Report to API SC18, Task Group 6, Welding

Transcription

1 Report to API SC18, Task Group 6, Welding API 2012 Summer Standardization Conference Chairman: Bud Weightman 2012 Qualified Specialists, Intl.

2 SC18, TG 6 Charge To review all API product specifications and Recommended Practices and to cross-functionally identify requirements for welding, brazing and soldering; the purpose is to identify welding criteria to be recommended for use in all product specifications where these processes welding are is required Qualified Specialists, Intl. 2

3 Purpose To identify cross functional requirements across the API Monogram Program Product Specifications To identify baseline requirements / references for API Auditors to use during API audits To identify other international welding requirements referenced in API Product Specifications 2012 Qualified Specialists, Intl. 3

4 Product Specifications Being Evaluated The following specifications serve as an example of some of the more critical specifications containing welding requirements under the API Monogram Program: 2C 4F 5CT 5DP 5L 6A 6D 6DSS 7-1 7K 8A 8C 14A 14L 16A 16C 16D 16F 16RCD 17D 17F 19G1 19G Qualified Specialists, Intl. 4

5 Members / Interested Parties Line Item Name Company Chairman Bud Weightman 1 Bamidele Agbogun Self Qualified Specialists, LLC 2 Bob Prince ExxonMobil 3 Rick Noecker ExxonMobil 4 Stacey Hagan ExxonMobil 5 Jim McHaney ExxonMobil 6 Charlie Ribardo British Petroleum 7 David Alva Drillmec 8 Ed Baniak API 9 Eric Wehner NOV 10 Don McDowell Antelope Oil Tools 11 Gary Devlin Cameron 12 Jerry Longmire 13 Jim Harris (alt) 14 Jimmy Hashem Halliburton GE Oil & Gas Pressure Control GE Oil & Gas Pressure Control Line Item Name Company 15 Jude Boudreaux Frank s Casing 16 Timothy Burns Shell 17 William Blue Baker Hughes 18 Allen Bolyard Baker Hughes 19 Billy Croker IQAS 20 Ron Schlappy Unique Machine 21 Nels Wickander 22 Eric Berger 23 Amos Ware 24 Gil Hunter 25 Randy Mariott 26 Carlos Medina Wickander & Associates Global Energy Service National Oilwell Varco National Oilwell Varco National Oilwell Varco National Oilwell Varco 27 David Bartholomew Amega West 2012 Qualified Specialists, Intl. 5

6 Members / Interested Parties Line Item Name Company 28 Angus Lamont Weatherford 29 Mike Briggs Cameron 30 Alan Johnson Alan Johnson Associates 31 Raouf Naguib Woodco USA 32 Chris North NOV 33 Dave Dufresne Inserpetrol 34 David Harris Schlumberger 35 Carlo Iasella 36 Mike Webber 37 Andrea Romero U.S. Steel Tubular Products Hunting Energy Services, LP. Hunting Energy Services, LP. 38 James Fraysur Weatherford 39 William Howie Weatherford 40 Stan Jones Weatherford 41 Justin Grimes SCV Line Item Name Company 42 Michael Teele Array Products 43 Mel Wright Shell 44 Philip Castle-Smith Shell 45 Chris Halbrook FMC 46 Bill Coble Cameron 47 Michael Wright 48 Oscar Baker 49 Gary Crisp 50 Garrett Schopper NOV 51 Teresa Comeaux T3 52 Scott Dillard T3 Permian Tank & MFG. Permian Tank & MFG. Independence Contract Drilling 53 Jim Alban Cameron 54 Bryan Busser Aker Solutions 55 Jim McCabe GE Oil & Gas 2012 Qualified Specialists, Intl. 6

7 Past Meetings August 10, 2011 August 31, 2011 September 21, 2011 February 1, 2012 March 14, 2012 April 6, 2012 June 4, Qualified Specialists, Intl. 7

8 Our Approach 1. To identify KEY CRITERIA FOR WELDING a. Focus: the need to identify requirements to demonstrate technical competence b. Considerations: to define requirements where known industry codes / standards do not provide guidance 2012 Qualified Specialists, Intl. 8

9 Our Approach KEY CRITERIA FOR WELDING Documented Program WPS PQR Welder Qualification Welding Equipment Approval Calibration of Monitoring & Measuring Equipment Welder Continuity Control & Issuance of Consumables Weld Repair Post Weld Heat Treatment Weld Acceptance Criteria Welding Program Revalidation Linkage to Q1 Traceability NDT Personnel Certification International References 2012 Qualified Specialists, Intl. 9

10 Our Approach Types of welding considered Welding processes covered by ASME Section IX and AWS D1.1 Brazing Hard Facing Overlay Corrosion Resistant Overlay Rotary Friction Welding (direct drive or inertia) 2012 Qualified Specialists, Intl. 10

11 Our Approach Electric Resistance Welding Soldering Hard Surfacing Hard Banding 2012 Qualified Specialists, Intl. 11

12 Our Approach 2. To provide linkage to known welding codes / standards where they address Key Criteria for Welding a. Focus: ASME SECTION IX AWS D Qualified Specialists, Intl. 12

13 Our Approach 3. To create benchmark requirements where they do not currently exist a. Focus: to utilize the technical experience of this Task Group s membership to identify requirements that will contribute to sound management practice for welding 2012 Qualified Specialists, Intl. 13

14 Our Approach 4. To perform gap analyses of API Product Specifications and to illustrate the visible gaps against requirements established by this Task Group a. Gap Analyses Assignment b. Illustration of API Spec. 8C Gap Analysis c. Illustration of API Spec. 2C Gap Analysis d. The Gap Analyses results will contain any disparities identified during the analysis of the product specification; the comments may be useful to the applicable product specification Task Group e. The Gap Analyses results will be reviewed and confirmed by a peer group within the Task Group 2012 Qualified Specialists, Intl. 14

15 a. Gap Analyses Assignment Our Approach Item # API Spec. Assigned To (for Gap Analysis) Reviewers 1 2C Bud Weightman Randy Mariott, Amos Ware 2 4F Amos Ware Jim Harris 3 5CT Mike Webber Bob Prince 4 5DP Mike Webber Bob Prince 5 5L Jude Boudreaux Billy Croker 6 5LC Jude Boudreaux Billy Croker 7 6A Jim Harris Mike Webber 8 6D Bob Prince Justin Grimes 9 6DSS Bob Prince Justin Grimes Mike Webber Randy Mariott, Amos Ware 11 7k Jude Boudreaux Randy Mariott, Amos Ware 12 8A Being withdrawn Being withdrawn 23 Completed Gap Analysis Gap Analysis to be finalized 23 of 23 completed 13 Completed Peer Reviews 5 Peer reviews assigned To be assigned 2012 Qualified Specialists, Intl. 15

16 Our Approach a. Gap Analyses Assignment (cont.) Item # API Spec. Assigned To (for Gap Analysis) 13 8C Jude Boudreaux Mike Webber 14 14A Allen Bolyard Mike Webber 15 14L Mike Webber 16 16A Bob Prince Jim Harris 17 16C Justin Grimes Bob Prince 18 16D Justin Grimes Bob Prince Reviewers 19 16F Bob Prince Randy Mariott, Amos Ware 20 16RCD Bob Prince 21 17D Jim Harris Raouf Naguib 22 17F Soldering 23 19G2 Soldering Randy Mariott Allen Bolyard 24 19G1 Allen Bolyard 23 Completed Gap Analysis Gap Analysis to be finalized 23 of 23 completed 13 Completed Peer Reviews 5 Peer reviews assigned To be assigned 2012 Qualified Specialists, Intl. 16

17 b. Illustration of API Spec. 8C Gap Analysis Our Approach 2012 Qualified Specialists, Intl. 17

18 Our Approach b. Illustration of API Spec. 8C Gap Analysis (cont.) i. Lessons Learned: Spec. 8C addresses most of the Key Criteria for Welding and has few gaps. Gaps are more related to managerial issues rather than technical issues Qualified Specialists, Intl. 18

19 c. Illustration of API Spec. 2C Gap Analysis Our Approach 2012 Qualified Specialists, Intl. 19

20 Our Approach c. Illustration of API Spec. 2C Gap Analysis (cont.) i. Lessons Learned: Spec. 2C addresses FEW of the Key Criteria for Welding and has NUMEROUS gaps. Gaps are both managerial issues and technical issues Qualified Specialists, Intl. 20

21 Results of TG6 s Work Concept has been proven Benchmark criteria has been finalized International standards have been identified 2012 Qualified Specialists, Intl. 21

22 Items to be considered by SC18 1. TG s goal, welding that occurs during the manufacturing process of product specified in API Product Specifications (E&P only) 2. A definition of welding was re-reviewed and revised as shown below: a. A process used to join metals by thermal input, with or without filler materials as defined by ASME Section IX and/or AWS D1.1. Processes and applications may also include: EW seam welding, hard surfacing and hard banding Qualified Specialists, Intl. 22

23 Items to be considered by SC18 3. A definition of soldering and brazing were reviewed: a. A process used to join metals by thermal input, with filler materials as defined by AWS A The Task Group discussed a probable need for additional auditor competency and questions for auditors who audit welding criteria in the future 5. The Task Group recommends that a Welding Program Document be developed following the TG output shown in the WIP, Requirements Matrix Rev. 5. This document can be included as a Normative Reference in applicable API Product Specifications. Likewise this document can be referred to as an Advisory to the API Monogram Program Qualified Specialists, Intl. 23

24 Items to be considered by SC18 Purpose: a. This will avoid tedious work for each API Product Specification Subcommittee. In other words, each Subcommittee would not have to go through each applicable product specification and include the output of the Requirements Matrix into their specification (See WIP, Requirements Matrix Rev 5). b. Provide a body of work (i.e., Welding Program Document) that may be referenced to establish consistency and baseline requirements for weld procedure qualification programs and documentation Qualified Specialists, Intl. 24

25 Items to be considered by SC18 6. Challenges faced when determining how to apply welding requirements to its tasks: a. Welding specified by API Product Specifications for Exploration & Production (in upstream only to date) b. Welding implied by the API Monogram Program Advisory 8; API Spec. Q1, c. Welding and/or repair welding on products manufactured under API Product specifications after initial manufacturing and/or Monogramming (not addressed) 2012 Qualified Specialists, Intl. 25

26 Items to be considered by SC18 6. Challenges faced when determining how to apply welding requirements to its tasks (cont.): d. Field welding on manufactured product (not addressed) e. Welding occurring independent from the manufacturer as a service to the end user during or related to the (re) installation process (consideration of API Spec. Q2) (not addressed) f. Welding being performed by the manufacturer as a service to the end user during or related to the (re) installation process as part of their contract (consideration of API Spec. Q2) (not addressed) 2012 Qualified Specialists, Intl. 26

27 SC18, TG6 Requests: 1. SC18 to approve TG6 s results 2. TG 6 to move forward with the development of a Welding Program Document (i.e., to standardize welding verbiage) 3. TG 6 to move forward with Auditor Competency and Audit Questions 4. SC18 to consider the challenges faced by TG6 and identify any further areas for addition to the TG Charge 2012 Qualified Specialists, Intl. 27

28 Questions 2012 Qualified Specialists, Intl. 28