hcr improvement & implementation - step change in … change... · 12.40-13.10 mechanical joint...
TRANSCRIPT
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
Peer-Assessments2015 2016
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
• 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
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.
© 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
• 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
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