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DRAFT FOR DEVELOPMENT

Flanges and their


joints Design rules
for gasketed circular
flange connections
Part 4: Qualification of personnel
competency in the assembly of bolted
joints fitted to equipment subject to the
Pressure Equipment Directive

ICS 23.040.60

12&23<,1*:,7+287%6,3(50,66,21(;&(37$63(50,77('%<&23<5,*+7/$:

DD CEN/TS
1591-4:2007

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DD CEN/TS 1591-4:2007

National foreword
This Draft for Development is the UK implementation of CEN/TS 1591-4:2007.
This publication is not to be regarded as a British Standard.
It is being issued in the Draft for Development series of publications and is of
a provisional nature. It should be applied on this provisional basis, so that
information and experience of its practical application can be obtained.
Comments arising from the use of this Draft for Development are requested so
that UK experience can be reported to the European organization responsible
for its conversion to a European standard. A review of this publication will be
initiated not later than 3 years after its publication by the European
organization so that a decision can be taken on its status. Notification of the
start of the review period will be made in an announcement in the appropriate
issue of Update Standards.
According to the replies received by the end of the review period, the
responsible BSI Committee will decide whether to support the conversion into
a European Standard, to extend the life of the Technical Specification or to
withdraw it. Comments should be sent to the Secretary of the responsible BSI
Technical Committee at British Standards House, 389 Chiswick High Road,
London W4 4AL.
The UK participation in its preparation was entrusted to Technical Committee
PSE/15, Flanges.
A list of organizations represented on this committee can be obtained on
request to its secretary.
This publication does not purport to include all the necessary provisions of a
contract. Users are responsible for its correct application.

This Draft for Development


was published under the
authority of the Standards
Policy and Strategy Committee
on 28 September 2007

BSI 2007

ISBN 978 0 580 57543 3

Amendments issued since publication


Amd. No.

Date

Comments

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TECHNICAL SPECIFICATION

CEN/TS 1591-4

SPCIFICATION TECHNIQUE
TECHNISCHE SPEZIFIKATION

August 2007

ICS 23.040.60

English Version

Flanges and their joints - Design rules for gasketed circular


flange connections - Part 4: Qualification of personnel
competency in the assembly of bolted joints fitted to equipment
subject to the Pressure Equipment Directive
Brides et leurs assemblages - Rgles de calcul des
assemblages brides circulaires avec joint - Partie 4 :
Qualification des comptences du personnel en charge du
montage des assemblages boulonns sur des quipements
relevant de la Directive quipements sous pression

Flansche und ihre Verbindungen - Regeln fr die


Auslegung von Flanschverbindungen mit runden Flanschen
und Dichtung - Teil 4: Qualifizierung der Kompetenz von
Personal zur Montage von Schraubverbindungen im
Geltungsbereich der Druckgerterichtlinie

This Technical Specification (CEN/TS) was approved by CEN on 26 May 2007 for provisional application.
The period of validity of this CEN/TS is limited initially to three years. After two years the members of CEN will be requested to submit their
comments, particularly on the question whether the CEN/TS can be converted into a European Standard.
CEN members are required to announce the existence of this CEN/TS in the same way as for an EN and to make the CEN/TS available
promptly at national level in an appropriate form. It is permissible to keep conflicting national standards in force (in parallel to the CEN/TS)
until the final decision about the possible conversion of the CEN/TS into an EN is reached.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, 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 and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION


COMIT EUROPEN DE NORMALISATION
EUROPISCHES KOMITEE FR NORMUNG

Management Centre: rue de Stassart, 36

2007 CEN

All rights of exploitation in any form and by any means reserved


worldwide for CEN national Members.

B-1050 Brussels

Ref. No. CEN/TS 1591-4:2007: E

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CEN/TS 1591-4:2007

Contents

Page

Foreword..............................................................................................................................................................3
1
1.1
1.2
1.3
1.4

Scope ......................................................................................................................................................4
General....................................................................................................................................................4
Requirement for competency ...............................................................................................................4
Validity ....................................................................................................................................................4
Quality management system ................................................................................................................4

Normative references ............................................................................................................................5

Terms and definitions ...........................................................................................................................5

Objective.................................................................................................................................................5

Training location ....................................................................................................................................5

6
6.1
6.2
6.3

Training curriculum ...............................................................................................................................6


General....................................................................................................................................................6
General knowledge ................................................................................................................................6
Specific knowledge................................................................................................................................7

Format of training ..................................................................................................................................7

Suitability of procedures and work instructions ................................................................................8

Effectiveness of training .......................................................................................................................8

10

Work-site experience.............................................................................................................................8

11
11.1
11.2

Competence assessment......................................................................................................................9
General....................................................................................................................................................9
Method of assessment ..........................................................................................................................9

12

Qualification of assessor ......................................................................................................................9

13

Competence management ....................................................................................................................9

Bibliography ......................................................................................................................................................10

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CEN/TS 1591-4:2007

Foreword
This document (CEN/TS 1591-4:2007) has been prepared by Technical Committee CEN/TC 74 Flanges and
their joints, the secretariat of which is held by DIN.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN shall not be held responsible for identifying any or all such patent rights.
The integrity of a bolted joint is key in any pressure containment system and should be subjected to personnel
competence. The aim of this document is to offer a procedure for training and competency assessment of
personnel who disassemble, assemble and tighten bolted joints under the Pressure Equipment Directive 97/23/EC.
EN / ENV / CEN/TS 1591 Flanges and their joints Design rules for gasketed circular flange connections
consists of the following parts:
Part 1: Calculation method (EN)
Part 2: Gasket parameters (ENV)
Part 3: Calculation method for metal to metal contact type flanged joint (CEN/TS)
Part 4: Qualification of personnel competency in the assembly of bolted joints fitted to equipment subject to
the Pressure Equipment Directive (CEN/TS)
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to announce this CEN Technical Specification: Austria, Belgium, Bulgaria, 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 and United Kingdom.

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CEN/TS 1591-4:2007

1
1.1

Scope
General

This European Technical Specification establishes a process for training and competency assessment of personnel who disassemble, assemble and tighten bolted joints such as fitted to equipment subject to the Pressure Equipment Directive 97/23/EC (PED), in the content of this Technical Specification named "PED".

1.2

Requirement for competency

Training and competence, experience and knowledge are often confused with each other. Training is no guarantor of competence, nor is experience a guarantor of knowledge and understanding. Training, experience,
and assessment of knowledge are all required to achieve competence.
Design codes for mechanical joints (see for example EN 1591-1 or CEN/TS 1591-3) increasingly require controlled bolt tightening in order to meet the specified bolt load tolerances.
The intent of this Technical Specification is to ensure personnel are competent to assemble and tighten bolted
joints using the design bolt load and documented work instructions, thereby establishing a joint capable of
maintaining a leak-free status throughout its service life.
Competency in the analysis of joint failure is not required beyond use of knowledge gained during training. A
correctly assembled and tightened joint that fails in service requires specialist knowledge and is out with the
scope of this Technical Specification.

1.3

Validity

This Technical Specification is applicable for bolted joints included on mechanical equipment subject to the
PED, or any joint where failure would endanger personnel, plant or the environment. Such joints may or may
not be fitted with a gasket.
The validity includes all bolting arrangements, both circular and non-circular, and fluids (gas or liquid) with the
exception of:

joints having less than 4 bolts, or bolt diameters less than M16;

potable or fire water, sewage systems.

This Specification excludes:

craft personnel who are trained, examined and verified as competent in their craft training or normal
course of work to assemble bolted joints, such as in the manufacture of equipment;

professional persons, who by their professional training and experience and contemporary practices are
regularly concerned with bolted joints and their assembly.

1.4

Quality management system

Manufacturers or operators need to develop and include a procedural framework within their quality management system to meet the requirements of this specification. Such a framework needs to address:

identification of personnel requiring training;

identification of a competent trainer or training provider, e.g. Qualified Person for Pressure;

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CEN/TS 1591-4:2007

evaluation of the effectiveness of the training.

For examples, refer to EN ISO 9001:2000, 6.2.2.

Normative references

Not applicable.

Terms and definitions

3.1
manufacturer
organisation that manufactures equipment subject to the PED directive
3.2
operator
organisation that is responsible for the operation and maintenance of equipment subject to the PED directive.
This includes suppliers or contractors employed to assemble the operators equipment joints
3.3
training provider
organisation with the capability to deliver the required training
3.4
trainer
individual assigned by the training provider to deliver the training

Objective

The objective of this Technical Specification is to set down a route for achieving competency in the skills required to safely and successfully disassemble, assemble and tighten bolted joints.
The essential elements to achieve competency are:

classroom training followed by monitored workshop practice;

written test to verify candidate has understood the classroom training;

period of monitored work site experience under the supervision of a competent person;

assessment by a qualified assessor to verify the training has been understood and applied.

These elements may be combined through perennial training including technical schooling, on-plant training,
and final examination.

Training location

Training may either take place at a suitable training centre or at the facility where the candidates normally
work.
The location should include a suitable classroom and practical workshop where the possibility exists to train
with bolted joints that are representative of the candidates normal place of work.

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CEN/TS 1591-4:2007

6
6.1

Training curriculum
General

The curriculum should include all joint types that will be encountered by the candidates when they return to
their work site. For candidates who are expected to work on a variety of sites the content should be sufficiently
generic to cover all commonly encountered joints. As a minimum, this will at least include bolted joints that are
representative of the candidates normal place of work.
The manufacturer or operator requiring the training should ensure the above requirement is met by the organisation selected to provide the training.
The curriculum will include a number of key topics to ensure a comprehensive understanding and appreciation
of the bolted joint. The topics can be divided between topics that require awareness and those requiring an
in-depth understanding.
Awareness topics are required to ensure candidates appreciate the engineering principles that underpin the
topics requiring in-depth understanding. For example, candidates should be shown and understand how the
relationship between torque and bolt load is impacted by the coefficient of friction, before being taught torque
tightening a bolted joint.
The training provider is responsible for setting the content of each module and will confirm the content is appropriate and detailed enough to meet the manufacturer or operators needs.

6.2

General knowledge

The curriculum will ensure candidates are aware of the following and their importance when working with
bolted joints. The list is exemplary; the exact content of the training depends on the quality management system, pipeline specifications, and operational requirements:

the principles of bolt elongation (strain), bolt load and stress;

importance of applied and residual bolt loads;

bolt load loss and the implications;

effect of coefficient of friction on bolt load when using torque;

bolt tightening methods and their relative accuracies;

joint assembly methods and tightening procedures;

the requirements to meet a specific class of tightness;

flange, bolt and gasket types and their limitations;

functionality of gasket and seal;

factors affecting the degradation of bolted assemblies, e.g. corrosion;

common causes of joint failure and leakage;

specific health or safety requirements associated with joint components;

maintenance requirements of bolt tightening systems;

importance of certification and records.

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CEN/TS 1591-4:2007

6.3

Specific knowledge

The curriculum will ensure candidates have a thorough understanding of the following aspects of joint disassembly, assembly and tightening. Training will take place using the appropriate tools, components, and bolted
joints. The list is exemplary; the exact content of the training depends on the quality management system,
pipeline specifications, and operational requirements:

general health and safety precautions;

procedure for preparing a joint for closure;

identification of correct joint components;

seal face preparation;

gasket handling, preparation and installation;

functionality of clamp or engineered joints;

importance of alignment and gap uniformity;

importance of using the specified lubricant;

manual torque joint tightening;

hydraulic torque joint tightening;

joint tightening using hydraulic bolt tensioners;

techniques for measuring bolt strain;

confirming joint can return to service;

identifying defects or faults;

variance or irregularity reporting;

safe joint disassembly;

safety requirements when selecting and operating bolt tightening tooling;

calibration of bolt tightening tooling;

recording bolted joint activity and maintenance of records.

Format of training

The training will be formatted to include both classroom and practical sessions. The duration of the course will
be at the discretion of the training provider.

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CEN/TS 1591-4:2007

Suitability of procedures and work instructions

At all times, candidates will be trained using procedures and work instructions deemed most suitable by either
the manufacturer or the operator. It is incumbent on the training provider to ensure the curriculum meets this
objective.

Effectiveness of training

The trainer should be able to demonstrate a thorough understanding of the technical and practical aspects of
the curriculum. For many institutions providing training, such as vocational technical schools, this will be mandated in the schools quality plan.
The manufacturer or operator will develop a method for verifying the effectiveness of the training provider and
document within their quality management system. Methods may include candidate questionnaires and trainer
performance reviews. Examination and certification at end of training period.
The training session will be concluded with a written examination. The examination will be used as evidence
that the candidate has understood the training undertaken.
The pass mark will be set at such level that the trainer can be confident the candidate has attained the required level of awareness and understanding.
Completion of the training and passing the written examination does not imply competency. It is acceptable to
issue a certificate of attendance.
The certificate of attendance will include the candidates name, training provider and confirmation that all modules have been covered.

10 Work-site experience
The candidate shall be given the opportunity to practice their training, supervised by a certified competent
person. This should take place at the earliest opportunity and as frequently as possible.
The candidate may be assessed for competency once they have had sufficient work-site experience.
Guidance is given in Table 1.
The candidate will log and document their experience gained during this period. The content of the log will be
determined by the trainer/assessor in discussion with the manufacturer or operator purchasing the training.
Table 1 Guidance for work-site experience before assessment
Work-site experience
Frequent and intense

3 months

Infrequent but with intense periods

6 months

Sporadic

Earliest assessment

12 months

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CEN/TS 1591-4:2007

11 Competence assessment
11.1 General
Assessment of competence is key to maintaining the highest performance from the bolted joint. The assessment will be undertaken by a qualified assessor and consist of three parts.

11.2 Method of assessment


Theoretical question paper.
The paper will include questions based on both 5.2 and 5.3. The pass park will be set at such a level as the
assessor thinks reasonable to be sure the candidate has retained the required level of awareness and understanding.
Simulated practical assessment.
The candidate will demonstrate to the assessor they can work safely and efficiently. The demonstration will
take place at the work-site using a bolted joint that is representative of the work-site. Throughout the assessment the candidate will explain what they are doing and its importance in safety terms and for good joint security.
Documented work place evidence.
The candidate shall produce written evidence that he or she has understood and correctly applied the training
undertaken.

12 Qualification of assessor
The assessor chosen should be qualified as competent to be an assessor in the field of mechanical joint related manual skilled vocations.

13 Competence management
It is essential that the manufacturer or operator initiating the training creates and maintains a register of site
personnel competencies.
The register will include each individuals date of training and assessment as well how frequently the individual
has worked with bolted joints.
The register will be reviewed, at least every six months, to determine whether any personnel should be removed or undertake refresher training. Table 2 gives guidance on the period after achieving competency before refresher training is normally required. The individuals competencies will also be reviewed to confirm applicability in regard of the types of bolted joint that the individual will encounter at their normal work site.
Table 2 Guidance for refresher training
Work-site experience

Period after achieving competency

Frequent and intense

3 years

Infrequent but with intense periods

2 years

Sporadic

12 months

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CEN/TS 1591-4:2007

Bibliography

[1]

EN 1591-1, Flanges and their joints Design rules for gasketed circular flange connections Part 1:
Calculation method

[2]

CEN/TS 1591-3, Flanges and their joints Design rules for gasketed circular flange connections
Part 3: Calculation method for metal to metal contact type flanged joint

[3]

EN ISO 9001:2000, Quality management systems Requirements (ISO 9001:2000)

[4]

Directive 97/23/EC of the European Parliament of the Council of 29 May 1997 on the approximation of
the laws of the Member States concerning Pressure Equipment (Brussels, Official Journal EC, July
1997)

10

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blank

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DD CEN/TS
1591-4:2007

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