importance of training certification in oil and gas industry

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WELCOME TO

Session 1 - March 08, 2012

IMPORTANCE OF TRAINING &

CERTIFICATION IN OIL & GASINDUSTRY

API Exhibition & ConferenceSingapore

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 peopleto 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 C

Collective 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 writtentestimony 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 makingcritical judgments that can have safety and/orsignificant financial consequences.



TRAINING & CERTIFICATION

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

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

Both “TRAINING & CERTIFICATION” are therefore vital andessential.




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 culturalapproaches, it can be challenging to ensure that the entire valuechain is consistently adhering to industry-specific quality standards.

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

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



API Certification Programs - Objective

API's Individual Certification Programs offer a means toimprove your skills and enhance your overall jobperformance. Simply, easily, and effectively.

API Individual Certification Programs are designed topromote improved inspection capabilities, andperformance.

Certified inspectors are recognized as professionals whoare knowledgeable of industry inspection codes, andpractices



API Certification Programs-Benefits

API's Inspector Certification Programs are based onindustry-developed standards that are recognized andused with confidence worldwide.

These standards have also provided a uniform platformthat serves as a model for many state and governmentregulations.

These API programs enable inspectors to play an activerole in improving industry health and safety; ensuringcompliance 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. ASMEBPV Codes

ASMEB 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 duringmanufacturing

‘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 inhigher than required

thickness for rest of the

component

“ In-service” Code

2) Evaluation of the

deterioration is based on

thickness required forindividual parts of a

component.


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

−= PSE

PR

t 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


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 thicknessavailable)

— 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



Crown PortionUniform Stress

distributionKnuckle portion

High level of Stress

Concentration (Requires

Higher Thickness than

Crown portion.)

Torispherical Head

NEW CONSTRUCTION CODE

V/S “IN-SERVICE” CODE





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, degradationmechanisms 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




Repair : Work necessary to restore a vessel

(or piping or tanks) suitable for safe

operations at Original design conditions




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”.




Re-rating : As a result of alterations

or otherwise, the new safe operatingconditions 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 QUTE - UT Shear Wave (Detection) Qualification Program

API QUSE - UT Shear Wave (Sizing) Qualification Program

BENEFITS OF API

http://www.api.org/certifications/icp/programs/api510.cfm







http://www.api.org/certifications/icp/programs/tes.cfm


http://www.api.org/certifications/icp/programs/api-571.cfm






http://www.api.org/certifications/icp/programs/api-qute.cfm


http://www.api.org/certifications/icp/programs/api-quse.cfm























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 condit ion, corroded, etc.)

3) Helps to determine the type, rate and causes of

deterioration

BENEFITS OF API INSPECTION



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




The benefits of t raining and Certif ication can be summed up as:

Less supervision : A well trained employee will be well acquainted wi th the job

and will need less of supervision. Thus, there will be less wastage of t ime 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 product ivity : Training improves efficiency and productivity of

employees. Well t rained employees show both quantity and quality

performance. There is less wastage of time, money and resources.



API Certification Objective, Control & Effectiveness

API

Codes,Standards,Industry best practices

API Conference & Expo

Awareness & Feed backfrom the Industry

Effective Implementation of

Codes, Standards for

industry Quality & Safety

ICP

TPCP Training organization

API-U

M-gram

Approved courses

Manufactures

Individuals

importance of training certification in oil and gas industry

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