the assessment of the ability to apply
knowledge.
a) theoretical knowledge in combination with practical experience gained in simulated work situations;
b) Assessment by a competent assessor to demonstrate that the required knowledge, skills and
competences have been acquired and can be applied in accordance with a work instruction.
These elements may be acquired through formal education and training or through experiential learning in the
workplace, or through a combination thereof. Nevertheless, competency can only be demonstrated by the
process specified in this document. The document contains not only the syllabi for training the bolting fitters
who actually dismantle, assemble and tighten the bolted joints that are pressurized in service, but also the
syllabi for the personnel who supervise these bolting fitters, the responsible engineers.
Beyond the application of the knowledge acquired during the training, no competence is required to analyze
the failure of a pressurized bolted joint in a pressurized system. A properly assembled and tightened bolted
joint in a pressurized system that fails in service requires expertise to understand why the failure occurred and
is not within the scope of this European Standard.
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EN 1591-4:2013 (D)
1 Area of application
This European Standard applies to bolting fitters and their supervisors, the responsible engineers, who
dismantle, assemble and tighten bolted joints of any type that are part of pressurized systems in critical
service. Failure of a connection in such a system would endanger personnel, equipment or the environment.
This document provides a pathway to achieve proficiency in the skills required to safely and successfully
disassemble, assemble and tighten bolted connections in pressurized systems of any form up to a calculated
bolt force using documented work instructions. The aim is to create a connection that is capable of remaining
"tight" over its entire service life.
This European Standard specifies a modular syllabus for training and an assessment procedure that can be
used to determine the competence of personnel who dismantle, assemble and tighten bolted joints of all types
installed in pressurized systems containing media in any combination of pressure and temperature.
Bolting fitters must install bolted joints of different requirement levels. For this reason, this document contains
training specifications that deal with bolted joints of different requirement levels and for different types of
bolted joints in pressurized systems. The modular structure enables bolting fitters to complete further training
once they have reached the basic qualification level.
Certification to this European Standard is an attestation of general competence in accordance with the
established syllabi and assessments.
Certification to this European Standard does not constitute a permit to work as this remains the responsibility
of the employer and it may be necessary for the competent person to have additional expertise of employer
specific procedures, processes and equipment.
2 Normative references
Not applicable.
3 Terms
The following terms apply to the application of this document.
3.1
Manufacturer
Organization that manufactures the assembly containing the bolted joint
3.2
Operator
Organization that is or becomes responsible for the operation and maintenance of equipment
Note 1 to entry: Thisincludes suppliers or contractors for the disassembly, assembly and tightening of bolted
connections on pressure-retaining systems.
3.3
Plant manufacturer
Organization responsible for the construction and/or commissioning of a facility containing piping and
equipment
Note 1 to entry: Thisincludes suppliers or contractors for the disassembly, assembly and tightening of bolted
connections with seals on pressure-retaining systems.
3.4
Training manager/training provider
Organization or individual w i t h the ability and skills to deliver the required training content
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3.5
Assessor/assessment body
Qualified individual or organization confirming that the bolting fitter, the responsible engineer or the technical
management is competent
3.6
Fitting fitter
Person whose task consists of disassembling, assembling or tightening screw connections of systems that are
pressurized during operation
3.7
Responsible engineer
Person whose task is to plan and supervise the activities of bolting fitters
3.8
Technical management
Person who, on behalf of the manufacturer, operator or plant constructor (see new: 3.3), is responsible for the
technical aspects of the project in the context of which the assembly of bolted connections became necessary
3.9
Focus topic
Subject requiring theoretical and/or practical understanding and the ability to apply this knowledge safely and
effectively
3.10
Understanding topic
Subject requiring an understanding that occurs when a person retains sufficient knowledge of a subject to be
aware of its existence and deeper content
3.11
Basic qualification level
required qualification level, subject to assessment of whether the content has been processed to ensure the
ability to assemble bolted joints whose bolts are suitable for tightening using hand-operated torque wrenches
Note 1 on the term: O n c e the basic qualification level has been reached, further training and assessment is possible
in relation to larger screws and special areas.
3.12
Critical use
Application that could endanger people or the environment in a pressurized system if the bolted connection fails
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EN 1591-4:2013 (D)
a) practical and theoretical training as part of an apprenticeship or similar craft training based on the
curriculum described in the following sections or an equivalent curriculum;
b) Practical learning on site by working with trained fitters without formal theoretical training.
For those bolting installers and responsible engineers who have acquired the necessary skills through
practical and theoretical training as part of a vocational or similar craft apprenticeship, the assessment of
competence under Section 10 can proceed directly, i.e. there is no need for the training described below. If
competency is not certified, training must be provided by a training provider as described below before
reassessment of competency under Section 10.
Those bolting installers and responsible engineers who have acquired their skills solely through practical
learning on site by working with trained installers without formal theoretical training must complete an
approved training course with a training provider before their competence can be assessed under Section 10.
7 Training location
Training must be provided either at a suitable training center within the framework of continuing professional
development or vocational training, or at the facility where the bolting installers normally work.
The training location must include a suitable classroom and a suitably equipped practical workroom so that the
personnel to be trained can gain both theoretical knowledge a n d practical experience with bolted joints that
are representative of different types of bolted joints and that occur in the usual workplace of the bolting fitter.
The curricula must contain a series of key topics that ensure a comprehensive understanding and
comprehension of bolted joints under pressure. The subject areas must be divided into topics that require
awareness and focus topics that require a deeper understanding.
Understanding topics must ensure that bolting installers grasp the technical basics, which in turn support the
key topics that require a deeper understanding. Key topics must be fully understood by the bolting technicians.
For example, bolting installers must be shown how the relationship between torque and bolt force is affected
by the coefficient of friction and understand this process before they are taught tightening torque.
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EN 1591-4:2013 (D)
The tables in 8.2 and 8.3 form the basis for the prescribed minimum curricula for the various qualification
levels. Additional topics of local importance may be added by agreement between the
manufacturer/operator/installer and the training provider. The scaffolding installers must always be trained on
the basis of procedures and work instructions that are deemed most suitable by the
manufacturer/operator/installer.
All additional topics added to the prescribed minimum curricula must be listed in the issued certificate for
verification purposes, see 10.3.
The training must be designed in such a way that both theoretical and practical content is taught. The duration
of the training must be agreed between the training provider and the manufacturer/operator/installer and must
take into account the previous training of the personnel to be trained.
There are various qualification levels for bolting fitters that go beyond the basic qualification level and these
are represented by the contents of the tables below.
Once training at the basic qualification level (see Table 1) has been completed and the subsequent
assessment has demonstrated that the qualification has been achieved, bolting fitters may choose to obtain a
further qualification at one or more higher level(s). The training content for these higher qualification levels is
shown in Tables 2, 3, 4, 5, 6, 7, 8, 9 and 10 below.
Competency at the basic qualification level must be demonstrated before training and skills assessment at
higher qualification levels are carried out.
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Focus
Understandin
Topic topic
g topic
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8.2.3 Tightening the joint with hydraulically operated clamping tools Table 2 -
Focus
Understandin
Topic topic
g topic
1
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Focus
Understandin
Topic topic
g topic
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Focus
Understandin
Topic topic
g topic
Focus
Understandin
Topic topic
g topic
1
2
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Table 6 - Training specifications for determining the bolt force after assembly
Focus
Understandin
Topic topic
g topic
Focus
Understandin
Topic topic
g topic
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Focus
Understandin
Topic topic
g topic
Focus
Understandin
Topic topic
g topic
1
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Focus
Understandin
Topic topic
g topic
The engineer in charge must be competent for all qualification levels acquired by the bolting assemblers for
whom he is responsible on site and must also be competent in the subjects listed in the curriculum for the
engineer in charge in Table 11.
Focus
Understandin
Topic topic
g topic
The person acting as technical supervisor does not need to be trained, tested, assessed and certified in the
same way as the bolting installers and supervisors on site. However, it is recommended that the technical
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supervisor completes the relevant training courses if he/she has not already acquired the required level of
knowledge and understanding during his/her professional development.
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EN 1591-4:2013 (D)
10 Assessment of capability
The assessment of competence must be carried out by a qualified assessor and consists of two parts: a
theoretical questionnaire and a practical assessment.
The assessor must have been assessed as competent both as an assessor and in relation to bolted joints of
the relevant type in pressurized systems.
The pass level must be set at a level at which the assessor can be confident that the bolting fitter has
achieved the required level of awareness and understanding.
The bolting fitter must demonstrate to the assessor, either at the training venue or at the workplace, that he is
able to work safely and efficiently in accordance with the relevant work instructions. This demonstration shall
be made using bolted joints representative of the different types of joints encountered in the workplace.
Throughout the assessment, the bolting fitter must explain his approach and its importance in terms of safety
and the proper execution of the joint. Following the assembly and tightening demonstration, the bolted joint
must be inspected to verify correct assembly and proper tightening of the bolts. If feasible, the connection
must be checked for leaks at the end. The joints must then be disassembled to demonstrate the disassembly
procedure and to allow the joint to be checked for signs of poor gasket installation.
10.3 Certificate
Once proficiency has been successfully demonstrated, the certificate of proficiency must state t h e date and
location of the assessment and the proficiency achieved at the relevant qualification level (basic qualification,
heat exchanger and pressure vessel, etc.). The training syllabus with documentation of any locally agreed
additional topics must always be attached to the certificate.
The certificate must clearly state the names of the training provider, the assessor or assessment body and the
date of the assessment.
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11 Competence management
11.1 Documentation by the manufacturer, operator or system builder
In order to meet the requirements of this standard, manufacturers, operators or plant constructors must
develop and implement a procedural framework within their quality management system. Such a framework
must deal with:
The manufacturer, operator or system builder who arranges the training or employs a qualified bolting fitter
must compile and maintain a list of the qualifications of the installation personnel.
The listing must include the training dates and rating for each person and the frequency of the individual's
work with bolted joints with gaskets.
The manufacturer, operator or plant constructor does not have to employ bolting fitters whose certificate has
expired.
a) the bolting fitter has worked with bolted flange connections without interruptions for more than six months;
b) there are no particular reasons to question the qualifications, skills or knowledge of the bolting fitter when
using bolted flange connections.
If one of these two conditions is not met, the certificate must be withdrawn.
12.2 Extension
The validity of the bolting fitter's or responsible engineer's certificate may be extended every five years for a
further period of five years by reassessment of competence in accordance with Section 10. If the bolting fitter
or engineer in charge does not pass the reassessment test, he must undergo full training again before his
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competence is reassessed.
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EN 1591-4:2013 (D)
References
[1] EN 1591-1, Flanges and their joints - Rules for the design of flanged joints with circular flanges and
gaskets - Part 1: Calculation
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