compiled 5 talks

IPEIA 2014Roundtable on Bolted Flange Joint

Assembler Training and Qualification

Organized by: Trevor Seipp, Becht Engineering CanadaMark Palynchuk, Western Instruments

ASME PCC-1: 2013 Appendix A

The 2013 Edition of ASME PCC-1 has a new Appendix titled: Training and Qualification of Bolted Flange Joint Assembly Personnel

Includes requirements for training, qualification, duties and responsibilities of Qualified Bolting Specialists, Qualified Senior Bolting Specialists, and Qualified Bolting Specialist Instructors

Competence in a specific work environment is the goal Qualification is different from competence, but training,

demonstrations, practical and written examinations can be used to qualify Bolted Flange Joint Assembly Personnel

Comparison to Welders / NDE Technicians

Welders of pressure equipment have extensive training and apprenticeship

Each welder is tested for competence in every welding procedure Every weld is tested by either NDE or hydrotest or both NDE technicians are also subject to extensive training and

apprenticeship Technicians are also tested periodically for ability to detect flaws Equipment is required to undergo periodic calibration and testing

Training, Testing and Inspection for Bolted Flange

Joint Assembler None, yet

Comparison to Welds

After all of the protocols in-place, how many welds leak? None How many bolted flange joints leak? Many

Is it conceivable that there is a correlation between welder training, qualification and ongoing competence and the final outcome?

Should we expect any different outcome with bolted flange joints?

An Opportunity for Industry

With the new Appendix A, industry now has the means to create and develop a training and qualification programme to meet the needs of pressure equipment integrity and safety

Once-in-a-lifetime opportunity to get in front of government/regulator

Purpose of IPEIA Roundtable

Discuss whether or not there is a need for something better in the way that bolted flange joint assembly personnel work

Discuss the role of: Operating Company, Service Company, Specialty Consulting Company, Training Organizations, etc in creating a framework for requiring and providing training and qualification

Discuss how to best implement WITHOUT government/regulator action. Is there a current industry group that could assist?

Discuss the role of the government/regulator in the future

Format

Each panel member will have about 5 minutes to present their thoughts on these 4 items, from the perspective of their company/industry segment

The remainder of the time slot will be spent in ACTIVE discussion and debate involving panel members AND the audience

Audience participation is not only encouraged, but required to ensure maximum benefit

IPEIA 2014Roundtable on Bolted Flange Joint Assembler Training and

Qualification

Michael B. Huang, P.Eng.Manager, Plant EngineeringSuncor Mackay River SAGD

Discuss whether or not there is a need for something better in the way that bolted flange joint assembly personnel work

Stupidity or Lack of Knowledge: Not cleaning the flange face. Use tape to hold large gasket, not adhesive. Not apply the lubricant, wrong lubricant. Using different size stub/bolt entirely or one or two. Bolting around the circumference. Impact wrench (no torque control). Different or wrong gasket. Over torquing and under torquing. Safety: hot bolting at small bore bolt flange Safety: Securemax flanges.

Discuss the role of: Operating Company, Service Company, Specialty Consulting Company, Training Organizations, etc in creating a framework for requiring and providing training and qualification

Operating companies to make it mandatory requirement for BFJ assembler qualification.

Operating companies to start this as a regional mandatory requirement such as Wood Buffalo, or Ft Saskatchewan.

Discuss how to best implement WITHOUT government/regulator action. Is there a current industry group that could assist?

Operating companies/service companies sponsor the development of this qualification via IPEIA and/or Training organization.

IPEIA/Training organization to deliver the trainings and issue the qualifications.

Operating companies/service companies to provide feedback and improve the qualification program.

Discuss the role of the government/regulator in the future

Supervision and re-enforcement (like AER, ABSA) with aims for: Zero leak Zero emission Zero spill

United States Houston, TX

Gonzalez, LA

New Iberia, LA

Benicia, CA

Claymont, DE

LocationsCanada Edmonton, AB

Sarnia, ON

Dartmouth, NS

2014 EPEIA ConferenceBolting Round Table

Feb 20, 2014

Mark JohnsonEngineering Manager12 years with INTEGRA

Greg Murphy Business Development Manager - Canada14 years with INTEGRA

Training and Qualification of Bolted Flange Joint Assemblers

is there a need for something better?

PCC-12013 Appendix A does not represent all the pieces to the puzzle.

However, it is a large step toward the end goal of achieving safe bolted joint operations.

Implementation

Comes from the End Users

2014 IPEIA ConferenceBolting Round Table

Presenter: Chris Coombs, C.E.TQuality Assurance Manager

Your Partner In Building A Leak Free Workplace

Something Better?What we know Mechanical Joints have the potential to cause serious injury and

hydrocarbon release. Serious incidents and accidents can occur during assembly,

maintenance, disassemblyand steady-state operations.

Competence related failures are one of the main causes of incidents & injuries.

A Chance to improve With a BFJ Assembler Qualification program we can expect:

Reduction is Safety and Environmental incidents. Reduction in injury incidents. Reduction in both serious and minor Bolted Joint leakage.

Development and implementation of this Training and Qualification program will not only increase the knowledge of BFJ Assemblers, but also the industry as a whole

Owner / Users, Equipment Manufacturers and Service Providers can all benefit from this type of program

Service Provider PerspectiveResponsibilities

As a provider of Specialty Maintenance & Construction Services, we employ a range of personnel including entry level to senior BFJ Assemblers.

It is our responsibility to ensure these workers are equipped with ALL the necessary tools to safety perform their duties, not just PPE.

This program will provide that minimum standard of training and knowledge base that ensures each worker can not only effective perform their job, but also ensures they arrive home safely at the end of each shift.

What can we do?

Establish baselines for BFJ Assembler qualifications in conjunction with guidelines set forth in ASME PCC-1.

Qualified Bolting Specialist Qualified Bolting Senior Specialist Qualified Bolting Specialist Instructor

Lead the development of the Training and Qualification program by leveraging existing training programs already in place.

Program ImplementationGetting Started

A very important role in qualification program is that of the Review Organization: an independent organization that conducts Quality Control reviews of the Qualification Program.

This could be a committee formed from various industry sectors and subject matter experts.

Utilize Standards & Educational Organizations: CSA ISO CASTI NAIT

Role of Government

Adopt the responsibilities of the Review Organization. Issue Certificates of Authorizations for performing Bolting Services

on: Pressure vessel pressure-boundary bolted joints Pressure vessel pressure-boundary bolted joints Storage tank pressure-boundary bolted joints.

Issue Certificate of Authorization for performing Training and Qualification services.

Existing Training Programs

Currently Atlas Interactive, a company based out of Aberdeen Scotland, has a MJI, Mechanical Joint Integrity Program that has been developed in conjunction with ASME PCC-1.

This program is accredited by ECITB, Engineering Construction Industry Training Board.

In order for this program to be successful it must by a joint venture between Owner / Users and Service Providers

Total Asset Integrity ManagementRAE21

Where Engineering and Inspection connect with integrity!

Practical Gasket Training Comments

Presented by:

Cobus du PlessisRAE Engineering and Inspection Ltd.


Do we need better?The inspections of bolted joints have several errors

Miss match bolts Long bolting, short bolting Incorrect gasket alignment

Little understanding of the consequence resulting from basic errors Gasket over torqueing (Cupping) Incorrectly cleaned flange faces

Construction time wasted due to lack of knowledge Identifying correct bolt/nut as per requirements Knowing when to use insulation kits Identifying correct gasket


Inspection supporting Concept

Inspectors understand the concept.Create training in various levels to meet the audienceHelp write bolt-up procedures.Perform QC and help correcting errors on the floor level.Do audits to ensure quality is being implemented and maintained (QA).Review designs.

Total Asset Integrity ManagementRAE

Implementation ResponsibilityOwner to have correct procedures in place.The constructor should be bound in the contract to follow the approved procedures.Have competent 3rd party or owners inspectors to perform random QC and ongoing QA.Motivate quality by costs, leaks and failures are very expensive.

24


Legislative ResponsibilityAdd bolt-up procedures as a mandatory element to AQP programs.Audit companies to validate compliance.Critical bolt-up closure weld|

25


Questions related to ASME PPC1 -2013

Torque values are inconsistent calibration of equipment.Stretch bolt technologyFocus should be on the compression forceStorage and care

26

IPEIA 2014ASME PCC-1: 2013 Appendix AComparison to Welders / NDE TechniciansTraining, Testing and Inspection for Bolted Flange Joint Assembler Comparison to WeldsAn Opportunity for IndustryPurpose of IPEIA RoundtableFormatIPEIA 2014Discuss whether or not there is a need for something better in the way that bolted flange joint assembly personnel workDiscuss the role of: Operating Company, Service Company, Specialty Consulting Company, Training Organizations, etc in creating a framework for requiring and providing training and qualificationDiscuss how to best implement WITHOUT government/regulator action. Is there a current industry group that could assist?Discuss the role of the government/regulator in the futureSlide Number 14Slide Number 15Slide Number 162014 IPEIA ConferenceSomething Better?Service Provider PerspectiveProgram ImplementationPractical Gasket Training CommentsDo we need better?Inspection supporting ConceptImplementation ResponsibilityLegislative ResponsibilityQuestions related to ASME PPC1 -2013

compiled 5 talks

Documents