1. Annual Review 2010MECHANICAL JOINT INTEGRITYROUTE TO
COMPETENCE GUIDANCEPreventing Hydrocarbonreleases through
safetycritical competence
2. Mechanical joints have the potential to cause serious injury
andhydrocarbon releases. This has been seen in the last few years
wherea number of serious incidents and accidents have occurred
duringconstruction, maintenance, disassembly and steady-state
operations.Competence related failures are one of the main causes
of loss-of-containment incidents, and may lead to major
accidents.As a result of this, there is a strong desire within the
oil and gas industryto improve the safety performance of such
operations. To achieve thisaim, a work group was established to
produce this Mechanical JointIntegrity Competence guidance.This
guidance reflects current industry practice guidance as well asa
definition of minimum standards of competency for carrying outsuch
work. It has been developed by a joint working group
includingmembers from industry and standard setting bodies. In
compiling thisdocument, it was recognised that organisations
already have processesand procedures. With this in mind, they are
designed to provideguidance in two ways: To enable you to assess
your current working methods against theprinciples put forward here
and so help you identify improvementsto those methods in line with
current best practice. To allow companies to adopt improved methods
for demonstratingspecialist critical bolting and small bore tubing
competence, basedon current good practice.We recommend the review
of company procedures against theprinciples and practical guidance
contained in this publication. Anaction plan should then be
prepared for the implementation of anynecessary
improvements.Effective and lasting improvement can be achieved
where all concerned,from senior management to those carrying out
work on the plant, sharea genuine commitment to achieving and
maintaining mechanical jointoperations procedures to a high
standard.AN OVERVIEW
3. Scope and Target AudienceThe guidance sets out a structured
approach to the principles ofmanaging competence for those involved
in mechanical joint operations.It describes how to train, develop
and assure competence, reducingthe risk of personal injury and
hydrocarbon and non-hydrocarbonrelease when working with mechanical
joint related activities such asconstruction, maintenance and
disassembly operations.The guidance is intended to reflect industry
good practice for themanagement of competence in relation to
mechanical joint operations.It applies to the onshore and offshore
oil and gas industry to the extentthat it is reasonably practicable
to do so. It also has general applicationto all industries where
mechanical joint operations are undertaken.These guidelines are
therefore aimed at all personnel involved inmechanical joint
operations, particularly those who are expected toundertake related
duties in the workplace. Correspondingly those whoare expected to
plan these operations and the supervisors of thosepersonnel
performing them should be familiar with these
principles.Additionally those involved with the management of
training andcompetence, including the delivery of related material
should be aware of the importance of utilising good practice in the
demonstration ofcompetence of new and existing workers; a revised
and restructured development routesRisk ReductionThe main focus is
on risks to the safety of people and avoiding lossof containment,
particularly where activities present potential majoraccident
hazards. It will also improve environmental protectionand reduce
business interruption. For all assembly and disassemblyoperations
the risks should be formally assessed.Overview of HazardFire and
explosionUncontrolled release of pressure resulting in personal
injury throughexposure to hydrocarbons or flying
componentsINTRODUCTION01
4. Basic PrinciplesControl of the training and competence
assurance of personnel working on mechanical joints is a critical
factor inachieving asset integrity. Therefore an important element
of the competence assurance and management system is toensure that
any person working on a given joint has been trained and assessed
as competent to perform the task.All personnel involved in
mechanical joint operations should have sufficient knowledge of the
specific tasks to beundertaken and the risks which the work will
entail, along with sufficient experience and ability to carry out
their dutiesin relation to mechanical joint integrity operations,
whilst recognising their limitations and be able to take
appropriateaction in order to prevent harm to themselves and those
affected by the work.Moreover personnel should be assessed as
technically competent. Formal assessment should be underpinned by
nationaloccupational standards and provides demonstrable capability
for all personnel, including third-party vendors andcontractors,
who are expected to make, break or maintain mechanical
joints.Personnel Undertaking Mechanical Joint Integrity
OperationsThe diagram on page 3 shows the four key stages that an
individual has to pass through to reach full competency andmaintain
ongoing performance development.The chart on page 8 and 9
identifies the categories of personnel who undertake or are
involved with Mechanical Jointoperations and the suggested training
and competence assessment for these groups of personnel.There are a
number of training courses available, which are based upon and meet
industry occupational standardsdeveloped by the ECITB a training
standards organisation.Four Key Stages in Achieving CompetencyThe
first stage of all training comprises initial training and
assessment. This is normally carried out at a training
establishment.At the completion of Stage 1, the level of competency
is deemed sufficient for that person to undertake Mechanical
JointIntegrity operations under the direct supervision of a
competent person as part of their Stage 2 training.Stage 2 is
consolidation of skills, experience building and the practical
application of the learning obtained in Stage 1.Stage 3 is the
assessment of technical competency at an approved test centre with
Stage 4 as the ongoing performancedevelopment.These four stages of
achieving competency in Specialist Critical Bolting and Small Bore
Tubing are shown in Fig 1.In order to conduct mechanical joint
integrity operations to todays high standards, it is important that
employers havea system in operation which permits personnel to
progress through the stages to become competent to
undertakemechanical joint integrity operations and to maintain this
competence.In the case of non-core personnel employed on short-term
contracts, employers must have a system in operation tovalidate the
competency of these personnel and, if necessary, update and refresh
the skills and knowledge of suchpersonnel.Key Stages of
MechanicalJoint Integrity Competence02
6. ROUTE TO COMPETENCE04New Workers and Existing WorkersNew
Workers who have no experience in working with mechanical joints
must start at Stage 1 of the training andprogress through Stages 2,
3 & 4 over time.Existing workers may go straight to Stage 3 (as
shown in Fig. 2) if their company can endorse that the existing
workerhas previously attended a training course in bolting or small
bore tubing and has recent experience in that subject area.Some
existing workers may require refresher training on the knowledge
aspects and computer based training moduleswill be available that
are aligned with ECITBs technical training standardsPersonnel
involved in mechanical joint integrity activitieswill attend an
ECITB approved training provider toundertake a period of training
in either specialist criticalbolting or small bore tubing
assemblies. The training willnormally take place onshore and
consist of classroom andworkshop learning activities. The courses
are normallyfrom one day to two and half days depending upon
thesubject matter. Each person will be taught theoreticaland
practical skills regarding the relevant subject matterto a
technical training standard specified by the ECITB.The training
courses require each person to demonstratethe attainment of
knowledge and practical skills throughan individual knowledge test
and practical workshopexercises. Successful personnel will gain a
certificate oftraining and be issued with a Work Based Task
Assignmentto be used in Stage 2.Each person after attending an
approved training courseand attaining the training certificate
requires a periodof workplace experience to practise new skills
andknowledge. This period allows for the consolidationof skills and
knowledge against work based tasks. Thelearner is issued with a
Work Based Task Assignmentspecifying the range of tasks and complex
jobs requiredbefore the person can move on to Stage 3. A
workplaceconsolidation period of 3 to 12 months is recommendedto
give the person the opportunity to complete the WorkBased Task
Assignment. The individual must satisfactorilydemonstrate that they
have carried out each of thesteps indicated in the Work Based Task
Assignment on aminimum of three occasions. This may mean in
practicethat they complete more than three task assignmentrecords
as they may not carry out every step on eachoccasion.The task
assignment record may be verified by anyperson with overall
responsibility for the correct, safe andaccurate completion of the
task. This could be: A supervisor or team leader A line manager Any
other person with responsibility for the finalapproval and quality
assurance for the relevant task,for example a QC Inspector or
permit authorityWhen the person has achieved satisfactory
completionof the Work Based Task Assignment they can move ontoStage
3.Stage 3 requires each person to complete a formalassessment of
their job knowledge, skills and abilityin each Mechanical Joint
Integrity subject. The ECITBtechnical competence validation tests
are standards basedconsisting of a bank of online knowledge
questions anda practical task to validate the learners skills,
knowledgeand ability. Successful learners achieve the certificateof
achievement which is valid for a period of 3 years.Unsuccessful
personnel must wait a minimum period of4 weeks between the
unsuccessful test session and nexttest session to allow a period of
training to address anyskills or knowledge gaps.To confirm the
individuals current skills, knowledge andability the ECITB
technical competence validation test isundertaken every 3 years to
prove ongoing performancedevelopment. If required the individual
can undertake ashort computer based training module to refresh
their jobknowledge before attempting the technical test.Stage
1Stage 2Stage 3Stage 4
7. 05StartNoYesIs the candidatealready practisingin this skill
area?Is there clearevidence ofknowledge
andskillsNoYesOPTIONComplete MechanicalJoint Integrity CBTCarry out
an analysisof individual trainingneedsStage 1Complete theendorsed
trainingcourse(s)Certificate ofTrainingStage 2Complete a workbased
task assignmentStage 3Carry out the technicalcompetence
validationtestDid thecandidate successfullycomplete the
technicalcompetence validationtest?NoYesCertificate ofAchievement
issuedfor individual(valid 3 years)Stage 4Refresher training
tomaintain currencyDirect learningsubject toexaminer
feedbackCandidates for Stage 3 assessmentrequire: A Valid Stage 1
TrainingCertificateand A complete and valid workbased task
assignmentor A formal letter from thecandidates
employerrepresentative stating thatthe candidate has met
theequivalent of the ECITB Stage 2experience WBTA criteria. The
formal letter should includedetails of the employersrepresentative
position in thecompany, full contact detailsand be signed and dated
by theemployer representative.ExistingWorkersNewCandidatesFigure
2
8. Roles & ResponsibilitiesThe following matrix provides
guidance on the roles and responsibilities in mechanical joint
integrity operations to beapplied in conjunction with the training
and competence Fig. 1. The numbers refer to the 4 stage model
described onpage 3.Competence Management ofMechanical Joint
Integrity06Activity Key role stages requiredWork safely and
minimise riskin mechanical joint integrityoperations1 1,2,3 1,2,3,4
1,2,3 1,2,3,4 1,2,3,4 1,2,3,4Identify and deal with hazards
andemergencies in mechanical jointintegrity operations1 1,2,3
1,2,3,4 1,2,3 1,2,3,4 1,2,3,4 1,2,3,4Prepare the work area,
materialsand equipment in accordancewith health and safety and
qualitystipulations for mechanical jointintegrity operations1 1,2,3
1,2,3,4 1,2,3 1,2,3,4 1,2,3,4 1,2,3,4Ensure intended task
conformsto related specification, methods,processes, techniques
andprocedures1 1,2,3 1,2,3,4 1,2,3 1,2,3,4 1,2,3,4 1,2,3,4Dismantle
bolted connections(torque or tension)1 1,2,3 1,2,3,4 1,2,3 1,2,3,4
1,2,3,4 1,2,3,4Remove components from boltedconnection systems1
1,2,3 1,2,3,4 1,2,3 1,2,3,4 1,2,3,4 1,2,3,4Replace components in
boltedconnection systems1 1,2,3 1,2,3,4 1,2,3 1,2,3,4 1,2,3,4
1,2,3,4Assemble, secure and hand torquebolted connections1 1,2,3
1,2,3,4 1,2,3 1,2,3,4 1,2,3,4 1,2,3,4Assemble, secure and
hydraulicallytension bolted connections1 1,2,3 1,2,3,4 1,2,3
1,2,3,4 1,2,3,4 1,2,3,4Assemble, secure and hydraulicallytorqued
bolted connections1 1,2,3,4 1,2,3 1,2,3,4 1,2,3,4 1,2,3,4Verify the
integrity of theassembled joint1 1,2,3,4 1,2,3 1,2,3,4 1,2,3,4
1,2,3,4SupervisorDecommissioningOperativeMaintenanceTechnicianProductionOperatorConstructionCraftspersonBoltingTechnician/SupervisorInspectorSpecialist
Critical Bolting
9. 07Activity Key role stages requiredWork safely and minimise
riskin mechanical joint integrityoperations1 1 1,2,3 1,2,3,4 1,2,3
1,2,3,4 1,2,3,4 1,2,3,4Identify and deal with hazards
andemergencies in mechanical jointintegrity operations1 1 1,2,3
1,2,3,4 1,2,3 1,2,3,4 1,2,3,4 1,2,3,4Plan and configure smallbore
tubing assemblies in theengineering construction industry1 1 1,2,3
1,2,3,4 1,2,3 1,2,3,4 1,2,3,4 1,2,3,4Dismantle and remove
componentsfrom small bore tubing assembliesin engineering
construction1 1 1,2,3 1,2,3,4 1,2,3 1,2,3,4 1,2,3,4 1,2,3,4Shape
small bore tubingcomponents in the offshore/engineering
construction industry1 1 1,2,3,4 1,2,3 1,2,3,4 1,2,3,4
1,2,3,4Replace components in small boretubing assemblies in
engineeringconstruction1 1 1,2,3,4 1,2,3 1,2,3,4 1,2,3,4
1,2,3,4Assemble small bore tubingcomponents to meet specificationin
the engineering constructionindustry1 1 1,2,3,4 1,2,3 1,2,3,4
1,2,3,4 1,2,3,4Install small bore tubing in theengineering
construction industry1 1 1,2,3,4 1,2,3 1,2,3,4 1,2,3,4 1,2,3,4Test
small bore tubing assembliesin the engineering
constructionindustry1 1 1, 1,2,3 1, 1,2,3,4 1,2,3,4Inspect small
bore tubing in theengineering construction industry1 1 1, 1,2,3 1,
1,2,3,4 1,2,3,4Small Bore
TubingDesignerSupervisorMaintenanceTechnicianProductionOperatorConstructionCraftspersonSBTTechnician/SupervisorInspectorDecommissioningOperativeSBT
Qualification A vocational qualification Installing Engineering
Construction Plant and Systems Small Bore TubingAssemblies is
available from the ECITB.
10. The right person for the right taskTraining and
CompetenceManagement responsibility08Level The task Training and
supervision Measuring performanceNew worker Specify the tasksfor
the new worker,the tools, PPE andequipment, specifylimits on tasks,
assignto a supervisorProvide approved training provisionand
supervision in accordance with 4stage model; provide opportunities
toconsolidate skills and knowledge inthe workplace using the work
basedtask assignments to a satisfactorystandard ready to undertake
thetechnical competence validation test.Set and monitor
trainingtargets, monitor performanceand behaviours of newworker and
supervisor.Achievement of technical testin relevant subject
area.Existing worker Specify and authorisetasks that can
beundertaken, accordingto valid technicaltest certificates
andexperience.Check technical test certificates,provided refresher
training andongoing performance development.Confirm validity of
technicaltest certificates; carryout assessments
againstcompany/client competencemanagement systems.Designer
Awareness andknowledge of SBTsystems, componentsand materials to
aiddesign skills.Provide approved SBT Assembliestraining provision
and supervision indesign project tasks.Set and monitor
trainingtargets, monitor performanceand behaviours in designproject
tasks.Supervisor Specify the awarenessand knowledge oftasks and
associatedrisks.Check qualifications and taskexperience, relevant
approved coursetraining, provide management andtechnical support to
workersSet, monitor performanceand behaviours of workers intasks,
task completed safelywith a do it right first timeapproach, HCR
reductiontarget met.DecommissioningOperativeSpecify the
awarenessand knowledge oftasks and associatedrisks when
destructingplant and systems.Provide approved relevant
trainingprovision and supervision indecommissioning tasks.Set and
monitor trainingtargets, monitor performanceand behaviours
indecommissioning tasks..MaintenanceTechnicianSpecify and
authorisetasks that can beundertaken, accordingto valid
technicaltest certificates andexperience.Check technical test
certificates,provider refresher training andongoing performance
development.Confirm validity of technicaltest certificates;
carryout assessments againstcompany/client competencemanagement
systems.ProductionOperatorAwareness andknowledge of MJIsystems,
componentsand materials to aidbasic maintenance taskskills.Provide
approved training provisionand supervision in accordanceto 4 stage
model if technicaltest certificate required; provideopportunities
to consolidate skills andknowledge in the workplace usingthe work
based task assignmentsto a satisfactory standard ready toundertake
the technical competenceSet and monitor trainingtargets, monitor
performanceand behaviours in basicmaintenance task skills.
11. 09Level The task Training and supervision Measuring
performanceConstructionCraftspersonSpecify and authorise tasksthat
can be undertaken,according to valid technicaltest certificates
andexperience.Check technical testcertificates, providerrefresher
training andongoing performancedevelopment.Confirm validity of
technicaltest certificates, carryout assessments
againstcompany/client competencemanagement systems.SBT/Bolting
Technician Specify and authorise tasksthat can be
undertaken,according to valid technicaltest certificates
andexperience.Check technical testcertificates, providerrefresher
training andongoing performancedevelopment.Confirm validity of
technicaltest certificates; carryout assessments
againstcompany/client competencemanagement systems.Inspector
Specify and authorise tasksthat can be undertaken,according to
valid technicaltest certificates andexperience.Check technical
testcertificates, providerrefresher training andongoing
performancedevelopment.Confirm validity of technicaltest
certificates; carryout assessments againstcompany/client
competencemanagement systems.Step Change in Safety Resources Asset
Integrity Toolkit Hydrocarbon Release Reduction Toolkit Good
Practices Breaking of Containment Golden Rules Good Practices
Breaking of Containment Checklistwww
12. address 3rd Floor The Exchange 2 62 Market StreetAberdeen
AB11 5PJtelephone 01224
577268emailinfo@stepchangeinsafety.netwebsitewww.stepchangeinsafety.netISBN
No. 978-1-905743-19-3designedbyfoyergraphicsProduced in association
with:www.ectib.org.ukFirst printed March 2012
