AGA Quality Management Best Practices Roundtable

Transcription

1 AGA Quality Management Best Practices Roundtable PSE Gas Operations Quality Management through Inspection, Auditing, Assessment and Corrective Action Kaaren Daugherty Manager Quality Assurance and Inspection Jac Hand Supervisor Quality Control February 13, 2013

2 Presentation Outline Introduction Quality Functions Overview Leak Management QA/QC Construction QA/QC 2

3 Puget Sound Energy Overview Largest utility in Washington State Serves 11 counties, 6,000 square miles 1.1 million electric customers 760,000 natural gas customers 12,000 miles natural gas mains 3

4 Quality Management at PSE - Drivers Stipulated agreement to settle WUTC audits of new construction Settlement agreement with WUTC related to leak records violation Federal regulatory requirements [ (b)(8) and ] 4

5 5 Quality Management at PSE - Timeline

6 Quality Management at PSE Definition Puget Sound Energy (PSE) defines quality management of our natural gas system as the integration of training and Operator Qualification (OQ) with inspections and audits of construction, operation, and maintenance activities. 6

7 Quality Management at PSE Method PSE utilizes a closed loop corrective action and reporting system for the purpose of improvement and to develop consistency of systems and services, as well as a cost effective means of compliance with regulatory requirements. 7

8 8 Quality Management at PSE Organization

9 9 Quality Management at PSE Quality Oversight

10 10 Quality Management at PSE Quality Oversight

11 Gas Operations QC Gas Operations Quality Control Department was established in A supervisor who serves as quality subject matter expert, and prepares and manages the quality plans and procedures. Currently there are 4 consultants that report on audits, assessments and field investigations for Gas Operations. 11

12 Gas Operations QC We report to our internal customers on the Quality of their practices with objective evidence We evaluate processes, procedures & standards vs. results in the spirit of continuous improvement 12

13 Assessment and Self Audit Procedures GQC-1200: GMI-GT Calibration Performed by GFR GQC-1300: Corrosion Control Test Site Inspections GQC-1400: Valve Inspections Performed by Gas First Response GQC-1500: H2RL Atmospheric Corrosion Monitoring GQC-1600: H2RL Valve Inspection GQC-1700: 4 Gas Indicator Calibration GQC-1800: Inspecting Regulator Stations GQC-1900: QC Plan Self Audit GQC-2000: Atmospheric Corrosion Monitoring GQC-2100: Valve Inspections by Pressure Control GQC-2200: Industrial Meters Maintenance & Inspection GQC-2300: Odorizing Station Inspection GQC-2400: Leak Repair, Re-evaluation GQC-2700: Mobile Home Patrols GQC-2800: Bridge and Slide Patrols GQC-2900: Leak Survey Self Audit GQC-3000: Emergency Calls GQC-3200: Exposed Pipe Condition Reports GQC-3300: Instrumentation Calibration in SAP Database GQC-3400: Liquid Natural Gas (LNG) Facility Operations GQC-3500: Propane-Air Plant Operation & Maintenance GQC-3600: Hard-to-Reach locations (H2RL) Leak Survey GQC-3800: Pressure Recorders & Electronic Corrector Calibration GQC-3900: Analog Pressure Gauge Calibration Performed by GFR GQC-4000: H2RL Pipeline Markers GQC-4100: Odor Level Testing GQC-2600: Corrosion Control Power Source Inspections 13

14 Assessment and Self Audit Procedures GQC-1200: GMI-GT Calibration Performed by GFR GQC-1300: Corrosion Control Test Site Inspections GQC-1400: Valve Inspections Performed by Gas First Response GQC-1500: H2RL Atmospheric Corrosion Monitoring GQC-1600: H2RL Valve Inspection GQC-1700: 4 Gas Indicator Calibration GQC-1800: Inspecting Regulator Stations GQC-1900: QC Plan Self Audit GQC-2000: Atmospheric Corrosion Monitoring GQC-2100: Valve Inspections by Pressure Control GQC-2200: Industrial Meters Maintenance & Inspection GQC-2300: Odorizing Station Inspection GQC-2400: Leak Repair, Re-evaluation GQC-2600: Corrosion Control Power Source Inspections GQC-2700: Mobile Home Patrols GQC-2800: Bridge and Slide Patrols GQC-2900: Leak Survey Self Audit GQC-3000: Emergency Calls GQC-3200: Exposed Pipe Condition Reports GQC-3300: Instrumentation Calibration in SAP Database GQC-3400: Liquid Natural Gas (LNG) Facility Operations GQC-3500: Propane-Air Plant Operation & Maintenance GQC-3600: Hard-to-Reach locations (H2RL) Leak Survey GQC-3800: Pressure Recorders & Electronic Corrector Calibration GQC-3900: Analog Pressure Gauge Calibration Performed by GFR GQC-4000: H2RL Pipeline Markers GQC-4100: Odor Level Testing Blue = Leak Management 14

15 Field Objective Evidence GQSV-2800: Bridge and Slide Patrols Tag GQSV-1400: ES Valves (GFR) Tag GQSV-1800: Regulator Stations Tag GQSV-2100: Pressure Control Valves Tag GQSV-2700: Mobile Home Patrol Tag GQSV-2300: Odorizing Station Log Book 15

16 Reports Detailed Self Audit & Assessment reports All objective evidence is captured Monthly Management Reports of activities summarizing results are distributed SharePoint is used for Document Control 16

17 17 Hertzler GainSeeker

18 Gas Operations CARs When corrective action is needed we assign Corrective Action Requests (CARs) We track, follow up and project manage the CARs to ensure the Corrective Actions are complete and effective. 18

19 Corrective Action Requests (CARs) Examples 19

20 Corrective Action Requests (CARs) Cycle 1 (2009 & 10) = assessments / audits Cycle 2 (2011) = 36 2 new 6 Cycle 3 (2012) = 29 2 new 6 20

21 Corrective Action Requests (CARs) CAR - Discrepancy Type Record Incomplete / Inaccurate Required Action Omitted Forms to Database Discrepancy Missing Record 21

22 Corrective Action Requests (CARs) CAR - Type of Action Taken Standard/ Procedure/ Work Process Change Training Record Correction Form/ Software Revision Moved to New CAR 22

23 Quality Management at PSE QA&I Resources Quality Assurance and Inspection Resources 3 Supervisors 18 Inspectors 3 Gas O&M 10 Gas Construction 4 Electric Construction 1 Vegetation Management 23

24 Quality Management at PSE QA&I Routine Audits 24 *Flagged for elimination; reduction in frequency; or transfer to others in 2013 Resource Documents: Written audit procedures Inspection Manuals Job Aids

25 25 Quality Management at PSE QA&I Audit Process

26 Quality Management at PSE QA&I Field Technology Each Inspector has laptop and digital camera. Gas construction audit team members have vehicle docking station. Gas construction audit team members have vehicle printers. Wireless network access from the job site to SAP, crew dispatch logs, . s containing audit reports and job photos can be sent from the job site to distribution list. 26

27 Quality Management at PSE QA&I Records Audit results are entered into a database. Database - Tracks deviations and corrections Allows searches for records matching specific criteria such as dates, personnel, materials, types of work Generates reports Assists QA&I in performing QC of inspection data 27

28 Quality Management at PSE QA&I Reporting QA&I provides detailed reports for all its inspection activities. Individual audit reports Summary reports by audit type and service provider Analytical reports Reports are distributed monthly, quarterly, and upon completion Service Provider QC Management PSE Contract Management PSE Compliance Management 28

29 Quality Management at PSE QA&I Target Audits Target Audits performed at Client request or as required by PSE Operating Standards Average 4 to 10 audits per year Written procedure guides audit development and process Specific audit plan prepared and documented Report generated and CARs issued Audits tend to focus on a specific task or product O&M work typically fits in this category Target audits may turn into routine audits Examples: CP 90-day remediation Tool calibration records Bridge and slide patrolling process 29

30 30 Quality Management at PSE Leak Management

31 Quality Management at PSE Leak Management Leak Survey walk-along audit (monthly) Leak evaluation/repair audit (monthly) Leak Record Audit (monthly beginning 1/1/12) Gas construction Service Provider records Leak survey Service Provider records Leak Record Assessment PSE records Leak Survey self audit (minimum every 3 year) Required by WUTC regulation 31

32 Leak Management CARs Cycle 1 (2009 & 10) = 7 Cycle 2 (2011) = 4 Cycle 3 (2012) = 4 32

33 Leak Management CARs Leaks CAR - Discrepancy Type Record Incomplete / Inaccurate Required Action Omitted Missing Record 33

34 Leak Management CARs Leaks CAR - Type of Action Taken Standard/ Procedure/ Work Process Change Training Moved to New CAR 34

35 Quality Management at PSE Leak Management Leak Record audit summary (August December 2012) 261 records (10% population) 1799 inspection items 86 deviations 95% satisfactory Leak Survey walk along audit 100% satisfactory 2012 Leak Survey self audit resulted in 3 CARs 35

36 Quality Management at PSE Construction Gas Site Audits pertain to intermediate and low pressure installations Random Sample Performed daily Inspectors rotated through region Quality Assurance Focus Work in progress and post construction audits Target 50% crew on site Some audits are of an entire job while other audits capture specific construction components Regular audits check different items and over a period of time provide a complete picture of the overall quality Provides quantifiable audit results 36

37 37 Quality Management at PSE Construction

38 Quality Management at PSE Construction High Pressure Inspections pertain to pipelines operating at >60 psig Main line and regulator stations 100% inspection while job in progress Quality Control focus QA Inspectors are certified weld inspectors Coordinate NDT of welds Weekend duty rotation Select GFR personnel provide weekend/after-hours backup 38

39 39 Quality Management at PSE Construction

40 40 Quality Management at PSE Construction

41 Quality Management at PSE Construction Unsatisfactory Inspection Items 41

42 Quality Management at PSE - Contacts Kaaren Daugherty, Manager Quality Assurance and Inspection kaaren.daugherty@pse.com Jac Hand, Supervisor Quality Control jac.hand@pse.com