It's easy to apportion blame when a joint won't seal or when a bolted connection leaks.
Usually, the blame is placed on the gasket and extra torque/load is often applied without considering the consequences to the components involved, in an attempt to seal the connection.
However while the gasket plays an important part in the seal, other factors may have contributed to the root cause such as:
- Flange misalignment (12%)
- Loose bolts (15%)
- Gasket defective (22%)
- Flange damaged (25%)
- Improper installation (26%)
Studies indicate that damaged components, misaligned equipment and improper joint assembly as a whole, caused more seal failures than gaskets.
Fundamental to joint integrity is the competence of the personnel involved in the process of inspection/assembly and tightening of bolted connections, including subcontractors during a shutdown when manpower is at its peak.
Training and competency, and experience and knowledge are often confused with each other; training is no guarantee of competency, nor is experience a guarantee of knowledge and understanding.
Training, experience and assessment of knowledge are all required to achieve competency.
While initial training provides an education on the specific standard it does not prove competence in the task. A best practice “Route to Competency” involves following a documented path including workplace experience, theoretical and practical testing.
Standardised programmes are provided in line with our “Technical Training & Competency Manual”, and external accreditations. Our programmes cover both theory and practical instruction including site simulation where possible at our Global training locations.
Workplace Evidence (pre-assessment)
Trainees document and submit workplace evidence under supervision of a competent person via a logbook with supporting appraisals from a competent person or supervisor.
Theoretical Technical Assessment
A theoretical test is a question paper or on-line test covering all aspects of the training to prove the technical understanding of the trainee.
Simulated Practical Assessment
A simulated practical test is completed at a test centre, under controlled conditions by an approved Examiner against a checklist covering health and safety, quality and technical criteria. Alternatively practical tests can be carried out at customer sites in line with the required workplace activity and project requirements following Permit to Work systems, considering access/egress, reference of drawings etc.
Ongoing regular assessment via theory testing, practical testing and/or online CBT/E learning programmes is then recommended on a minimum 3 year basis.
Hydratight offer industry proven best practice Assessment Programmes to support all of our Training Courses and Approved Technical Competence Tests to support the ECITB Mechanical Joint Integrity Units.
Where non-accredited qualification or assessment programmes are required the mandatory process below will be followed:
- Training via Hydratight only
- Recorded workplace experience using Hydratight documentation
- Employer/employee endorsement
- Technical theory testing/examination
- Practical assessment/examination
- 3 year renewal process
Please contact firstname.lastname@example.org for further details.
Download and watch related documents and videos: