Importance of Training Certification in Oil and Gas Industry

WELCOME TO Session 1 - March 08, 2012

IMPORTANCE OF TRAINING & CERTIFICATION IN OIL & GAS INDUSTRY API Exhibition & Conference Singapore Presented By Jaison

WHAT IS TRAINING?  It is a learning / upgrading process that involves the

acquisition of knowledge, sharpening of skills, understanding new concepts or changing of attitudes and behaviors to enhance the performance of employees

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It helps employees to develop and / or improve their personal and organizational abilities

Training is important because 

Rapid technological innovations have made it necessary for people to consistently update their knowledge and skills

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To bridge gap between skills requirements and skills availability

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To bridge gap between collage education and Industry needs. (the gap between a University Graduate and an industry professional).

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For career advancement.

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For higher motivation and retention

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Prevention of obsolescence and to keep pace with times

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For survival and growth of organization and nation

WHY INDUSTRY ADOPTS CODES?

2C

Collective knowledge and Experience Credibility

CODES Safety (Plant, Personnel, people)

2S

Training Program on ASME B 31.3 (2008)

Standardization

WHAT IS CERTIFICATION? 

Certification is a process of providing written testimony that an individual is adequately qualified to do certain work.

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In the field of Oil and Gas Industry, certification is very important as the inspectors are often making critical judgments that can have safety and/or significant financial consequences.

TRAINING & CERTIFICATION 

Inspection personnel must have a great deal of confidence in the results of their work and their judgments.

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While the training helps to acquire / improve the knowledge, skill and confidence level of the individual; the certification presents objective evidence of his knowledge and skill so that the stakeholders can rely on him.

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Both “TRAINING & CERTIFICATION” are therefore vital and essential.

TRAINING & CERTIFICATION

TRAINING & CERTIFICATION In oil and gas industry 

The oil, and gas industry is often exposed to hazardous and sometimes catastrophic risks.

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With equipment and service suppliers spread all over the world, working under varying local business conditions, and cultural approaches, it can be challenging to ensure that the entire value chain is consistently adhering to industry-specific quality standards.

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To monitor the in-service equipment degradation, to detect flaws developed if any, and evaluate whether these are innocuous or harmful; and also plan and execute the follow up action

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This is important not only for business, but also for the safety of industry workers, the environment and communities.

API Certification Programs - Objective 

API's Individual Certification Programs offer a means to improve your skills and enhance your overall job performance. Simply, easily, and effectively.

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API Individual Certification Programs are designed to promote improved inspection capabilities, and performance.

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Certified inspectors are recognized as professionals who are knowledgeable of industry inspection codes, and practices

API Certification Programs-Benefits 

API's Inspector Certification Programs are based on industry-developed standards that are recognized and used with confidence worldwide.

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These standards have also provided a uniform platform that serves as a model for many state and government regulations.

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These API programs enable inspectors to play an active role in improving industry health and safety; ensuring compliance with effective inspection methodology.

INSPECTION 

Inspection : — Determination of the conformity or nonconformity of a product or service with its stated / implied requirements

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These requirements bear on (or affect) usability of the product and are stipulated in the relevant Codes / Standards.

INSPECTION CODES INSPECTOR’S PERSPECTIVE From Inspector’s viewpoint, the Inspection Codes tell:

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What to inspect

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How to inspect (Method)

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How much to inspect (extent)

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When to inspect (Inspection Frequencies)

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Who should inspect

INSPECTION CODES INSPECTOR’S PERSPECTIVE

And above all, the Codes give:

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The acceptance criteria for inspection i.e., — What is “acceptable” imperfection — What is “rejectable” defect

PLANT INSPECTIONS The Plant equipment Inspections can be broadly divided as: 1)

Inspection of new plant equipment prior to placing them in service (during fabrication /installation) i.e., to ascertain the “suitability for proposed use”

2)

Periodic inspection of “In-service” plants i.e., to ascertain the “present condition and suitability for continued use”

MAJOR INSPECTION CODES FOR OIL AND GAS INDUSTRY Purpose

Pressure Vessels

Plant Piping

Storage Tanks

New Constr.

ASME BPV Codes

ASME B 31.3

API 650

In-Service Inspection

API 510

API 570

API 653

“NEW CONSTRUCTION” CODE V/S “IN-SERVICE” CODE New Construction Inspection Code 1)Addresses non-conformities, defects arising during manufacturing

‘In-Service’ Inspection Code 1)Addresses service-related degradations (corrosion, erosion, fatigue, HIC, HB, etc.) and their effects on the equipment life

“NEW CONSTRUCTION” CODE V/S “IN-SERVICE” CODE New Construction Code 2) Design calculations based on weakest element of a component, resulting in higher than required thickness for rest of the component

“In-service” Code 2) Evaluation of the deterioration is based on thickness required for individual parts of a component.

TYPICAL PRESSURE VESSEL

Dished Head

SHELL

“NEW CONSTRUCTION” CODE V/S “IN-SERVICE” CODE (cont’d) Thickness by ASME formula

Let thickness for seamless shell, (E = 1), is t = 20

PR   t =   SE − 0.6 P  For weld, Radiography = spot, (E =  0.85), t =23.4 (17% High), select plate thickness=24 mm.

4 mm

It Means as per ASME, (i) Extra thk.= 0.6 mm (on weld) (ii) Extra thickness = 4 mm In the shell

“NEW CONSTRUCTION” CODE V/S “IN-SERVICE” CODE (cont’d) After 10 years, vessel is corroded, say 2 mm throughout. Then, according to API 510:

— Weld portion is unsafe (only 0.6 mm was extra thickness available)

— Whereas, the shell away from weld is still safe. In fact, it still has further 2 mm extra allowance (extra thickness = 4 mm)

“NEW CONSTRUCTION” CODE V/S “IN-SERVICE” CODE Crown Portion Uniform Stress distribution

Knuckle portion High level of Stress Concentration (Requires Higher Thickness than Crown portion.)

Torispherical Head

“NEW CONSTRUCTION” CODE V/S “IN-SERVICE” CODE (cont’d) New Constr. Code

“In-service” Code

3) Constraints of operating

3) Considering the constraints

plant are not a consideration

of operating plant, the Code gives alternative solutions (e.g., PWHT)

MAIN FEATURES OF ‘IN-SERVICE’ CODE 

Understand the service conditions, degradation mechanisms present and their effect on equipment

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Monitor and evaluate service degradation during periodic inspection and decide “3R” aspects

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Safe to Run : Assess remaining life, inspection intervals

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Requires Repairs/: Do’s and Don’ts of repairs

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Replacement: Either the whole equipment or part thereof

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Documentation / Records

MAIN FEATURES OF ‘IN-SERVICE’ CODE

Repair: Work necessary to restore a vessel (or piping or tanks) suitable for safe operations at Original design conditions

MAIN FEATURES OF ‘IN-SERVICE’ CODE Alteration :

When restoration work

is not likely to bring back the equipment to its original design conditions, but safe to operate at some other changed conditions, then equipment undergoes “Alteration”.

MAIN FEATURES OF ‘IN-SERVICE’ CODE

Re-rating :

As a result of alterations

or otherwise, the new safe operating conditions are established by analysis. Determining these new operating conditions is “Re-rating”.

OBJECTIVES OF API CERTIFICATION PROGRAM 

To prepare the professional inspectors capable of performing the following:

1)

Understand and identify the various types of service degradations (corrosion, erosion, fatigue, creep, HIC, HB, etc.).

2)

Select correct methods of inspection frequency, inspection methods, monitor and assess the effects of service related degradation.

3)

Arrive at result and follow up action, namely ‘3R’ decisions RunRepair-Replace

OBJECTIVES OF API CERTIFICATION PROGRAM (cont’d)

4)

Supervise and ensure the repairs / alterations / re-rating are performed as required by Code.

5)

Suggest improvements which may be useful inputs to designer as well as operation personnel.

API CERTIFICATIONS - ICP 

API 510 Pressure Vessels Inspector Certification Program

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API 570 Piping Inspector Certification Program

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API 653 Storage Tanks Inspector Certification Program

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API 936 Refractory Personnel Certification Program

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API TES Tank Entry Supervisor Certification Program

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API 571 Supplemental Inspection Certification Program

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API 577 Supplemental Inspection Certification Program

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API 580 Supplemental Inspection Certification Program

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API QUTE - UT Shear Wave (Detection) Qualification Program

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API QUSE - UT Shear Wave (Sizing) Qualification Program

BENEFITS OF API “IN-SERVICE” INSPECTION PROGRAM 1)

Results in a systematic, well-structured and reliable inspection / repair / re-rating programs

2) Helps to determine the physical condition of the equipment (sound condition, corroded, etc.) 3) Helps to determine the type, rate and causes of deterioration

BENEFITS OF API INSPECTION PROGRAMS (cont’d) 4) Reduces unexpected break-downs

5) Improves reliability and provides a continued high level of safety of plant operation 6) Improves overall management control of process operation

TRAINING & CERTIFICATION 

The benefits of training and Certification can be summed up as:

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Less supervision : A well trained employee will be well acquainted with the job and will need less of supervision. Thus, there will be less wastage of time and efforts.

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Fewer accidents : Errors are likely to occur if the employees lack knowledge and skills required for doing a particular job. The more trained an employee is, the less are the chances of committing accidents in job.

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Increased productivity : Training improves efficiency and productivity of employees. Well trained employees show both quantity and quality performance. There is less wastage of time, money and resources.

TRAINING & CERTIFICATION

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Asset to organization: A well trained employees having skills and efficiency are the “HUMAN RESOURCE” in its true sense. They become an asset for the organization.

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Improved morale of employees: Training helps the employee to do the job Knowledgably, get job security and job satisfaction.

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Success Contributor: The more satisfied the employee is and the greater is his morale, the more he will contribute to organizational success

API Certification Objective, Control & Effectiveness API Codes,Standards,Industry best practices

TPCP API Conference & Expo Awareness & Feed back from the Industry

API-U M-gram

ICP Effective Implementation of Codes, Standards for industry Quality & Safety

Training organization Approved courses

Manufactures

Individuals