Novus Sealing - Professional Industry Training Services

ACCREDITED & AWARENESS COURSES

-	FADU (Flange Assembly Demonstration Unit) training on clients premises Course Duration 1 Day
-	Assembly & Hand Torque of Bolted Flanged Connections Course Duration 1 day - (JI 010)
-	Assembly & Hydraulic Tension of Bolted Flanged Connections Course Duration 1 day – (JI 018)
-	Assembly & Hydraulic Torque of Bolted Flanged Connections Course Duration 1 day- (JI 019)
-	Joint Integrity Management Programme Course Duration 1 Day – (JI 020)
-	Sealing Technology – Management of Joint Integrity for Pressurised Systems Course Duration 1 Day ë (JI 022)
-	Joint Integrity on Heat Exchangers Course Duration 1 Day – (JI 024)
-	Flange Alignment and Spreading Best Practice Course Duration 1/2 Day – (JI 028)

All Academy training is delivered by industry professionals, with current and directly relevant experience in the field.

Download the Training Brochure

For further information please contact info@academyji.com

AJI DELIVERS SUCCESSFUL SEMINARS TO NG BAILEY

The Problem

NG Bailey is among the UK's leading providers of building services, mechanical, electrical, ICT, off-site manufacture, interiors, systems integration and maintenance solutions. They employ some 3,100 people and have a turnover in the region of £500m, all through UK-based operations.As part of a push by the company to develop the knowledge of NG Bailey engineers, a series of training seminars were arranged with a number of suppliers.

The Solution

The AJI, through Novus Sealing were contacted and provided training on our products and their installation, highlighting the need for correct selection, using the Novus Select software, and the importance of correct assembly.

Following the presentation, it was agreed to invite the lead engineers to the Academy for further training. They also requested copies of Novus Select.

The seminar demonstrates the strength of Novus training, as well as the opportunities provided by the promotion of technical tools e.g. Novus Select, developed to aid selection and installation. We believe further business will result through the technical relationship we have built.

Pete Sutcliffe, Project Engineer, NG Bailey:
"NG Bailey’s Off-Site division engineering team used Novus sealing to deliver a seminar and develop engineer’s knowledge in flange gasket selection and bolting. The course was well prepared and delivered to a high standard. Of all the courses delivered to the engineering team this was one of the best received, the learning gained will allow our engineers to correctly specify flange jointing and ensure correct installation.”

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TERMS & CONDITIONS

Download a copy of our Terms & Conditions

For further information please contact us at info@academyji.com

TRACK RECORD

The Academy of Joint Integrity has delivered training courses on the safe control of flange joints to technicians and engineers in many leading companies within the petrochemical, chemical and OEM industries.

Some of our customers are listed below.

-	Cononco
-	BP
-	Sabic
-	Invista
-	Croda
-	Grasso
-	Spirax Sarco

For further information please contact us at info@academyji.com

NOVUS TRAINING TOOLKIT

Poor flange assembly is the most common cause of gasket leakage and yet experience shows that good practice is relatively simple to achieve: Trained technicians working to clear procedures and with the correct equipment will result in a properly assembled flange.

The Training Toolkit complements our joint making procedure in assisting technicians in the making of properly assembled and reliable flanged joints. Each kit contains a number of effective tools that help to ensure that the flange has the correct surface finish, is properly aligned and is assembled correctly.

All candidates attending a training course will receive a Novus Training Toolkit upon course completion.

-	Flange Gap Tool
-	Flange Surface Comparator
-	Slide Torque Rule
-	Notebook
-	Engineers Bible

For further information please contact us at info@academyofjointintegrity.com

TYPICAL COURSE CONTENT - BOLTING (JI-UNIT 010/018/019/020)

Course materials provide the candidate with a basic underpinning knowledge of Industry Best Practice, specific to legislative pre-requisites and personal responsibilities.

Key principles in competence

-	Health and Safety in relation to Offshore and COMAH Site
-	Principles of joint component sealing action
-	Function of gasket or seal types
-	Importance of correct bolt loading
-	Effect on bolt load and seal compression using different methods of tightening
-	Importance of using and applying correct lubrication in a torque application
-	Selection of joint components to comply with the design specification
-	Correct use of washers in a bolted connection
-	Principles and pre-requisites for safe use of Hydraulic Torque and Tensioning Equipment
-	Correct sequence and number of tightening passes required for torque and tensioning
-	Principles and techniques used for direct bolt length measurement
-	Components of a flanged bolted connection: fasteners/gaskets/flanges – theory/practical
-	Inspection and preparation of a flanged bolted connection for assembly and breakout
-	Clamp products and procedures specific to joint integrity – Techlok/Destec/Galperti
-	Assembly Industry Best Practice/ failure mechanisms
-	Methods of tightening hand/hydraulic/pneumatic
-	Bolted joint check lists and life cycle
-	Inspection process for all components
-	Torque and tension calculation process
-	Sealing materials
-	Function of a gasket, investigating gasket creep, gasket types, gasket selection, gasket storage, handling of gaskets, re-use of gaskets, latest gasket standards
-	Audit trail and record keeping
-	All candidates receive practical and theoretical tuition, with assessment via questionnaires to measure underpinning knowledge of the subject material

For further information please contact us at info@academyji.com

HUMAN FACTORS: TRAINING & COMPETENCE

This can be defined as the ability to undertake responsibilities and perform activities to a recognised standard on a regular basis. It is a combination of skills, experience and knowledge. The inadequate management of competence has not only contributed to disasters such as Esso Longford and BP Texas City, but also to fatalities, personal injuries and ill health.

Key principles in competence

-	Competence assurance should be linked to key responsibilities, activities and tasks identified in risk assessments
-	Competency assurance systems should aim to establish and maintain competency for all those involved in safety-related work, including managers. This is particularly important in the management and prevention of major accidents
-	Training is an important component of establishing competency but is not sufficient on its own. For example, consolidation of knowledge and skills through practice is a key part of developing competency
-	Competence assurance systems should take account of foreseeable work and operating conditions - including infrequent and complex activities, emergency situations and upsets, maintenance etc.
-	Training and competence assessment methods should be appropriate to the hazard profile of the tasks being undertaken. For example, competency assurance systems for safety critical tasks should be more robust
-	‘On-the-job’ training should be structured and linked to risk assessments and associated control measures including procedures. In safety critical environments, on-the-job training should be supported by other forms of training where appropriate e.g. classroom training, simulation
-	Training should be validated - Did it deliver what it was supposed to? -, evaluated - Is this the right kind of training for our needs? - and recorded
-	There should be refresher training for infrequent, complex or safety critical tasks and this may include appropriate reassessment
-	Vocational qualifications should include site-specific aspects and link appropriately to the hazards and risks in your workplace
-	Aim to achieve a suitable balance between competence and supervision
-	Careful consideration should be given to the potential consequences of out-sourcing of safety-related work. Companies must take steps to ensure that contractors are competent to carry out health and safety-related work
-	Companies should seek to retain intelligent customer capability to ensure that they can appropriately manage and oversee the work.

COMMON CAUSES OF FLANGE LEAKAGE
Human Factors remains the prime root cause of Flange Leakage, however with attendance at The Academy of Joint Interity all candidates who are responsible for the Assembly and Tightening of Flanged Bolted Connections on any asset will become aware of the key issues.
Attending a Training Course however does not make you competent, however it does help you onto the ladder of Training leading to competence.
As the candidates knowledge increases and experience in the field provides underpinning practical knowledge, Novus can provide mentoring and assessment leading to a formal accredited qualification.
Common Failure Mechanisms - download our report
For further information please contact us at info@academyji.com

THE IMPORTANCE OF TRAINING ALL STAFF INCLUDING CONTRACTORS

HSE monitoring of Hydrocarbon Releases indicate that over 10% of all reportable releases occur at flanged joints.

In July 2000 the Offshore Division of the Health and Safety Executive (HSE) produced Safety Notice SN2/2000 “Bolting of flanged joints in pressurised systems” This document was produced following two major incidents associated with joint making on offshore installations, and aimed to highlight poor practice and provide guidance in safe practice in joint making. The Safety Notice identified three major contributory factors to failures of bolted flanged joints:

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Incorrect loading of bolts during assembly
Poor training of technicians
Poor supervision and verification

In particular, the Safety Notice comments that the practice of flogging joints or using impact guns is “highly inaccurate and should not be used”, and advocates instead the use of controlled tightening by appropriately trained personnel using torque wrenches or hydraulic tightening equipment as appropriate. The Safety Notice requires that the owners of installations should ensure that:

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There are clear instructions and procedures for making flanged joints
Correct tools with clear instructions on their proper use are available to personnel involved in making flanged joints
Personnel involved in supervising and performing these activities is adequately trained and competent to work on the equipment
The verification system addresses the integrity of bolted joints in safety-critical systems
Appropriate records are kept

In June 2007 our Technical Team were invited to attend and contribute to a re-write of the June 2002 UKOOA Document entitled “Guidelines for the Management of Integrity of Bolted Pipe Joints”, with the new version to be targeted for Offshore and Onshore COMAH Sites.

The current version is entitled “Guidelines for the Management of the Integrity of Bolted Joints for Pressurised Systems”.

Course Material will contain examples of industry Best Practice

Please see downloads for supporting information

HSE - Bolting of Flanged Joints for Pressurised Systems (safety notice)
Guidelines for the management of the integrity of bolted joints in pressurised systems

Throughout the site all references to Novus Sealing, 5G, Graftec, Uniflon, Novatex are registered trademarks of Novus Sealing Ltd ( UK) and are protected under law worldwide.