GERMAN STANDARD December 2013

DIN EN 1591-4

ICS 23.040.60; 03.100. 30Replacement for

DIN CEN/TS 1591-4:2007-10

Flanges and their connections -

Part 4: Qualification of the ability of personnel to assemble bolted
connections in pressurized systems in critical applications;
German version EN 1591-4:2013
Flanges and their joints -
Part 4: Qualification of personnel competency in the assembly of the bolted connections of
critical service pressurized systems;
German version EN 1591-4:2013
Brides et leurs assemblages -
Partie 4: Qualification des compétences du personnel en charge du montage des
assemblages boulonnés sur des systèmes sous pression en service critique;
Version allemande EN 1591-4:2013

Total length 20 pages

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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
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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

The following changes have been made to DIN CEN/TS 1591-4:2007-10:

a) Change in the status of the document from a pre-standard (technical specification) to a standard;

b) The document has been completely restructured;

c) the title has been changed, the reference to the Pressure Equipment Directive has been removed;

d) the scope of application has been specified;

e) Some new terms have been defined in section 3;

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;

i) More detailed information on the certificate has been included in 10.3;

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;

l) The document has been editorially revised.

Previous issues

DIN CEN/TS 1591-4: 2007-10

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 EUROPEAN EN 1591-4
STANDARD
EUROPEAN August 2013

STANDARD NORME
EUROPÉENNE

ICS 03.100.30; 23.040. 60Replacement for CEN/TS

1591-4:2007

German version

Flanges and their connections -

Part 4: Qualification of the ability of personnel to assemble
bolted connections in pressurized systems in critical
applications

Flanges and their joints - Brides et leurs assemblages -

Part 4: Qualification of personnel competency in the Partie 4: Qualification des compétences du personnel en
assembly of the bolted connections of critical service charge du montage des assemblages boulonnés sur des
pressurized systems systèmes sous pression en service critique

This European Standard was adopted by CEN on June 22, 2013.

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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EUROPEAN COMMITTEE FOR

STANDARDIZATION EUROPEAN COMMITTEE FOR
STANDARDIZATION C OM I TÉ EUR OP ÉEN DE
NOR M ALI S ATI O N

Management center: Avenue Marnix 17, B-1000 Brussels

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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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.

This document replaces CEN/TS 1591-4:2007.

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, Flanges and their joints, consists of the following parts:

⎯ 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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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.

The essential elements required to achieve the qualification are:

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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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

4 Qualification of the trainer

The trainer must demonstrate a basic understanding of the technical and practical aspects of the curriculum.
For many institutions offering training, such as technical vocational schools, this is a requirement of the
school's own quality management plan.

5 Qualification of the assessor

The selected assessor must be competent and qualified in the field of bolted connections in pressurized
systems in critical applications and have the relevant practical professional experience.
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6 Staff trained through work-based learning

Bolting fitters and responsible engineers who have previously acquired skills in the workplace may have
acquired these skills in one of the following two ways:

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.

8 Curricula for the training

8.1 Content of the curricula
As a minimum, the relevant syllabi must cover all bolted joints in pressurized systems that the bolting fitters
will come into contact with on their return to work. For bolting fitters who are likely to be employed at many
work sites, the content must be sufficiently general to cover all commonly encountered bolted joints in
pressurized systems. The manufacturer or operator requesting the training must ensure that the selected
training provider meets the above requirement.

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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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.

8.2 Qualification level

8.2.1 General information

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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8.2.2 Basic qualification level

Table 1 - Training requirements for the basic qualification level

Focus
Understandin
Topic topic
g topic

Types of screw connections X

Functionality of seals X
Types of gaskets and their respective characteristics X
Relationship between bolt elongation (elongation), bolt force and gasket
X
surface pressure
General causes of failure of bolted connections with seals
X

Loss of screw force and consequences X

Applied and remaining screw force X
General health and safety precautions X
Safe disassembly of the connection X
Preparation of the sealing surface X
Recognizing errors and defects X
Alignment of the sealing surfaces and uniform spacing X
Storage, handling, preparation and installation of the seal X
Effect of thread friction on the bolt force when using the torque-controlled
X
tightening method
Importance of using the specified thread lubricant X
Screw tightening process and associated accuracies X
Necessity of screw tightening procedures X
Screw tightening pattern X
Tightness classes X
Requirement to fulfill a certain tightness class X
Manual torque-controlled tightening X
Maintenance and calibration of manually operated torque wrenches
X

Requirements for hydraulic torque-controlled tightening and tightening with

X
hydraulically operated clamping tools
Confirmation that the connection can be put back into operation X
Documentation of the work carried out X
Documentation of deviations or irregularities X
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Emission monitoring and leakage procedure X

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8.2.3 Tightening the joint with hydraulically operated clamping tools Table 2 -

Training requirements for tightening the joint with hydraulically

operated clamping tools

hydraulically operated clamping tools

Focus
Understandin
Topic topic
g topic

Permanently installed hydraulic clamping nuts X

Basics of hydraulic clamping X
Understanding when to use hydraulic clamping devices X
Types of hydraulic clamping tools X
Hydraulic clamping process X
Maintenance of the pump and the hydraulic clamping tool X
Calibration of hydraulic clamping tools X
Hose arrangement X
Method for calculating the correct bolt force and associated equations
X

Understanding of total bolt force/remaining bolt force X

Number of hydraulic tensioners, percentage coverage and effect on bolt
X
force loss
Hydraulic clamping pressure/load conversion X
Hydraulic clamping processes X
Tightening procedure for tightening with hydraulically operated clamping
X
tools
Hole spacing X
Screw coatings and their effect on the thread safety of both the nut and the
X
withdrawal sleeve
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8.2.4 Hydraulic torque-controlled tightening of the connection

Table 3 - Training specifications for hydraulic torque-controlled tightening of the connection

Focus
Understandin
Topic topic
g topic

Safe use and handling of hydraulic hoses X

Proper use of the inserts, wear/damage to the inserts
X

Risk of injury due to escaping pressure medium - prevention and measures

X

Suitable working practices to avoid pinch points for fingers/hands

X

Secure use of an account key X

Types of hydraulic torque wrenches X
Selection of the tool pressure to deliver the required torque for a specific tool
X

Use of single and multiple tools to tighten a connection

X

Numbering of screws when using single and multiple tools

X

Understanding when to use hydraulic torque tools X

Basics of hydraulic torque control X
Tool fit and hole spacing X
Recognizing suitable reaction points X
Tightening procedure for torque-controlled tightening X
Importance of lubrication and spreading of friction X
Effects of screw coatings X
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8.2.5 Heat exchangers and pressure vessels

Table 4 - Training requirements for heat exchangers and pressure vessels

Focus
Understandin
Topic topic
g topic

Types of heat exchangers/TEMA designations X

Interaction of seals during assembly X
Seal types X
Chambered gaskets X
Handling and storage of gaskets X
Requirement for bolt preload X
Connection configuration and terminology X
Checking the flange sealing surfaces X
Gap size check X
Tube bundle and chamber alignment X
Risk of damage X
Considerations regarding the tube sheet X
Tightening shoulder screws X
Aligning the primary and secondary seal before tightening X
Preference for a tightening method depending on the screw length and
X
accessibility for the tool

8.2.6 Flanges made from brittle materials

Table 5 - Training specifications for flanges made of brittle materials

Focus
Understandin
Topic topic
g topic

Types of flanges made from brittle materials X

Brittle materials for flanges X
Interaction with seals during assembly X
Seal types X
Handling and storage of flanges and gaskets X
Requirement for bolt preload X
Tightening process for flanges made of brittle materials X
Connection configuration and terminology X
Checking the flange sealing surfaces X
Gap size check X
Preference for a tightening method depending on the screw length and
X
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accessibility for the tool

Safe disassembly of flanges made of brittle materials X

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8.2.7 Determining the bolt force after assembly

Table 6 - Training specifications for determining the bolt force after assembly

Focus
Understandin
Topic topic
g topic

Method for measuring the bolt force after assembly X

Measuring the bolt force by measuring the linear expansion X
Measurement of bolt force by torque application X
Measuring the bolt force by applying tension X
Measurement of the bolt force by ultrasonic measurement X
Proprietary devices for indicating the bolt force (bar-type indicator and
X
washer-type indicator)
Measuring the bolt force with extensometer X

8.2.8 Compact flanges

Table 7 - Training specifications for compact flanges

Focus
Understandin
Topic topic
g topic

Types of compact flanges X

Assembly requirements for each type of compact flange X
Knowledge of sealing ring types and materials X
Determining the bolt force X
Tightening procedure X
Suit pattern X
Checking the components before assembly X
Checking the flange after installation X
Gap size check X
Safe disassembly of compact flanges X
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8.2.9 Clamp connector

Table 8 - Training specifications for clamp connectors

Focus
Understandin
Topic topic
g topic

Types of clamp connectors X

Assembly requirements for each type of clamp connection X
Knowledge of sealing rings and materials X
Determination of bolt tension and bolt force X
Tightening procedure X
Suit pattern X
Checking the components before assembly X
Checking the connecting elements after assembly X
Safe disassembly of clamp connections X

8.2.10 Special connections

Table 9 - Training specifications for special connections/flanges

Focus
Understandin
Topic topic
g topic

Knowledge of special connections/flanges and types of special

X
connections/flanges
Assembly of special connections/flanges X
Knowledge of gaskets, sealing rings and materials X
Determination of bolt tension and bolt force X
Tightening procedure X
Suit pattern X
Checking the components before assembly X
Checking the components after assembly X
Safe disassembly of special flanges X
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8.2.11 Screw connections for pipe fittings with small bore

Table 10 - Training specifications for tube fittings with small bore

Focus
Understandin
Topic topic
g topic

Types of tube fittings with small bore X

Seal types X
Checking the components before assembly X
Assembly of pipe fittings with small bore X
Knowledge of pressure ratings and sealing materials X
Tightening process for special fittings with small diameters X
Avoid overtightening of fittings with small diameters X
Importance of avoiding stresses in the pipes and fittings
X

Checking the components after assembly X

Safe disassembly of pipe fittings with a small bore X

8.3 Responsible engineer

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.

Table 11 - Training requirements for the engineer in charge

Focus
Understandin
Topic topic
g topic

Health and safety considerations X

Establishing safety rules X
Creation of work instructions X
Method for determining the surface pressure for a required tightness class
X

Determination of bolt force/surface pressure, value for a flange/gasket

X
combination
Confirmation that a bolted connection can be put back into operation
X

Emission monitoring and leakage procedure X

8.4 Technical management

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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9 Effectiveness of the training

The manufacturer, operator or system builder must develop a procedure for reviewing the effectiveness of the
training provider and documenting this as part of their quality management system. Possible procedures may
include questionnaires for the bolting fitters and reviews of the performance of the training instructors.

10 Assessment of capability

10.1 General information

The assessor and the trainer must be two different persons.

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.

10.2 Evaluation procedure

10.2.1 Theoretical questionnaire

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.

10.2.2 Practical assessment

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.
E.ON New Build &;Technology GmbH;

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EN 1591-4:2013 (D)

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:

a) the determination of a capable training provider;

b) the assessment of the effectiveness of the training for each person participating in the training;
c) the assessment of staff competence; and
d) the documentation of the date on which the qualification was achieved.
NOTE Reference is made to EN ISO 9001:2008, 6.2.2, for examples.

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.

11.2 Documentation by the assessor

The assessor must keep documentation of the location and date of assessment of persons certified as
competent and the details of the employment of the competent person as provided by that person. This
documentation must be kept available for inspection by potential employers of the qualified person.

11.3 Information to be provided by the qualified person

The competent person must ensure that the assessor is informed of any changes to the employer so that the
dates of commencement and termination of all employment relationships as a scaffolding fitter or responsible
engineer are recorded.

12 Period of validity of the certificate

12.1 First certificate
The validity of the bolting fitter certificate begins on the date on which the assessment of competence was
passed. The period of validity is five years, provided that the following two conditions are met:

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
E.ON New Build &;Technology GmbH;

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

[2] EN ISO 9001:2008, Quality management systems - Requirements (ISO 9001:2008)

E.ON New Build &;Technology GmbH;

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