report to api sc18, task group 6, welding api 2012 summer standardization conference © 2012...

Report to API SC18,Task Group 6, Welding

API 2012 Summer Standardization Conference

© 2012 Qualified Specialists, Intl.

Chairman: Bud Weightman

Report to API SC18 on Task Group 6, Welding

© 2012 Qualified Specialists, Intl. 2

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.



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



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

4F5CT5DP5L6A6D6DSS

7-17K8A8C14A14L16A16C16D

16F16RCD17D17F19G119G2



Members / Interested Parties

Line Item Name Company

Chairman 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 GE Oil & Gas Pressure Control

13 Jim Harris (alt) GE Oil & Gas Pressure Control

14 Jimmy Hashem Halliburton


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

25 Randy Mariott National Oilwell Varco

26 Carlos Medina National Oilwell Varco

27 David Bartholomew Amega West



Members / Interested Parties


28 Angus Lamont Weatherford

29 Mike Briggs Cameron

30 Alan Johnson Alan Johnson Associates

31 Raouf Naguib Woodco USA

32 Chris North NOV

33 Dave Dufresne Inserpetrol

34 David Harris Schlumberger

35 Carlo Iasella U.S. Steel Tubular Products

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


42 Michael Teele Array Products

43 Mel Wright Shell

44 Philip Castle-Smith Shell

45 Chris Halbrook FMC

46 Bill Coble Cameron

47 Michael Wright Permian Tank & MFG.

48 Oscar Baker 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



Past Meetings

August 10, 2011

August 31, 2011

September 21, 2011

February 1, 2012

March 14, 2012

April 6, 2012

June 4, 2012



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



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

Weld Repair Post Weld Heat Treatment Weld Acceptance Criteria Welding Program Revalidation Linkage to Q1

Traceability NDT Personnel Certification International References



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)



Our Approach

Electric Resistance Welding

Soldering

Hard Surfacing

Hard Banding



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



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



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



Our Approach

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

a. Gap Analyses Assignment

23 Completed Gap Analysis

Gap Analysis to be finalized

23 of 23 completed

13 Completed Peer Reviews

5 Peer reviews assigned

To be assigned



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 Raouf Naguib

22 17F Soldering

Randy Mariott

23 19G2 Soldering

Allen Bolyard

24 19G1 Allen Bolyard

23 Completed Gap Analysis

Gap Analysis to be finalized

23 of 23 completed

13 Completed Peer Reviews

5 Peer reviews assigned

To be assigned



Our Approach

b. Illustration of API Spec. 8C Gap Analysis



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.



Our Approach

c. Illustration of API Spec. 2C Gap Analysis



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.



Results of TG6’s Work

Concept has been proven

Benchmark criteria has been finalized

International standards have been identified



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.”




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.




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.




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)




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)



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



Questions

report to api sc18, task group 6, welding api 2012 summer standardization conference © 2012...

Documents

welding api

api sc18

api product specifications

api auditors

api audits

task group

welding criteria

processes welding