Ensuring the safety and reliability of our hazardous process industries is paramount. And when we look specifically at working with bolted flanged joints on pressurised systems, it’s all too clear why we must adhere to the relevant industry standards for skills and competency, controlled methods of bolting and quality assurance.
Although we operate our hazardous chemical sites, refineries and petrochemical plants to comply to a multitude of regulations, standards and guidelines, it’s all too apparent that the compliance isn’t equal across all sectors and assets. Why is this? It’s something that has frustrated me and continues to frustrate me… are these sites aware of their responsibilities? Are they up to speed with the newest guidelines and industry standards for mechanical joint integrity such as ASME PCC-1 2022? Do they really believe it’s acceptable to have unskilled and incompetent people working on maintenance events event’s such as turnarounds etc?…
Maybe they just don’t know. Perhaps they don’t want to know.
“Adhering to standards ensures safety, reliability, and excellence—compromising them risks lives, injuries, and environmental catastrophes.”
To really understand this poor approach to mechanical joint integrity lets’ first take a look at an industry that has a rather different approach and maybe even ‘culture’ toward compliance to standards; the aviation industry.
The aviation industry is a critical part of global transportation, connecting countries and facilitating economic growth. Ensuring the safety and reliability of aircraft is paramount, which relies heavily on the expertise and competence of maintenance personnel. This paper discusses the importance of having well-trained and qualified workers conducting maintenance, emphasising qualifications, quality assurance checks, traceability, compliance to standards, and the use of calibrated tools.
Qualifications and Training
Aircraft maintenance personnel must possess the necessary qualifications and training to ensure they are knowledgeable about the complexities of modern aircraft systems. These qualifications often include certifications from recognised aviation authorities, such as the Federal Aviation Administration (FAA) or the European Union Aviation Safety Agency (EASA). Comprehensive training programmes cover various aspects of aircraft maintenance, including airframe and powerplant systems, avionics, and safety procedures. Continuous professional development ensures that workers stay up-to-date with the latest technological advancements and regulatory changes.
Quality Assurance Checks
Quality assurance checks are integral to maintaining high safety standards in aircraft maintenance. These checks involve systematic inspections, testing, and evaluations to identify and rectify potential issues before they become critical. Competent maintenance personnel are trained to perform these checks meticulously, ensuring that every component and system meets the required safety and performance standards. Regular independent audits and assessments by internal and external bodies further enhance the quality assurance process.
Traceability
Traceability is essential in the aviation industry to track the history and origin of aircraft components. Accurate documentation and record-keeping enable maintenance personnel to trace parts back to their manufacturers and verify their authenticity and compliance with safety standards. This practice helps in identifying and managing potential issues, such as counterfeit or substandard parts. Trained workers are adept at maintaining detailed records, which are crucial for regulatory compliance and ensuring the airworthiness of aircraft.
Compliance to Standards
Compliance with industry standards and regulations is fundamental to aircraft maintenance. Aviation authorities establish stringent guidelines to ensure the safety and reliability of aircraft. Maintenance personnel must be well-versed in these standards and adhere to them meticulously during maintenance activities. Compliance involves following approved procedures, using certified parts, and maintaining accurate records. Competent workers understand the importance of adhering to these standards to prevent accidents and ensure passenger safety.
Use of Calibrated Torque Wrenches and Tools
The use of calibrated tools, such as manual or powered torque wrenches, is critical in aircraft maintenance to ensure that components are installed correctly and securely. Torque wrenches allow maintenance personnel to apply precise amounts of torque to bolts and nuts, preventing over-tightening or under-tightening, which can compromise the integrity of the aircraft. Regular calibration of these tools ensures their accuracy and reliability. Trained workers understand the significance of using calibrated tools and follow strict protocols to maintain tool accuracy.
“The safety and reliability of aircraft depend significantly on the competence and expertise of maintenance personnel”.
Trained and qualified workers play a crucial role in ensuring that maintenance activities are performed to the highest standards. By adhering to qualifications, quality assurance checks, traceability, compliance to standards, and using calibrated tools, these professionals help maintain the airworthiness of aircraft and ensure the safety of passengers and crew.
The disparity in integrity and compliance levels between the UK process industries (such as chemical and oil/gas) and the aircraft industry can be attributed to several factors;
1. Regulatory Environment
The aviation industry is subject to stringent regulations and oversight by authorities like the Federal Aviation Administration (FAA) and the European Union Aviation Safety Agency (EASA). These regulations are enforced rigorously, with regular audits and inspections. In contrast, while the process industries also have regulations such as the Control Of Major Accident Hazards regulations 2015 (COMAH), the Pressure Systems Safety Regulations 2000 (PSSR) and Health & Safety Executive (HSE) guidance, the enforcement and oversight may not be as stringent or consistent at site. This can lead to variations in compliance levels.
2. Safety Culture
The aviation industry has a deeply ingrained safety culture, where safety is prioritised above all else. This culture is reinforced through continuous training, strict adherence to procedures, and a proactive approach to identifying and mitigating risks. In the process industries, safety culture can vary significantly between companies and even within different parts of the same company. This inconsistency can result in lapses in compliance and integrity.
3. Complexity and Standardisation
Aircraft maintenance involves highly standardised procedures and practices, with detailed documentation and traceability. The process industries, on the other hand, deal with a wide range of processes and equipment, making standardisation more challenging. While there are standards and guidelines available for specific tasks, such as the ASME PCC-1 for bolted flange joints, the implementation of these standards can vary.
4. Training and Competence
In the aviation industry, maintenance personnel are required to have specific qualifications and undergo rigorous training. Continuous professional development ensures that they stay up-to-date with the latest advancements and regulatory changes. In the process industries, the level of training and competence can vary, and there may be less emphasis on continuous professional development. Some sites literally adopt an ‘all are welcome’ attitude to contractor labour coming to site with no evidence required of industry approved qualifications such as ECITB MJI10, BS EN 1591-4:2013 or ASME PCC-1 2022.
5. Economic Pressures
Economic pressures can influence compliance levels in both industries. However, the process industries may face more significant cost-cutting pressures, leading to compromises in maintenance practices and quality assurance. In contrast, the aviation industry is acutely aware of the catastrophic consequences of failures, which can result in loss of life and significant financial and reputational damage. This awareness drives a more robust approach to compliance and integrity.
6. Use of Calibrated Tools
The use of calibrated tools, such as torque wrenches, is critical in both industries. However, the aviation industry places a higher emphasis on the accuracy and reliability of these tools, with strict protocols for calibration and maintenance. In the process industries, the use of calibrated tools may not be as rigorously enforced, leading to potential issues with the integrity of bolted joints and other critical components. Some sites still allow the use of flogging spanners and or other undesirable methods of tightening bolts such as impact wrenches – surely these should be placed in the appropriate museum under ‘this is how we used to tighten bolts’..
Conclusion
While both the aviation and process industries have standards and guidelines in place, the levels of integrity and compliance can differ due to variations in regulatory enforcement, safety culture, standardisation, training, economic pressures, and the use of calibrated tools.
Addressing these disparities requires a concerted effort to enhance regulatory oversight, foster a strong safety culture, and ensure consistent implementation of standards and guidelines across all sectors.
For me in recent years, the UK offshore industry has been the shining light throughout all process sectors – we only know too well what happened at Piper Alpha on 6th July 1988 and we do not want any repeat tragedies. The use of torque equipment, high levels of QA/QC and obtaining training qualifications such as ECITB TMJI10 has certainly helped to maintain compliance to regulations and standards in the North Sea.
Some downstream process industry sectors are certainly on-board with the practice of ‘TOTAL COMPLIANCE’ and there are certain sites in the United Kingdom that are a shining light for all things ‘best practice’ for mechanical joint integrity but the overall ‘state of our nation‘ continues to fall short many aspects of mechanical joint integrity; the evidence is only too obvious – the continuous accidents, incidents and issues relating to loss of primary containment still resonates throughout our process industries and will continue to do so unless we change.
We don’t want our aircraft to fall out of the skies, so why are we willing to take such risks with our hazardous process industries?..