Technical Training Synopsis - hydratight.com · Technical Training Synopsis ... an ECITB approved Technical Test. ... certificate of achievement plays a key role in validating an

ECITB On-Site Machining

Technical Training Synopsis

OSHENS Doc No: P-TRA-21587-5.0 Page 1 of 8 Technical Training

“Copyright © Hydratight Limited 2018. All rights reserved”


Hydratight as ECITB Approved Training Providers will ensure all personnel who

are responsible for On-site Machining activities are trained and tested to in line

with ECITB and Step Change in Safety guidance.

Our ECITB training courses are fully documented and meet the requirements of

the relevant technical training standards.

Hydratight Training Instructors are competent in the courses that they deliver

with industry specific experience and follow an ECITB and internal Training

Instructor and Examiner approval process verified by regional external

qualifications where applicable.

ECITB - On-Site Machining Training Page

ECITB On-Site Machining Overview 2

ECITB On-Site Machining Route to Competency Model 3

OSM 01 - On-Site Cutting and Weld Preparation 4

OSM 02 - On-Site Joint Face Machining – Full & Raised Face Flanges 5

OSM 03 - On-Site Drilling and Thread Tapping (Available during 2018) 6

OSM 04 - On-Site Milling 7

OSM 05 - On-Site Joint Face Machining – RTJ Flanges & Clamp Connector Hubs 8





ECITB On-Site Machining Overview:

The ECITB has introduced a new method of training and validating skills in the specialist area of on-site machining with

approved training courses derived from the new ECITB On-Site Machining technical training standards.

Work Based Task Assignments have been implemented and new ECITB Technical Tests introduced.

The new technical training standards cover joint facing and milling of flanged and clamp connectors, pipe cutting and

weld preparation and drilling and thread tapping operations.

The new technical training standards are:

TS OSM 01 - On-Site Cutting and Weld Preparation

TS OSM 02 - On-Site Joint Face Machining – Full & Raised Face Flanges

TS OSM 03 - On-Site Drilling and Thread Tapping

TS OSM 04 - On-Site Milling

TS OSM 05 - On-Site Joint Face Machining – RTJ Flanges & Clamp Connector Hubs

ECITB Approved Courses (onshore training centre based):

The ECITB has approved five specific training courses which are derived from the new technical training standards:

OSM 01 - On-Site Cutting and Weld Preparation – 2 days duration

OSM 02 - On-Site Joint Face Machining – Full & Raised Face Flanges – 2 days duration

OSM 03 - On-Site Drilling and Thread Tapping – 2 days duration

OSM 04 - On-Site Milling – 2 days duration

OSM 05 - On-Site Joint Face Machining – RTJ Flanges & Clamp Connector Hubs - 3 days duration

These courses are grant aided for ECITB registered employers.

Work Based Task Assignments:

A new approach to the workplace consolidation of knowledge has been developed; Work Based Task Assignments.

Each assignment lists the activities to be undertaken by the learner and validated by the supervisor.

Five work based task assignments have been approved by the ECITB:

OSM 01 - On-Site Cutting and Weld Preparation

OSM 02 - On-Site Joint Face Machining – Full & Raised Face Flanges

OSM 03 - On-Site Drilling and Thread Tapping

OSM 04 - On-Site Milling

OSM 05 - On-Site Joint Face Machining – RTJ Flanges & Clamp Connector Hubs

The task assignments are normally completed between three to twelve months after the initial training course and the

learner can then undertake an ECITB approved Technical Test.

Technical Tests (onshore test centre based):

Technical Testing with an associated ECITB certificate of achievement plays a key role in validating an Individual’s skill,

ability and job knowledge in a specific task area.

Each test consists of a knowledge test and practical activity test against identified test criteria.

There are five ECITB approved Technical Tests covering the On-Site Machining:

TOSM 01 - On-Site Cutting and Weld Preparation – 1 day duration

TOSM 02 - On-Site Joint Face Machining – Full & Raised Face Flanges– 1 day duration

TOSM 03 - On-Site Drilling and Thread Tapping – 1 day duration

TOSM 04 - On-Site Milling – 2 days duration

TOSM 05 - On-Site Joint Face Machining – RTJ Flanges & Clamp Connector Hubs – 2 days duration

These tests are grant aided for ECITB registered employers.





ECITB On-Site Machining Route to Competency Model

ECITB On-Site Machining Technical Test Application Procedure

Stage 3 requires each individual to complete a formal assessment of their job knowledge, skills and ability in each On-

Site Machining subject. The ECITB technical competence validation tests are standards based consisting of a bank of online knowledge questions and a practical task to validate the learner’s skills, knowledge and ability. Successful candidates attain the ECITB certificate of achievement which is valid for a period of 3 years.

Stage 3 must be completed within 12 months of Stage 1 and unsuccessful candidates must wait a minimum period of 4 weeks between an unsuccessful test session and the next test session to allow for a period of training to address any

skills or knowledge gaps.

The Test Centre will confirm the following information with the employer/candidate before arranging the test session:

New workers must have successfully completed Stages 1 and 2 and must submit their completed Work Based Task Assignments and OSM Approved Course certificate to the Test Centre prior the test session. Stage 3 Technical Testing must be completed within 12 months of Stage 1 training.

Stage 4 requires each individual to re-validate the ECITB technical competence validation test certification achieved at

Stage 3 upon expiry after 3 years.

The Test Centre will confirm the following information with the employer/candidate before arranging the test session:

Previous TOSM certificate of achievement must be submitted for review before arranging the test session.

Candidates with expired TOSM test certificates must submit a Company letter of endorsement confirming OSM

activities are regularly carried out. Private individuals will be required to submit a detailed CV with two referees

confirming OSM activities are carried out regularly.

Note: Hydratight requires that the above application information relevant to Stage 3 and Stage 4 is submitted a minimum

of 2 working days prior to the test session to enable verification or will reserve the right to cancel the test session.





Training Course Synopsis

Course Title:

ECITB Approved On-Site Machining

o OSM 01 – On-Site Cutting and Weld Preparation

Course Summary

One of five modular on-site machining training courses derived from ECITB technical training standards covering in-situ machining techniques in cutting and weld preparation of pipework using portable machine tools delivered by an ECITB Approved Training Provider and Tutor.

Certification

ECITB Training and Technical Test Certification

Training Certificates - 12 months validity for technical test application purposes

Technical Test Certificates - 3 years validity

Course Duration

2 Days

Course Content

Instruction and practice in observing health and safety requirements and approved working practices

Equipment safety and safety valve operation

Types of tools and methods

Inspection, measurement and drawing interpretation

Equipment component identification

Equipment and cutting tool selection

Basic tool maintenance

Practical Use of Equipment to include:

o Machining of various size diameters of pipework with differing wall thickness to include the use of various machine tools

o Straight pipe cuts on pipework, all diameters and wall thickness o Carry out match/counter bore operations o Carry various end preps single, multi angle and “J” prep. o Carry out outside diameter machining of pipework

Practical use of various tool slides, boring attachments and tooling to carry out additional prep/counter

bore/excavation profiles:

o Standard “V” prep o Multi angle “J” prep o Compound bevel “single point cutting” o Match/Counter bores

Instruction and practice in the selection and grinding of:

o Parting blades o Form tools o Single point cutting tools

Reporting and Quality Assurance

Pre- requisites

Candidates must prove relevant previous machining experiences from a toolmaker, turner, fitter/turner

Candidates must have a basic mechanical background preferably in pipe-fitting, mechanical fitting, mechanic, millwright, boilermakers, apprentices and engineering craft trades.

PPE Requirements

Safety footwear, coveralls, eye protection, ear protection & gloves

Related Technical Test

TOSM 01 - On-Site Cutting and Weld Preparation






Course Title:


o OSM 02 – On-Site Joint Face Machining – Full & Raised Face Flanges

Course Summary

One of five modular on-site machining training courses derived from ECITB technical training standards covering in-

situ machining techniques in facing of flat and raised face flange joints using portable machine tools delivered by an

ECITB Approved Training Provider and Tutor.

Certification




Course Duration

2 Days

Course Content

Instruction and practice in observing health and safety requirements and approved working practices Equipment safety and safety valve operation Types of tools and methods Inspection, measurement and drawing interpretation Interpretation of manufacturer technical data sheets Equipment component identification Equipment and cutting tool selection Basic tool maintenance Practical Use of Equipment to include:

o Machining of various size diameter flanges to include the use of various machine tools o Cutting, boring and forming processes o Flat and raised face applications o Back facing operations o Internal and external mount machine tools o Internal and external collets and hubs o Measuring devices to include, dial test indicator, micrometers and Vernier calipers

Overview of various tool slides, boring attachments and tooling to carry out additional profiles including:

o Internal and external diameters

o Shoulders, faces and chamfers


o Single point cutting tools o Carbide index tip tools


Pre- requisites



PPE Requirements

Safety footwear

Eye protection

Coveralls

Ear protection

Gloves


TOSM 02 - On-Site Joint Face Machining – Full & Raised Face Flanges






Course Title:


o OSM 03 - On-Site Drilling and Thread Tapping

Course Summary


situ machining techniques in drilling and thread tapping operations using portable machine tools delivered by an

ECITB Approved Training Provider and Tutor.

Certification

ECITB Training and Technical Test Certification Training Certificates - 12 months validity for technical test application purposes Technical Test Certificates - 3 years validity

Course Duration

2 Days

Course Content

Instruction and practice in observing health and safety requirements and approved working practices Equipment safety and safety valve operation Types of tools and methods Inspection, measurement and drawing interpretation Interpretation of manufacturer technical data sheets and drilling/tapping charts Equipment component identification Equipment and cutting tool selection Basic tool maintenance Practical Use of Equipment to include:

o Drilling and tapping of holes using both air and electric driven machine tools to include: - Drilling, reaming, thread tapping and cutting - Hole boring and trepanning - Stud drilling and removal - Thread picking and de-burring

o Cutting tools and ancillary equipment to include: - Straight shank, Morse taper shank drills/reamers and hole saws - Straight fluted taps, spiral machine taps, tapping heads, trepanning heads and boring attachments - Granlund cutting system - Morse taper adapters and extensions

o Mounting methods to include: - Chucks, clamps and vices - Vee block and chain - Magbase and vacuum suction pad - G clamps and finger clamps - Welding, studs

o Measuring devices to include, dial test indicator, micrometers, Vernier calipers, Go/No Go gauges and thread gauges


o Drills, Tapping drills and Reamers o Granlund cutters and guide bushes o Locating and Top Hat guide bushes


Pre- requisites

Candidates must prove relevant previous machining experiences from a toolmaker, turner, fitter/turner Candidates must have a basic mechanical background preferably in pipe-fitting, mechanical fitting, mechanic,

millwright, boilermakers, apprentices and engineering craft trades.

PPE Requirements



TOSM 03 - On-Site Drilling and Thread Tapping






Course Title:


o OSM 04 - On-Site Milling

Course Summary


situ machining techniques in milling of pump bed applications using portable machine tools delivered by an ECITB

Approved Training Provider and Tutor.

Certification

ECITB Training and Technical Test Certification Training Certificates - 12 months validity for technical test application purposes Technical Test Certificates - 3 years validity

Course Duration

2 Days

Course Content


o Milling of surfaces using air, hydraulic and electric driven milling beds, multi axis rails and key mill tools to include:

- Pump motor beds and shafts o Cutting tools and ancillary equipment to include:

- Slot drills and end mills - Face mills and fly cutters - International tapers

o Mounting methods to include: - Chucks, clamps and vices - Vee block and chain - Magnetic and vacuum chucks - G clamps, rack clamps and finger clamps - Welding

o Measuring devices to include, dial test indicator, micrometers, Vernier calipers, Go/No Go gauges, slip gauges and shims


o Slot drills o End mills o Fly cutters o Carbide inserts


Pre- requisites



PPE Requirements



TOSM 04 - On-Site Milling






Course Title:


o OSM 05 - On-Site Joint Face Machining – RTJ Flanges & Clamp Connector Hubs

Course Summary


situ machining techniques in facing of ring type joint flange, clamp connector hub sealing faces using portable

machine tools delivered by an ECITB Approved Training Provider and Tutor.

Certification




Course Duration

3 Days

Course Content


o Machining of various size diameter connections to include the use of various machine tools o Cutting, boring and forming processes o Ring type joint flanges and clamp connector hub sealing faces o Internal and external mount machine tools o Measuring devices to include, dial test indicator, micrometers, Vernier calipers, shoulder Vernier caliper,

Vernier bevel protractor, ball trammels and bows Overview of various tool slides, boring attachments, back facing heads, extensions and tooling to carry out

additional joint profiles including: o Internal and external diameters

o Shoulders, faces and chamfers

o Radii, grooves and tapers


o Straight single point cutting tools o Right and left hand cranked single point cutting tools o Carbide index tip tools


Pre- requisites



Completion of “OSM 02 - On-Site Joint Face Machining – Full & Raised Face Flanges” training

PPE Requirements



TOSM 05 - On-Site Joint Face Machining – RTJ Flanges & Clamp Connector Hubs

Documents

Technical Training Synopsis - hydratight.com · Technical Training Synopsis ... an ECITB approved Technical Test. ... certificate of achievement plays a key role in validating an