Moduls of the Assembly Training acc. EN 1591-4
In order to meet the diverse qualification requirements of a flange fitter, the training is modular according to EN 1591-4. The basis for the training is always the basic qualification level. Building on this, further training modules can then be taken, in which special topics are dealt with in a targeted manner.
Basic Qualification Level
The basic qualification can be proven taking into account the professional training or professional experience.
Validity of the basic qualification: 5 years
Training in the basic qualification level and the associated assessment can be carried out in one day. Training and assessment are carried out by different people.
» content: basic qualification level
The training is performed in accordance with tab. 1 of EN 1591-4.
Theory (summary):
- function of flanged joints
- Requirements regarding tightness
- Forces, moments, elongation
- Health and safety precaution
- Joint disassembly
- Preparation of appropriate assembly
- Manual torque controlled tightening
- Documentation of the work carried out
- Documentation of variance or irregularity
- Emission monitoring
- Procedure in case of leaks
- Tightening procedures
- Assembly using torque wrenches
- Influence of lubricants
Practice (summary):
- Safe joint disassembly
- Proper application of torque wrenches
- Demonstration of influence of thread friction
- Bolt tightening
- Use of tightening patterns
Examination:
- Theoretical questionnaire
- Practical skills assessment
Extension of Basic Qualification
The basic qualification can be proven according to education or professional experience. After the validity has expired, the certificate can be extended by a further period of 5 years on the basis of a positive evaluation.
For the renewal of the certificate, AMTEC offers refresher training with subsequent assessment, according to 8.2.2, basic qualification level.
» content: extension of basic qualification level
The refresher course to extend the basic qualification includes:
- Health and safety Precautions
- Functionality of flange connections
- Forces, moments, elongation
- Disassembly of flange connections
- Preparations for appropriate assembly
- Manual torque controlled tightening
as well as practice like
- Handling of torque wrenches
- Assembly with torque wrenches
- Influence of lubricants
Hydraulic Tension Tightening
In this module, knowledge about working with hydraulic tensioners is deepend.
In particular, the advantages of hydraulic tensioning like low influence of friction at the bolts and almost direct adjustment of bolt forces.
» content: Hydraulic Tension Tightening
The content of the module includes
- Basics of hydraulic tensioning
- Understanding when to use hydraulic tensioners
- Types of Hydraulic TensionersMethodes of Hydraulic tensioning
- Maintenance of pump and hydraulic tensioner
- Calibration of hydraulic tensioners
- Hose configuration
- Methods of calculating correct bolt load and associated formulae
- Hydraulic clamping methods
- Hydraulic tensioning pressure / load conversion
- Understanding gross load/residual load
- Tightening procedure for tightening with hydraulically operated tensioning tools
Hydraulic Torque Tightening
In addition to the basic qualification, knowledge of
- hydraulic,
- pneumatic and
- electric torque-controlled
tightening is intensified in this module.
» content: Hydraulic Torque Tightening
The module includes
- Safe use and handling of hydraulic hoses
- Correct socket usage, wear/damage of sockets
- Risk of pressure inhection injuries - avoidance and action
- Good working practices to avoid fingers/hand pinch points
- Safe use of a backing wrench
- Types of hydraulic, pneumatic and electric torque wrenches
- Selection of tool pressure to provide required torque for a particular tool
- Use of single and multiple tools to tighten a joint
- Numbering of the bolts when single and multiple tools are used
- Fundamentals of hydraulic torqueing
- Tool fit and clearance issues
- Identifying good reaction points
- torque tightening patterns
- Importance of lubrication and dispersion of friction
Heat Exchangers and Pressure Vessels
In addition to the basic qualification, knowledge of
- plate and
- tube bundle heat exchangers
is essentially imparted in this module.
» content: Heat Exchangers and Pressure Vessels
The module includes
- Types of heat exchangers/TEMA designations
- Interaction of seals during assembly
- Gasket types
- Confined gaskets
- Handling and storage of gaskets
- Load requirements
- Joint configuration and terminology
- Flange surfaces inspection
- Bundle and channel orientation
- Damage risks
- Tube sheet considerations
- Tightening
Flanges made from Brittle Materials
In addition to the basic qualification, knowledge of flange connections made of brittle materials is essentially imparted in this module.
» content: Flanges made from Brittle Materials
The module "Flanges made of brittle materials" includes
- Types and material of brittle flanges
- Interaction of seals during assembly
- Gasket types
- Handling and storage of flanges and gaskets
- Load requirements
- Tightening methods for brittle flanges
- Joint configuration and terminology
- Flange surface inspection
- Gap measurement
- Tightening method preference relative to bolt length and tool access
- Safe disassembly of brittle flanges
Bolt Load Determination after Assembly
In addition to the basic qualification, this module provides knowledge about the methods to determine bolt forces after assembly.
These force measurements are of great importance in order to reduce the causes of leaks in sealed connections. Last but not least, the reasons are often to be found in insufficient surface pressure of the seal.
» content: Bolt Load Determination after Assembly
The module includes
- Methods of measuring bolt load after assembly
- Measurement of bolt load by extension measurement
- Measurement of bolt load by Torque application
- Measurement of bolt load by Tension application
- Measurement of bolt load by Ultrasonic measurement
- Measurement of bolt load using extensometer
- Evaluation of the measured bolt forces
Next training date on request.
Compact Flanges
Due to their geometry, the compact flanges represent a special kinf of bolted flanged joint.
These special features are discussed in more detail in this module.
» content: Compact Flanges
Contents of the module "Compact Flanges" are e.g.
- Compact flange types
- Assembly requirements for each type of compact flange
- Identification of seal types and materials
- Bolt load determination
- Tightening methods
- Tightening patterns
- Inspection of components before assembly
- Inspection of components after assembly
- Gap measurement
- Safe disassembly of compact flanges
Clamp Connectros and Special Connectors/Flanges
Currently not in the training program.
» content: Clamp Connectors
Contents of the module "Clamp Connectors" are e.g.
- Clamp connector types
- Assembly requirements for each type of clamp connector
- Identification of seal types and materials
- Bolt stress and load determination
- Tightening methods
- Tightening patterns
- Inspection of components before assembly
- Inspection of components after assembly
- Safe disassembly of compact flanges
Next training date on request.
» content: Special Connectors/Flanges
We extend and optimize our training program, continously!
Contact us!!
Responsible Engineer
The basis for a reliable flange connection begins with the design and work preparation.
For this reason, the EN 1591-4 standard also recommends the training of supervisors and responsible engineers.
» content: Responsible Engineer
- Basics of the standard
- Health and safety considerations
- Generation of safety rules
- Generation of work instructions
- Evaluation of seal characteristics
- Selection of suitable "high quality" seals
- Principles of designing flange connections according to EN 1591-1
- Methods of determination of gasket stress for a given tightness
- Calculation of assembly values according to EN 1591-1
- Determination of bolt load/gasket stress value for a flange gasket combination
- Confirmation that a gasketed bolted connection can be returned to operation
- Tightness measurement and leakage management
Additional Modul for Trainer
Would you like to train your fitters yourself? A trainer should have a thorough understanding of the technical and practical aspects of the syllabus.
We provide you with the information you need to successfully implement the requirements of the standard.
» content: trainers
This topic is summarized in this module. Additionally, a trainer should be aware of e.g.
- Basics of the standard
- Requirements for trainer
- Requirements for assessors
- Requirements for training location
- Health and safety considerations
- Methods of determination of gasket stress for a given tightness
Customer Specific Training
We are also ready to develop customer-specific training courses or to address your special requirements in your plant. This means that the focus of the training can be set individually, and you have the best possible benefit from the introduction of this training concept.
Online Registration
Your contact for training courses according to EN 1591-4
Benjamin Schiefer
Tel.: +49 7133 9502-261
E-Mail: temes@amtec.de
Christian Six
Tel.: +49 7133 9502-163
E-Mail: temes@amtec.de
