7/24/2019 DD CEN TS 01591-4-2007

1/14

DRAFT FOR DEVELOPMENT DD CEN/TS1591-4:2007

Flanges and theirjoints Design rules

for gasketed circular

flange connections

Part 4: Qualification of personnelcompetency in the assembly of boltedjoints fitted to equipment subject to thePressure Equipment Directive

ICS 23.040.60

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

2/14

DD CEN/TS 1591-4:2007

This Draft for Developmentwas published under theauthority of the StandardsPolicy and Strategy Committeeon 28 September 2007

BSI 2007

ISBN 978 0 580 57543 3

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 thatinformation and experience of its practical application can be obtained.

Comments arising from the use of this Draft for Development are requested sothat UK experience can be reported to the European organization responsiblefor its conversion to a European standard. A review of this publication will beinitiated not later than 3 years after its publication by the Europeanorganization so that a decision can be taken on its status. Notification of thestart of the review period will be made in an announcement in the appropriateissue of Update Standards.

According to the replies received by the end of the review period, theresponsible BSI Committee will decide whether to support the conversion intoa European Standard, to extend the life of the Technical Specification or to

withdraw it. Comments should be sent to the Secretary of the responsible BSITechnical Committee at British Standards House, 389 Chiswick High Road,London W4 4AL.

The UK participation in its preparation was entrusted to Technical CommitteePSE/15, Flanges.

A list of organizations represented on this committee can be obtained onrequest to its secretary.

This publication does not purport to include all the necessary provisions of acontract. Users are responsible for its correct application.

Amendments issued since publication

Amd. No. Date Comments

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

3/14

TECHNICAL SPECIFICATION

SPCIFICATION TECHNIQUE

TECHNISCHE SPEZIFIKATION

CEN/TS 1591-4

August 2007

ICS 23.040.60

English Version

Flanges and their joints - Design rules for gasketed circularflange connections - Part 4: Qualification of personnel

competency in the assembly of bolted joints fitted to equipmentsubject to the Pressure Equipment Directive

Brides et leurs assemblages - Rgles de calcul desassemblages brides circulaires avec joint - Partie 4 :Qualification des comptences du personnel en charge du

montage des assemblages boulonns sur des quipementsrelevant de la Directive quipements sous pression

Flansche und ihre Verbindungen - Regeln fr dieAuslegung von Flanschverbindungen mit runden Flanschenund Dichtung - Teil 4: Qualifizierung der Kompetenz von

Personal zur Montage von Schraubverbindungen imGeltungsbereich 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 theircomments, 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 availablepromptly 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 E UROP E N DE NORMAL ISAT ION

EUROPISCHES KOMITEE FR NORMUNG

Management Centre: rue de Stassart, 36 B-1050 Brussels

2007 CEN All rights of exploitation in any form and by any means reservedworldwide for CEN national Members.

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

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

4/14

2

Contents Page

Foreword..............................................................................................................................................................3

1 Scope ......................................................................................................................................................41.1

General....................................................................................................................................................4

1.2 Requirement for competency...............................................................................................................41.3 Validity ....................................................................................................................................................41.4 Quality management system................................................................................................................4

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

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

4 Objective.................................................................................................................................................5

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

6 Training curriculum ...............................................................................................................................66.1 General....................................................................................................................................................6

6.2

General knowledge................................................................................................................................66.3 Specific knowledge................................................................................................................................7

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

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

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

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

11 Competence assessment......................................................................................................................911.1 General....................................................................................................................................................911.2 Method of assessment..........................................................................................................................9

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

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

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

CEN/TS 1591-4:2007

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

5/14

3

Foreword

This document (CEN/TS 1591-4:2007) has been prepared by Technical Committee CEN/TC 74 Flanges andtheir 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 patentrights. 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 personnelcompetence. The aim of this document is to offer a procedure for training and competency assessment ofpersonnel who disassemble, assemble and tighten bolted joints under the Pressure Equipment Direc-tive 97/23/EC.

EN / ENV / CEN/TS 1591 Flanges and their joints Design rules for gasketed circular flange connectionsconsists 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 tothe 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, CzechRepublic, 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.

CEN/TS 1591-4:2007

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

6/14

4

1 Scope

1.1 General

This European Technical Specification establishes a process for training and competency assessment of per-sonnel who disassemble, assemble and tighten bolted joints such as fitted to equipment subject to the Pres-sure 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 guar-antor 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 con-trolled 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 boltedjoints using the design bolt load and documented work instructions, thereby establishing a joint capable ofmaintaining 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. Acorrectly assembled and tightened joint that fails in service requires specialist knowledge and is out with thescope 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 maynot be fitted with a gasket.

The validity includes all bolting arrangements, both circular and non-circular, and fluids (gas or liquid) with theexception 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 areregularly 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 manage-ment 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;

CEN/TS 1591-4:2007

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

7/14

5

evaluation of the effectiveness of the training.

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

2 Normative references

Not applicable.

3 Terms and definitions

3.1manufacturerorganisation that manufactures equipment subject to the PED directive

3.2

operatororganisation 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

3.3training providerorganisation with the capability to deliver the required training

3.4trainer

individual assigned by the training provider to deliver the training

4 Objective

The objective of this Technical Specification is to set down a route for achieving competency in the skills re-quired 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.

5 Training location

Training may either take place at a suitable training centre or at the facility where the candidates normallywork.

The location should include a suitable classroom and practical workshop where the possibility exists to trainwith bolted joints that are representative of the candidates normal place of work.

CEN/TS 1591-4:2007

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

8/14

6

6 Training curriculum

6.1 General

The curriculum should include all joint types that will be encountered by the candidates when they return totheir work site. For candidates who are expected to work on a variety of sites the content should be sufficientlygeneric to cover all commonly encountered joints. As a minimum, this will at least include bolted joints that arerepresentative of the candidates normal place of work.

The manufacturer or operator requiring the training should ensure the above requirement is met by the or-ganisation selected to provide the training.

The curriculum will include a number of key topics to ensure a comprehensive understanding and appreciationof the bolted joint. The topics can be divided between topics that require awareness and those requiring anin-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 therelationship between torque and bolt load is impacted by the coefficient of friction, before being taught torquetightening a bolted joint.

The training provider is responsible for setting the content of each module and will confirm the content is ap-propriate 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 withbolted joints. The list is exemplary; the exact content of the training depends on the quality management sys-tem, 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.

CEN/TS 1591-4:2007

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

9/14

7

6.3 Specific knowledge

The curriculum will ensure candidates have a thorough understanding of the following aspects of joint disas-sembly, 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.

7 Format of training

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

CEN/TS 1591-4:2007

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

10/14

8

8 Suitability of procedures and work instructions

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

9 Effectiveness of training

The trainer should be able to demonstrate a thorough understanding of the technical and practical aspects ofthe curriculum. For many institutions providing training, such as vocational technical schools, this will be man-dated in the schools quality plan.

The manufacturer or operator will develop a method for verifying the effectiveness of the training provider anddocument within their quality management system. Methods may include candidate questionnaires and trainerperformance 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 evidencethat 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 re-quired level of awareness and understanding.

Completion of the training and passing the written examination does not imply competency. It is acceptable toissue a certificate of attendance.

The certificate of attendance will include the candidates name, training provider and confirmation that all mod-ules have been covered.

10 Work-site experience

The candidate shall be given the opportunity to practice their training, supervised by a certified competentperson. 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 bedetermined 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 Earliest assessment

Frequent and intense 3 months

Infrequent but with intense periods 6 months

Sporadic 12 months

CEN/TS 1591-4:2007

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

11/14

9

11 Competence assessment

11.1 General

Assessment of competence is key to maintaining the highest performance from the bolted joint. The assess-ment 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 theassessor thinks reasonable to be sure the candidate has retained the required level of awareness and under-standing.

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 assess-ment the candidate will explain what they are doing and its importance in safety terms and for good joint se-curity.

Documented work place evidence.

The candidate shall produce written evidence that he or she has understood and correctly applied the trainingundertaken.

12 Qualification of assessor

The assessor chosen should be qualified as competent to be an assessor in the field of mechanical joint re-

lated manual skilled vocations.

13 Competence management

It is essential that the manufacturer or operator initiating the training creates and maintains a register of sitepersonnel competencies.

The register will include each individuals date of training and assessment as well how frequently the individualhas worked with bolted joints.

The register will be reviewed, at least every six months, to determine whether any personnel should be re-

moved or undertake refresher training. Table 2 gives guidance on the period after achieving competency be-fore refresher training is normally required. The individuals competencies will also be reviewed to confirm ap-plicability 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

CEN/TS 1591-4:2007

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

12/14

10

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 ofthe laws of the Member States concerning Pressure Equipment (Brussels, Official Journal EC, July1997)

CEN/TS 1591-4:2007

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

13/14

blank

py

g

py()

7/24/2019 DD CEN TS 01591-4-2007

14/14

DD CEN/TS1591-4:2007

BSI

389 Chiswick High Road

London

W4 4AL

BSI British Standards Institution

BSI is the independent national body responsible for preparingBritish Standards. It presents the UK view on standards in Europe and at theinternational level. It is incorporated by Royal Charter.

Revisions

British Standards are updated by amendment or revision. Users ofBritish Standards should make sure that they possess the latest amendments oreditions.

It is the constant aim of BSI to improve the quality of our products and services.We would be grateful if anyone finding an inaccuracy or ambiguity while usingthis British Standard would inform the Secretary of the technical committeeresponsible, the identity of which can be found on the inside front cover.Tel: +44 (0)20 8996 9000. Fax: +44 (0)20 8996 7400.

BSI offers members an individual updating service called PLUS which ensuresthat subscribers automatically receive the latest editions of standards.

Buying standards

Orders for all BSI, international and foreign standards publications should beaddressed to Customer Services. Tel: +44 (0)20 8996 9001.Fax: +44 (0)20 8996 7001. Email: orders@bsi-global.com. Standards are alsoavailable from the BSI website at http://www.bsi-global.com.

In response to orders for international standards, it is BSI policy to supply theBSI implementation of those that have been published as British Standards,unless otherwise requested.

Information on standards

BSI provides a wide range of information on national, European andinternational standards through its Library and its Technical Help to ExportersService. Various BSI electronic information services are also available which give

details on all its products and services. Contact the Information Centre.Tel: +44 (0)20 8996 7111. Fax: +44 (0)20 8996 7048. Email: info@bsi-global.com.

Subscribing members of BSI are kept up to date with standards developmentsand receive substantial discounts on the purchase price of standards. For detailsof these and other benefits contact Membership Administration.Tel: +44 (0)20 8996 7002. Fax: +44 (0)20 8996 7001.Email: membership@bsi-global.com.

Information regarding online access to British Standards via British StandardsOnline can be found at http://www.bsi-global.com/bsonline.

Further information about BSI is available on the BSI website athttp://www.bsi-global.com.

Copyright

Copyright subsists in all BSI publications. BSI also holds the copyright, in theUK, of the publications of the international standardization bodies. Except aspermitted under the Copyright, Designs and Patents Act 1988 no extract may bereproduced, stored in a retrieval system or transmitted in any form or by anymeans electronic, photocopying, recording or otherwise without prior writtenpermission from BSI.

This does not preclude the free use, in the course of implementing the standard,of necessary details such as symbols, and size, type or grade designations. If thesedetails are to be used for any other purpose than implementation then the priorwritten permission of BSI must be obtained.

Details and advice can be obtained from the Copyright & Licensing Manager.Tel: +44 (0)20 8996 7070. Fax: +44 (0)20 8996 7553.Email: copyright@bsi-global.com.

py

g

py()