Attachment E - SC18 - TG06 ppt Summer 2012

Report
Report to API SC18,
Task Group 6, Welding
API 2012 Summer Standardization Conference
Chairman: Bud Weightman
© 2012 Qualified Specialists, Intl.
Report to API SC18 on Task Group 6, Welding
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.
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
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.
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Report to API SC18 on Task Group 6, Welding
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
© 2012 Qualified Specialists, Intl.
 7-1
 7K
 8A
 8C
 14A
 14L
 16A
 16C
 16D
 16F
 16RCD
 17D
 17F
 19G1
 19G2
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Report to API SC18 on Task Group 6, Welding
Members / Interested Parties
Line Item
Name
Company
Bud Weightman
Qualified Specialists,
LLC
1
Bamidele Agbogun
Self
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
14
Chairman
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
Wickander &
Associates
22
Eric Berger
Global Energy
Service
23
Amos Ware
National Oilwell
Varco
24
Gil Hunter
National Oilwell
Varco
GE Oil & Gas Pressure
Control
25
Randy Mariott
National Oilwell
Varco
Jim Harris (alt)
GE Oil & Gas Pressure
Control
26
Carlos Medina
National Oilwell
Varco
Jimmy Hashem
Halliburton
27
David Bartholomew
Amega West
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
Members / Interested Parties
Line Item
Name
Company
Line Item
Name
Company
28
Angus Lamont
Weatherford
42
Michael Teele
Array Products
29
Mike Briggs
Cameron
43
Mel Wright
Shell
30
Alan Johnson
Alan Johnson
Associates
44
Philip Castle-Smith
Shell
45
Chris Halbrook
FMC
31
Raouf Naguib
Woodco USA
46
Bill Coble
Cameron
32
Chris North
NOV
33
Dave Dufresne
Inserpetrol
47
Michael Wright
Permian Tank &
MFG.
34
David Harris
Schlumberger
48
Oscar Baker
35
Carlo Iasella
U.S. Steel Tubular
Products
Permian Tank &
MFG.
49
Gary Crisp
Independence
Contract Drilling
50
Garrett Schopper
NOV
51
Teresa Comeaux
T3
52
Scott Dillard
T3
53
Jim Alban
Cameron
54
Bryan Busser
Aker Solutions
55
Jim McCabe
GE Oil & Gas
36
Mike Webber
Hunting Energy
Services, LP.
37
Andrea Romero
Hunting Energy
Services, LP.
38
James Fraysur
Weatherford
39
William Howie
Weatherford
40
Stan Jones
Weatherford
41
Justin Grimes
SCV
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
Past Meetings
 August 10, 2011
 August 31, 2011
 September 21, 2011
 February 1, 2012
 March 14, 2012
 April 6, 2012
 June 4, 2012
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
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.
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Report to API SC18 on Task Group 6, Welding
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
© 2012 Qualified Specialists, Intl.








Weld Repair
Post Weld Heat Treatment
Weld Acceptance Criteria
Welding Program
Revalidation
Linkage to Q1
Traceability
NDT Personnel
Certification
International References
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Report to API SC18 on Task Group 6, Welding
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.
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Report to API SC18 on Task Group 6, Welding
Our Approach
 Electric Resistance Welding
 Soldering
 Hard Surfacing
 Hard Banding
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
Our Approach
2. To provide linkage to
known welding
codes / standards
where they address
“Key Criteria for
Welding”
a. Focus:
 ASME SECTION IX
 AWS D1.1
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
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.
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Report to API SC18 on Task Group 6, Welding
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.
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Report to API SC18 on Task Group 6, Welding
Our Approach
a. Gap Analyses Assignment
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
10
7-1
Mike Webber
Randy Mariott, Amos Ware
11
7k
Jude Boudreaux
Randy Mariott, Amos Ware
12
8A
Being withdrawn
Being withdrawn
© 2012 Qualified Specialists, Intl.
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Completed Gap Analysis
Gap Analysis to be finalized
23 of 23 completed
13
Completed Peer Reviews
5
Peer reviews assigned
To be assigned
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Report to API SC18 on Task Group 6, Welding
Our Approach
a. Gap Analyses Assignment (cont.)
Item
#
API
Spec.
Assigned To (for
Gap Analysis)
Reviewers
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
19
16F
Bob Prince
Randy Mariott, Amos Ware
20
16RCD
Bob Prince
21
17D
Jim Harris
22
17F
Randy Mariott
23
Completed Gap Analysis
Gap Analysis to be finalized
23 of 23 completed
13
Completed Peer Reviews
5
Peer reviews assigned
To be assigned
Raouf Naguib
Soldering
23
19G2
Allen Bolyard
Soldering
24
19G1
Allen Bolyard
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
Our Approach
b.
Illustration of API Spec. 8C Gap Analysis
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
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.
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
Our Approach
c.
Illustration of API Spec. 2C Gap Analysis
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
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.
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
Results of TG6’s Work
 Concept has been proven
 Benchmark criteria has been finalized
 International standards have been identified
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
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.”
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
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 A3.0.”
4. 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.
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
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.
© 2012 Qualified Specialists, Intl.
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Report to API SC18 on Task Group 6, Welding
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, 7.5.2
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.
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Report to API SC18 on Task Group 6, Welding
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.
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Report to API SC18 on Task Group 6, Welding
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.
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Report to API SC18 on Task Group 6, Welding
Questions
© 2012 Qualified Specialists, Intl.
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