EN 1591-4 – The key to success?

provided a valid and unified foundation training of fitters but also for the staff who
By S. Schulz, ESA Member
for a European wide system. This is now supervise them, such as the responsible
represented by the EN 1591 (EN 1591- engineers and technicians. They too are

A
wareness and commitment to 1:2001 - Rules for the design of circular also required to confirm/reconfirm their
the issues of “environmental flange connections and gasket: Part 1 - skills!
protection” have grown in Calculation method) which was adopted There is also set a clear distinction
recent years and have become key parts in 2001. The first of five parts, it set the between a trainer and an assessor. This
of political debates, conferences and physical properties and calculation system means that the training and assessment
legislations worldwide. An important so that leakage classes of bolted flange cannot be performed by one and the
aspect for the preservation of our connections could be designed in mind. same person. In the training courses
environment is the reduction of so-called This allowed a plant designer to design offered with foresight on the market it
“fugitive emissions” from, for example, in any required compliance with emission was usual that a single person performed
chemical and petrochemical plants. legislations. the training and also carried out the
The revision of the “Technical Instructions The assembly values determined by the final knowledge tests. This is no longer
on Air Quality Control” (TA-Luft) in 2002 EN1591-1 calculation method requires permitted under the EN 1591-4; a third
and the referring directive 2290 of the the controlled tightening of bolts, so party assessor must be used.
“Association of German Engineers” (VDI) therefore it needs competent and Within the group being trained it will be
set the political and technical standards qualified fitters to perform the work. distinguished if any trained mechanics,
in Germany. Other European states will As a result of this, and after many years engineers and so-called career changers
follow this example and gradually adapt of work, the EN 1591-4 (Flanges and their are present, because the participation
their national fugitive emission regulations. joints - Part 4: Qualification of personnel in the theoretical training is optional for
It requires all industrial plants to operate competency in the assembly of the bolted participants who have the necessary
according to the current best available connections of critical service pressurized knowledge. If they have proven prior
techniques (BAT). This includes not only systems) was brought into force in knowledge the assessment can be carried
for the reduction of emissions, but also 2013. It now has the status of a national out immediately with no training, only if
for the reliability of each component of standard within the CEN member states they fail the assessment must a training
the system. Bolted flanged connections so can therefore be legally binding. course be taken. For employees without
are highlighted key factors in the safe There have been training courses offered specialized training or qualifications an
operation of pressure-stressed systems, by various companies and institutions with approved training course must be taken
for the protection of human health and foresight throughout the development before any assessment can be performed.
the environment. cycle of the EN1591-4. They were Where the training takes place is for
The technical committees of the CEN described as being in accordance with the provider to decide, it can be on a
member states (Comité Européen EN 1591-4, but sadly many failed to customer site or a purpose built building.
de Normalisation) developed a draft completely cover the requirements of the It is however crucial that the site has
standard which, among other things, set final standard. both an adequate classroom and a
the design of bolted flange connections suitably equipped workshop for the
and the qualifications and technical The basic content of the implementation of the practical training
ability of installation personnel. This EN 1591-4 is as follows: sections.
It requires the installer to have the ability The course content requires each
to disassemble, assemble and tighten participant to first attain a basic
bolted flange connections correctly qualification. The basic training module
and safely. This knowledge can only is the most extensive within the new
be acquired according to the standard standard and includes a variety of topics
through theory and practical experience. of different value. After the successful
These capabilities must be tested and completion of this basic course several
confirmed by a certified expert assessor. optional higher levels are available, which
The standard provides a modular training provide additional knowledge in specific
curriculum and is very thorough with its areas such as heat exchangers, pressure
technical content. It is important to note vessels, special flanges etc. A crucial
that the curriculum exists not only for the aspect is that any responsible engineers
or technicians must have acquired at Finally, upon successfully proving their With the entry into force of EN 1591-4,
least the same skill levels as the fitters or abilities the training participant will there has been given a possibility in
mechanics supervised by them. In addition receive a certificate with all the relevant Europe to bring the quality of installation
to this, the EN 1591-4 sets further information about the course content, work during plant construction
requirements that they must be proven skill levels, additional qualifications, etc. projects, maintenance work and shut-
by a separate advanced training module. This certificate has a validity of 5 years, downs to a uniformly high level and
Any person who acts as “technical although they must be able to prove that thereby reduce environmental damage,
management” and isn’t involved in the they have worked with bolted flange accidents and production losses to a
disassembly or assembly of connections connections for at least 6 months without minimum.
on site or the supervision of people doing interruption. An extension for another Ultimately, however, this requires a
so are not required under the standard 5 years is possible after a re-assessment rethinking of the plant operators to
to be trained and tested. However it is only, no new training is required if the employ fully qualified staff and requires
strongly recommended! assessment is passed. The documentation them to have confidence in what this
The fixed training course content may of the complete training course is required standard brings. The paths are now
be supplemented by operator-specific to be kept by the assessor, participant and paved, so the journey should be a lot
factors, such as local site regulations, the operator for the duration of its validity. easier.
specialist equipment training and local
environmental policies.
The evaluation of the training course is The European Sealing Association (ESA) has produced this article as a guide
carried out in two steps - a theoretical towards Best Available Techniques for sealing systems and devices. These articles
and practical assessment by the assessor. are published on a regular basis, as part of their commitment to users, contractors
The requirements of the theoretical and OEM’s, to help to find the best solutions for sealing challenges and to achieve
exam are subject to the assessor and maximum, safe performance during the lifetime of the seal. The ESA is the voice
can be discussed with the operator. of the fluid sealing industry in Europe, collaborating closely with the Fluid Sealing
The practical demonstration of the Association (FSA) of the USA. Together, they form the key global source of
disassembly, assembly and tightening of technical knowledge and guidance on sealing technology, which is the basis for
bolted flange connections must be proven these articles. For more information, please visit www.europeansealing.com
as well, within a controlled environment.