Track Welding Competencies: A First For Sentinel

February 2003 saw the first technical engineering competencies recorded on the NCCA Sentinel Card System, a separate card with the same unique personal identification number on which safety competencies such as PTS and COSS competencies are recorded.

The aluminothermic welding competencies are defined by process supplier; Thermit Welding (GB) Ltd or Railtech (UK). The Thermit competencies abbreviated to TW are split into 5 categories (TW1-TW5). Categories 1-4 are hierarchical, ie, if the TW3 competency is displayed on the card it means that competency has been demonstrated in TW1 and TW2 also. TW5 is a stand-alone competency for the Thermit SoWoS (manganese rail) and SkV-ST (slab track) processes. If the TW5 competency is displayed on the card, a further TW competency must also be included.

Railtech currently have three separate categories, RT1, RT2 and RT3 covering their processes that have Network rail approval, again this uses a hierarchical system. If RT3 is displayed on the card then competency has been demonstrated in the process variants covered by competencies RT1 and RT2.

Maintenance Arc Welding covering both manual metal-arc (MMA) and flux-cored arc welding (FCAW) covers the range of process application for the repair of plain rails, crossings and switches for all rail steel grade groups. Originally the system specified five MMA and two FCAW competencies (MMA 1-5 and FCAW 1 and 2). This has recently been extended to seven competencies for MMA and four for FCAW to cover the requirements for joining of conductor rails and stainless steel welding for track circuiting purposes. Unlike the Aluminothermic processes which uses the hierarchal system of defining which competencies are held, each individual maintenance arc welding competency held must be detailed on the card.

It should also be noted that the Sentinel card must be accompanied by the appropriate powered plant and abrasive wheels certification. Proposals are currently being considered to accommodate these competencies on the Sentinel Card. This could possibly be in conjunction with the introduction of a system similar to the current two-part driving licence; the Sentinel card to register the welding competencies and the A4 paper licence to record the appropriate powered plant and abrasive wheel certification. Ultimately, the information will be recorded on a Sentinel Smart Card, which stores data electronically on the card.

December 2003 saw the extension of the scheme to cover both the Trainee/Assistant Welder. This will ensure Welders Assistants gain the mandatory six months experiences prior to being considered for further training to Trainee Welder status and that newly trained welders can be identified and mentored by an experienced welder for a period of no less than six months before being considered for further assessment to gain full Welder Status, this will ensure that Welders have a minimum of 12 months track experience.

Reassessment of competencies

Aluminothermic welding

Both Thermit and Railtech competencies are subjected to two-yearly renewal. Initial assessment following training, is carried out at Approved Training Centres through practical and written theoretical examination. Upon successful completion, the results of these assessments and competencies demonstrated, are forwarded to NCCA usually online and a new card issued with a two year expiry. It should be noted that separate assessments are required for both the Thermit and Railtech processes.

After twelve months the welder carries out an interim assessment on-site for each process held, this takes the form of a practical assessment with oral questioning to cover the range of process applications and theoretical knowledge. Individual companies' Competency Assessors can carry out this assessment. The assessments must be registered with NCCA to ensure continued validity of the competency.

After two years, the welder must successfully complete an out-of-track assessment at an Approved Training Centre through practical and theoretical knowledge, in order for a new card to be issued with a further two-yearly validity. Again, the assessments must be registered with the NCCA.

Maintenance Arc Welding

Following initial training of each competency shown on the Sentinel Card, each competency is given a two-year validity. These competencies are subject to on site reassessment at 12 month intervals, which requires the welder to demonstrate practical competency supported by oral questioning to confirm underpinning knowledge. On successful completion the results are recorded with NCCA who will reissue certification biannually.

By October 2005 and in addition to the requirements of Sentinel, both welder approval and welding procedure approval will be subjected to European Standards. BS EN287-1 will cover welder approval and BS EN288-8 will cover procedure approval. In the light of recent developments with Network Rail reclaiming responsibility for maintenance activities, the welding procedures will be produced and issued directly by Network Rail. Network Rail and its subcontractors will need to ensure their welders are approved to the stipulated procedures relevant to the competencies held, re-approval of welders to BS EN287-1 will be required biannually.

In conclusion, the Sentinel Scheme ensures welders are trained at Approved Training Centres that have demonstrated the pre-requisite requirements. All assessments and reassessments are recorded independently, the validity of competencies can be checked instantly either by phone or on-line and competencies are now aligned to recognised standards.

It is also reassuring to know that track welding, one of the most safety critical Civil Engineering activities, has the ability to demonstrate compliance with such transparency, no doubt giving an example for other disciplines to follow.

Example of Sentinel Card

Geoff Chapman
Jarvis Rail Welding Engineer