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.