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

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 To bridge gap between skills requirements and skills availability To bridge gap between collage education and Industry needs. (the

gap between a University Graduate and an industry professional). For career advancement. For higher motivation and retention Prevention of obsolescence and to keep pace with times For survival and growth of organization and nation

WHY INDUSTRY ADOPTS CODES?

Training Program on ASME B 31.3 (2008)

CODES

2 S2 S2 S

2 C2 C2 CCollective knowledge and ExperienceCCollective knowledge and Experienceollective knowledge and Experience

CredibilityCCredibilityredibility

Safety(Plant, Personnel, people)

SSafetyafety(Plant, Personnel, people) (Plant, Personnel, people)

StandardizationSStandardizationtandardization

WHAT IS CERTIFICATION?

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

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.

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.

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.

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.

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

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.

API Individual Certification Programs are designed to

promote improved inspection capabilities, and performance.

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.

These standards have also provided a uniform platform

that serves as a model for many state and government regulations.

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 non-conformity of a product or service with its stated / implied requirements

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:

What to inspect

How to inspect (Method)

How much to inspect (extent)

When to inspect (Inspection Frequencies)

Who should inspect

INSPECTION CODES INSPECTOR’S PERSPECTIVE

And above all, the Codes give:

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

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.

“NEW CONSTRUCTION” CODE V/S “IN-SERVICE” CODE

SHELL

TYPICAL PRESSURE VESSEL

Dished Head

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

Thickness by ASME formula

−=

PSEPRt

6.0

Let thickness for seamless shell, (E = 1), is t = 20 For weld, Radiography = spot, (E =

0.85), t =23.4 (17% High), select plate thickness=24 mm.

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

4 mm

“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)

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

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

New Constr. Code

3) Constraints of operating plant are not a consideration

“In-service” Code

3) Considering the constraints 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

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

Safe to Run : Assess remaining life, inspection intervals

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

Replacement: Either the whole equipment or part thereof

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 Run- Repair-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

API 570 Piping Inspector Certification Program

API 653 Storage Tanks Inspector Certification Program

API 936 Refractory Personnel Certification Program

API TES Tank Entry Supervisor Certification Program

API 571 Supplemental Inspection Certification Program

API 577 Supplemental Inspection Certification Program

API 580 Supplemental Inspection Certification Program

API QUTE - UT Shear Wave (Detection) Qualification Program

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: 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.

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.

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

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.

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

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

API Conference & Expo

Awareness & Feed back from the Industry

Effective Implementation of Codes, Standards for

industry Quality & Safety

ICP

TPCP Training organization

API-U

M-gram

Approved courses

Manufactures

Individuals