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HCR Improvement & Implementation 3 rd party competence assurance Asset Integrity

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HCR Improvement & Implementation3rd party competence assurance

Asset Integrity

12.00-12.10 Introduction to HCR Improvement and Implementation workgroup

Neil McIntyre – HCR workgroup

Wood Group

12.10-12.40 Third party competence assurance

Neil McIntyre –Business ManagerKaren Jenkins –People and Organisation Business Partner

Wood Group

12.40-13.10 Mechanical joint integrity competencies

Jason Barnard –Global Technical Competence Leader

Hydratight

13.10-13.40 Small bore tubing competencies

Alasdair MacNeil –Operations Director

AFS Technologies

13.45 close

Agenda

INTRODUCTION TO HCR IMPROVEMENT AND IMPLEMENTATION WORKGROUP

Neil McIntyre – HCR Improvement & Implementation workgroup

HCR Improvement & Implementation• Drive and support company / asset by asset

improvement actions• Identify & share MAH/HCR good practice• Monitor plan execution and performance impact

Learning & Sharing• Better sharing of information• Continuous application of past learning

Asset Integrity Steering Group

Major Accident Hazard Understanding• Pan-industry education in “Major Accident Hazard

management”• Map how everyone plays their part, tailor learning

content to suit

Assurance & Verification• Update the existing guidance in line

with European Safety Directive

HCR Working Group

• Collaborative self-help group

• Improve industry HCR performanceWhat?

Who?

• HCR peer-assessments of Operators and Non-Operators

• Best-practice sharing – issue new guidanceHow?

7 Assessment ThemesPerformance

Operational activities

Investigation

CompetenceIntegrity management

Communication

Human factors

Assessment exampleStrengths

• Open and comprehensive reporting culture

• Facility-focused organisation (facility Hydrocarbon Release Prevention plans)

• Robust incident investigation process

• Comprehensive Authorised Persons Register

• Facility Risk Review to manage high risk threats

• FLIR cameras in routine inspections

• ‘Goal Zero’ ambition (no harm, no leaks)

• Leadership commitment (to bring about performance improvement)

• Human Factors Incident Investigation Tool

Opportunities

• Standardised reporting (to remove confusion)

• Re-energise some facility Hydrocarbon Release Prevention plans

• Better use of cross-asset learnings

• Make more of Major Accident Hazards awareness offerings

• Consolidated approach to leak detection technologies

• Make HCR prevention message clearer at the working level

• Bring process safety into Mind Safety

• De-mystify human factors into tangible activities

2017 look ahead

New HCR Guidance

Existing HCR

Guidance

Peer Assessment

Insights

HSExInspection

Insights

• Continue Operator and Non-Operator peer-assessments

• Develop updated HCR guidance

• Promote good practice e.g. via Lunch & Learns

THIRD PARTY COMPETENCE ASSURANCE

Neil McIntyre, Wood Group – Business Manager

Karen Jenkins, Wood Group – People and Organisation Business Partner

3rd Party Competence Assurance

• Introductions

• Safety Moment

• Assurance Process

• New Supplier

• On boarding Process

• Work Scope Completion Feedback

• Improvement Opportunities

Safety Moment – Texas City 10 Years On: Are We Afraid

15

Hyperlink : https://www.youtube.com/watch?v=v1PeOyMCB5o

• New Supplier Request

• Supplier Approval Form

– Denied Parties Listing

– FPAL

– Financial Assessment

– HSE Assessment

– QA Assessment

New Supplier Approval

16

• Supplier Evaluation Form

– Training & Competence Assurance

– HSE

– Risk Assessment & Control

– Policies & Procedures

– Quality Assurance

• Approved Supplier List

Supplier Evaluation

17

• Supplier Engagement

– Work Scope Requirements

– Competence Requirements

– Review of Skills & Experience

– Approval (IAP Gate Criteria)

– Pre Mobilisation Requirements

– Site Specific Induction

– Buddy System

Onboarding Process

18

• Site Feedback to Individual and / or Onshore Support

Focal Point

• One to One Discussions with 3rd Party Onshore

Supervision

• Quarterly FPAL Feedback (where applicable)

Work Scope Completion Feedback

19

• Specialist Vendors

• Ensure Consistent Approach Applied

– Pre Mobilisation Certification Demonstration

• Register of Approved Competent Personnel

– Site v Centralised

Improvement Opportunities

20

Questions

21

MECHANICAL JOINT INTEGRITY COMPETENCIES

Jason Barnard – Hydratight, Global Technical Competence Leader

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

− Introduction

− Route to Competence

− Program Effectiveness Data

− International Delivery

− Membership Services Portal

− Competency Data Management System

− Summary of MJI vs Other Programs

Agenda

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

What is Mechanical Joint Integrity (MJI)?

Flanged Connections

Clamped Connections

Disassembly

Inspection

Assembly

Torque Tightening

Bolt Tensioning

Introduction

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

Introduction

2011− Technical Tests

− TMJI 10

− TMJI 11

− TMJI 18

− TMJI 19

− TMJI 20

− Work Based Task Assessments

2006− TECSkills introduced

2008− PF19 split into 2 units

− PF10 Hand Torque

− PF19 Hydraulic Torque

1994− NSDS PF15

2002− NSDS PF15 split into:

− PF18 Tension

− PF19 Torque

2010-2011− TECSkills updated

− Dismantling added

− Isolation added

− Clamps added

2011− TECSkills revised to Mechanical Joint

Integrity

− Technical Training Standards

− TS MJI10

− TS MJI18

− TS MJI19

− Step Change Route to Competence

Guidance released

How has MJI evolved?

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

MJI Route to Competence Model

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

ECITB Approved Training Courses

− MJI10

− Hand Torque Bolted Connection Techniques

− 1 day duration

− MJI18

− Hydraulically Tension Bolted Connection Techniques

− 1 day duration

− MJI19

− Hydraulically Torqued Bolted Connection Techniques Module

− 1 day duration

− MJI10 &19

− Hand & Hydraulically Torqued Bolted Connection Techniques

− 1.5 days duration

− MJI10, 18 & 19

− Hydraulically Torque and Tension Bolted Connection

Techniques

− 2.5 days duration

ECITB Mechanical Joint Integrity – Stage 1

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

ECITB Work Based Task Assignments

− MJI 10 Dismantling, Assembling and Hand Torque Flange Connections

− MJI 11 Dismantling, Assembling and Hand Torque Clamped Connections

− MJI 18 Dismantle, Assemble and Hydraulically Tension Bolted Connections

− MJI 19 Dismantle, Assemble and Hydraulically Torque Flange Joints

− MJI 20 Dismantling, Assembling and Hydraulically Torque Clamped Joints

ECITB Mechanical Joint Integrity – Stage 2

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

ECITB Technical Test Units

− TMJI10 Dismantle, Assemble and Hand Torque Flanged Joints

− TMJI11 Dismantle, Assemble and Hand Torque Clamp

Connectors

− TMJI18 Dismantle, Assemble and Tensioning Bolted

Connections (Hydraulic Tensioning)

− TMJI 19 Dismantle, Assemble and Hydraulically Torque Flanged

Joints

− TMJI 20 Dismantle, Assemble and Hydraulically Torque Clamp

Connector Joints

Each test consists of a knowledge and practical test.

The knowledge test requires an 80% pass rate and on successful completion of the knowledge

test the candidate will proceed to a practical activity test against identified test criteria.

Successful candidates attain the ECITB certificate of achievement which is valid for a period of

3 years.

ECITB Mechanical Joint Integrity – Stages 3 & 4

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

Hydratight MJI Technical Test Application Matrix

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

More than 3000 people were trained and over 2000 technician tests completed viathe MJI program during 2015.

UK ECITB MJI Training & Technical Testing Data (Data Source ECITB – Correct at 15/02/2016)

There is a current network of 22 MJI approved training providers in the UK andinternational recognition is increasing.

Program Effectiveness Data

80

82

84

86

88

90

92

94

0

500

1000

1500

2000

2500

3000

3500

2012 2013 2014 2015

Technic

al T

est

Pass R

ate

%

Tota

l T

rain

ed/T

este

d

Trained Qty Tested Qty Test Pass Ratio %

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

All training and technical testing activity is recorded by the ECITB and comparedagainst industry leak rate performance as detailed below.

UK Hydrocarbon Release Data vs ECITB MJI Technical Test Ratio (Data Source ECITB and Step Change in Safety – Correct at 15/02/2016)

The data above clearly shows that technical test pass rates are increasing as theprogram evolves and this is contributing to hydrocarbon release reduction.

Program Effectiveness Data

80

82

84

86

88

90

92

94

0

20

40

60

80

100

120

140

2011/2012 2012/2013 2013/2014 2014/2015

Technic

al T

est

Pass R

ate

%

Tota

l Leaks

Total No of Leaks Test Pass Ratio %

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

− Great Britain

− United Arab Emirates

− Oman

− Qatar

− Saudi Arabia

− Kuwait

− Bahrain

− Azerbaijan

− Korea

− Singapore

− Malaysia

− Indonesia

− Australia

ECITB MJI is also accepted in Holland as an equivalent to WFPr Werken aan flenzen volgensprotocol (Working on Flanges according protocol) for UK personal.

International Delivery

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

Membership Services Portal

ECITB MSP

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

Competency Data Management System

Hydratight CDMS

The information contained in this document and all related materials are property of Hydratight Limited and are confidential.No reproduction or disclosure of these materials without the written authorisation of Hydratight Limited is permitted.Copyright © Hydratight Limited 2016. All rights reserved.

Summary of MJI vs Other Programs

Program Key Points

ECITB MJI

• Clear and proven route to competence with new worker and existing worker options included.

• Only ECITB approved and licensed Training Providers can deliver MJI training and technical testing.

• Trainer/Examiner registration and approval route via application process and testing controlled by the ECITB.

• Step Change in Safety approved programme.

• Program is licensed and audited via awarding body.

• Controlled by detailed operating procedures.

• Delivered by an extensive training provider network.

• Central certificate database (MSP)

• Industry support, collaboration and recognition.

EN 1591-4

• Two routes to competence.

• Experience evidence or a minimum required period is not defined within the standard.

• Trainer and Assessor must be different people.

• Third party or awarding body approval is not required,

• Standard states that it is the responsibility of the manufacturer, operator or constructor to develop a method for

verifying the effectiveness of the training provider and shall document it within their quality management system

• Standard is vague when compared with ECITB MJI and ASME PCC-1 Appendix A.

• Program lacks control.

• Not widely adopted outside of mainland Europe.

ASME PCC-1

(Appendix A)

• Qualification based process as defined within Para A-1.1.3 of the guideline.

• Experience can be recognised before training and examination but all three elements, training, experience and examination

must be completed before qualification is awarded.

• Portfolio of workplace experience with co-worker/supervisor references is required.

• Assembler, specialist, senior and instructor roles apply.

• Different experience levels apply to each role with a minimum 6 months required for a Specialist.

• Only third party approved Qualifying Organisations can train and qualify individuals.

• Appendix A was published 3 years ago but the program has not been widely adopted or is it fully understood.

• Program does not have sufficient Qualifying Organizations to enable effective delivery.

• ASME T&D are promoting an alternative online training program.

SMALL BORE TUBING COMPETENCIES

Alasdair MacNeil, AFS Technologies – Operations Director

© 2016

AFS Technologies

© 2016

AFS Technologies – ECITB/SBT training content

Safety moment

AFS Technologies training and competence profile

ECITB/Step Change in Safety SBT route to

competence

Course and Technical Test overviews

Training and Testing trends

Technical Test pass/referral rates

Delegate feedback

Future Coarse Development

© 2016

A “Weep”

AFS Technologies – Safety moment

© 2016

• Hydrocarbon Gas

• At 190bar

• What next?

• Nip it up?

• Highly likely Catastrophic failure would

have occurred

• Injury likely

• Hydrocarbon release certain

Why We Don’t “nip them up”

AFS Technologies – Safety moment

© 2016

AFS Technologies – SBT SkillsCentre™

Facilities in Aberdeen and Newcastle

EI steering group major contributor

ECITB approved trainers, testers, expert witness

advisors, assessor and verifier

An ECITB Approved Training Provider and ECITB

Approved Centre

Since 2005 provided SBT training to over 8,000

delegates

SBT01, SBT02, SBT03, SBT04, RESBT, Reskilling

SCQF Level 5 courses

TSBT01, TSBT02, TSBT03, TSBT04 & CBT

2014 ECITB UK Training Provider of the Year & finalist

in 2015

© 2016

Is the candidate

already practising

in this area?Yes No

NoIs there evidence of

knowledge and skills?

Stage 1

Complete training

Set training

needs through

matrix or analysis

Stage 2

Complete WBT

assignmentStage 3

Technical Competence

Validation Test

Yes

Complete CBT

refresher

(Optional)

ReferralPass

Valid for 3

Years

ECITB/Step Change in Safety route to competence

© 2016

SBT01 – Assemble and Install Small Bore

Tubing – Twin Ferrule

• 2 day course including theory and

practical elements

• available 5 times per week between

Aberdeen and Newcastle

TSBT01 – Assemble and Install Small Bore

Tubing Assemblies – Twin Ferrule

• 2 hour Technical Test

• Available every day in Aberdeen and

Mon-Wed in Newcastle

TSBT02 – Disassemble and Re-install Small

Bore Tubing Assemblies – Twin Ferrule

• 2 hour Technical Test

• Available every day in Aberdeen and

Mon-Wed in Newcastle

ECITB Approved Courses and Tests

© 2016

SBT02 – Assemble and Install Small Bore Tubing

– Cone and Threaded Medium and High Pressure

• One day course including theory and practical

elements

• Delegate must have completed SBT01 or have

passed TSBT01

• Available in Aberdeen and Newcastle

TSBT03 – Assemble and Install Small Bore Tubing

Assemblies – Cone and Threaded

• 2 hour Technical Test

• Available in Aberdeen and Newcastle

ECITB Approved Courses and Tests

© 2016

SBT04 – Hydrotest SBT Assemblies

• 2 days course including theory and practical

elements

• Delegates must have passed TSBT01 or

TSBT03

• Available upon request in Aberdeen

TSBT04 – Hydrostatic Pressure Testing of

Small Bore Tubing Assemblies

• 2 hour Technical Test

• Available upon request in Aberdeen

ECITB Approved Courses and Tests

© 2016

Approved SBT Training Courses and SBT Technical Tests Trends

In 2016 annualised

Training for 1,092 delegates

Testing for 768 delegates

CBT for 158 delegates

0

200

400

600

800

1000

1200

1400

1600

1800

Training Testing CBT

Training - Testing - CBT

Yr-13

Yr-14

Yr-15

Yr-16

© 2016

ECITB Test results

0

50

100

150

200

250

300

350

2013 2014 2015 2016

TSBT01

Pass Refer

0

50

100

150

200

250

300

350

400

450

2013 2014 2015 2016

TSBT02

Pass Refer

0

2

4

6

8

10

12

14

16

2014 2015 2016

TSBT03

Pass Refer

0

1

2

3

4

5

2015 2016

TSBT04

Pass Refer

© 2016

Delegate feedback

© 2016

Delegate feedback

© 2016

Delegate feedback

© 2016

Delegate feedback

© 2016

Delegate feedback

© 2016

Written delegate feedback

Written feedback

that provides AP

learning opportunity

Only positive

written

feedback

provided

No written

feedback

provided

Total

evaluation

responses

Is AP learning available 909 3536 1085 5530

Delegate feedback

© 2016

AFS Technologies

Questions?

© 2016

HCR Improvement &

Implementation3rd party competence

assurance

Asset Integrity