Iso/ api Quality Management Blog

Report
API Quality Specifications and the
Efficiency of Leveraging a QHSE
Management System
2013 Safety Driven Performance Conference
9-10 October 2013
Robyn Stephens, PhD CRMA
Principal Consultant
Atkins, Energy, Oil & Gas
Agenda
Who is Atkins?
What is the link between Quality and Safety?
What is a Management System
History of API Q1 and Q2
Understanding API Q1 and Q2
Examples of Overlap with HSE/PS MS
Advantages of Integration
2
Songjiang Shimao
Intercontinental Hotel
People’s Republic of China
Who is Atkins?
Why are they here?
Architecture, structural engineering, civil engineering
Who is Atkins?
Atkins is one of the world's leading design, engineering and
project management consultancies.
Plan
Design
Enable
4
Why are they Here?
Management Systems
5
Capital Fort, Sofia
Bulgaria
What is the link between Quality and Safety?
Architecture, interior design, mechanical, electrical,
civil and structural engineering, BREEAM assessor,
acoustics, ICT strategy
6
Risk Management
Different Sons of the Same Mother . . .
Procedure
Failure
Work
Interruption
Equipment
Failure
Human
Error
Loss of
Primary
Containment
Release to
Environment
Fire
and/or
Explosion
7
Olympic Park
London 2012 Games
What is a Management System?
How risks are controlled
Multidisciplinary engineering infrastructure design, project
managing enabling works,
site clearance and remediation,
environmental impact assessment
Management System Fundamentals
A Management System is
●
a System of processes
● Sustainable
● Suitable to the organization
● “The way we do business“
9
Typical Hierarchical Structure
Management System
Structure
Organizational
Structure
Framework of
Expectations
Corporate
Methodologies
and Standards
Site Specific
Procedures
Business 1
Site A
Site B
Business 2
Site C
10
What is a Process
Resources
Input
Process
Output
Controls
11
A Sustainable System
Plan
Act
Do
Check
12
Burj Al Arab
United Arab Emirates
History of API Q1 and Q2
Quality Management Systems
Architecture,
civil and structural engineering,
MEP engineering,
cost consultancy
Evolution of Q1 and Q2
Originally titled "Specification for Quality Programs for the
Petroleum and Natural Gas Industry"
QMS for "product" – originally manufacturing oriented
Jointly managed with ISO as ISO 29001
ISO/API Separation 2012
Q1 8th Edition released December 2007
Quality impacts to industry rising
●
Failures of equipment
● Problems with service delivery
Increase in Nonproductive Time (NPT) exacerbated
●
Increasing complexity of wells
● Increasing rig costs
14
Evolution of Q1 and Q2 - continued
Root causes of NPT:
●
●
●
●
●
●
Competency/Training
Lack of procedures or adherence
Lack of robust Mechanical Integrity programs
Lack of contingency planning
Lack of history data
Lack of effective change management
Need for industry standardization
15
Evolution of Q1 and Q2 - continued
SC18 TG 5 Created
Developed & balloted document in less than 9 months
Published Q2 in Dec 2011
Specification for Quality Management System
Requirements for Service Supply Organizations for the
Petroleum and Natural Gas Industries
Q1 9th Edition issued June 2013 – effective June 2014
Specification for Quality Management System
Requirements for Manufacturing Organizations for the
Petroleum and Natural Gas Industry
16
World Trade Center Redevelopment
United States of America
Understanding API Q1 9th and Q2 1st
Differences from Q1 8th Edition
Program management,
cost consultancy
New Quality Elements
Q1 9th & Q2 1st Over Q1 8th / ISO 29001
Documented competency of personnel
Risk assessment and management
Contingency planning
Supply chain controls – critical / non-critical services
Specific evaluation and selection requirements for "critical"
product or service providers
Product / Service Quality Plan
Preventive Maintenance, Inspection and Test Program
Management of Change (MoC)
18
Bahrain World Trade Center
Bahrain
Examples of Overlap
SEMS Requirements
Architecture,
civil and structural engineering,
MEP engineering, sustainable design,
construction supervision
Overlap with SEMS
30 CFR 250 Subpart S
SEMS/RP 75 Requirement
API Q1 / Q2
(1) General (see § 250.1909)
4.1.2 Quality Policy
4.1.3 Objectives
4.1.4 Planning
4.1.5 Communications
4.2 Management Responsibility
4.3.2 Human Resources
6.5 Management Review
5.9 Product/Service Validation
6.2.2 Internal Audit
6.3 Analysis of Data
(2) Safety and Environmental Information
(see § 250.1910)
4.4 Documentation Requirements
4.5 Control of Records
6 Quality Management System
Measurement, Analysis, and Improvement
(3) Hazards Analysis (see § 250.1911)
5.3 Risk Assessment and Management
(4) Management of Change
(see § 250.1912)
5.3 Risk Assessment and Management
5.11 Management of Change
20
Overlap with SEMS
30 CFR 250 Subpart S
SEMS/RP 75 Requirement
API Q1 / Q2
(5) Operating Procedures (see
§ 250.1913)
4.4 Documentation Requirements
5.7.2 Product/Service Quality Plan
(6) Safe Work Practices and
4.3.2 Human Resources
Contractor Selection (see § 250.1914) 4.5 Control of Records
5.6.1 Purchasing Control
5.6.3 Verification of Purchased
Products and Services
(7) Training (see § 250.1915)
4.3.2 Human Resources
(8) Mechanical Integrity (Assurance of 5.6 Purchasing
Quality and Mechanical Integrity of
5.7.2 Product/Service Quality Plan
Critical Equipment) (see § 250.1916) 5.7.6 Identification and Traceability
5.7.8 Preventive Maintenance,
Inspection, and Test Program
5.8 Control of Testing, Measuring,
Monitoring, and Detection Equipment
21
Overlap with SEMS
30 CFR 250 Subpart S
SEMS/RP 75 Requirement
API Q1 / Q2
(9) Pre-startup Review (see
§ 250.1917)
5.1.1 Requirements Review
5.4.4 Design and Development Verification
5.4.5 Design and Development Final
Review and Approval
(10) Emergency Response and Control
(see § 250.1918)
5.5 Contingency Planning
(11) Investigation of Incidents (see
§ 250.1919)
5.10 Control of Nonconformities
6.4.2 Corrective Action
6.4.3 Preventive Action
(12) Auditing (Audit of Safety and
Environmental Management Program
Elements) (see §§ 250.1920)
6.2.2 Internal Audit
(13) Recordkeeping (Records and
Documentation) and additional
BOEMRE requirements (see § 250.1928)
4.4 Document Control
4.5 Control of Records
22
Processes vs. Procedures
Required Documented Procedures
Q1 8th Edition
Q2 1st Edition
Q1 9th Edition
Control of Documents
Control of Documents
Control of Documents
Control of Records
Control of Records
Control of Records
Internal Audit
Internal Audit
Internal Audit
Control of
Nonconforming Product
Control of
Nonconforming Product
Control of
Nonconforming Product
Corrective Action
Corrective Action
Corrective Action
Preventive Action
Preventive Action
Preventive Action
6 Procedures
Plus 18 More – Total 24
Plus 17 More – Total 23
23
Hurricane Protection
United States
Advantages of Integration
PgM/PM/CM, coastal restoration, engineering,
environmental, GIS support,
cost estimating, CPM scheduling
24
Advantages of Integration
Consistency in Risk Tolerance & Appetite
Silo Minimization
Clarity on Applicability and Accountability
Reduced number of Procedures
More Consistent Procedure Application
Minimize Duplicative Infrastructures
More Efficient Governance and Administration
System Management – Process Interaction
Improved System Management
25
Opportunity Realization
QHSE
MS
HSE
MS
QMS
26
Solan Offshore Development
People’s Republic of China
Questions
Structural design & assessments
Mechanical engineering
Safety Process engineering
Concept design

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