Bolting Reliability for Offshore Oil and Natural Gas Operations Proceedings of a Workshop (2018) / Chapter Skim
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5 Panel 4: Standards and Regulations
5 Panel 4: Standards and Regulations
Pages 89-113
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From page 89... ...
Kachele's remarks focused on how the Navy deals with the challenges of the ocean environment, how designing the interactions between components and people can help to reduce variability, and on the use of quality assessments to inform decision making. Dealing with the Ocean Environment Kachele stressed the importance of understanding the environment and its effects.
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From page 90... ...
For example, if a bolt connects a valve to heat exchange piping, the valve operators and the heat exchange operators need to understand each others' needs in order to reduce negative conse quences. Building effective working relationships between people with different ar eas of expertise, such as metallurgists and fastener engineers, can sometimes require bridging cultural divides between different fields.
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From page 91... ...
The risk cube is a visual way to communicate complex technical idea paths and the likelihood of various outcomes to engineers, accountants, and sailors (Figure 5.1)
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From page 92... ...
Finally, understanding quality can improve the decision-making process. Two publicly accessible documents, MIL-STD-777 for controlling piping systems and MIL-STD-882, the risk cube for resolving system safety, are especially helpful in informing Navy decisions about the most critical components.
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From page 93... ...
, including its Monogram Program, and API Spec 20E, Specification for Alloy and Carbon Steel Bolting for Use in the Petroleum and Natural Gas Industries, 2nd Edition (20E)
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From page 94... ...
, which consists of industry professionals, equipment manufacturers, service and supply companies, regulators, and quality systems professionals. It is the leading international standard for the petroleum, petrochemical, and natural gas industries, and goes above and beyond other QMSs because of its industry specific requirements.
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From page 95... ...
20E As described by other workshop presenters, API Spec 20E, Specification for Alloy and Carbon Steel Bolting for Use in the Petroleum and Natural Gas Industries, 2nd Edition, is the specification for carbon and steel alloy bolting for oil and natural gas applications. It covers many aspects of bolt manufacturing, including production, calibration, testing, marking, record keeping, storage, and shipping.
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From page 96... ...
The second most common nonconformity for 20E was in the qualification of raw material sourcing, and the analysis of Q1 nonconformities also pointed to gaps in purchase control. Echoing the views expressed by a few other workshop presenters, Miller emphasized the importance of managing the entire supply chain.
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From page 97... ...
Together, Miller said Q1 and 20E are important resources for producing quality products for industry use. Subsequent to Miller's presentation, API published the fourth edition of API specification 16A, Specification for Drill-through Equipment, which calls out the use of both Spec 20E, Specification for Alloy and Carbon Steel Bolting for Use in the Petroleum and Natural Gas Industries, and Spec 20F, Specification for Corrosion Resistant Bolting for Use in the Petroleum and Natural Gas Industries, with Specification 16A, requiring minimal bolting specification levels depending on the type of bolting (pressure containing, pressure controlling, or closure)
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From page 98... ...
These events did not cause accidents like the Sioux City crash, but they could have, and the aviation industry missed the opportunity to learn from them, Woodfield said. This experience, he said, under scores how important it is to study near misses, especially if true failures are rare.
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From page 99... ...
After the Crash: JETQC After the disc failure was determined to be caused by a hard alpha inclusion, the FAA convened JETQC to address inclusions in premium quality titanium material with the overall goal of improving aviation safety. JETQC includes representatives from the FAA, premium quality titanium suppliers, and U.S.
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From page 100... ...
JETQC compiles annual reports and shares that information with the suppliers; these published reports follow a standard format that the FAA requires but do not become public record. The suppliers also conduct a formal root cause analysis on each melt inclusion with an assigned confidence level in the analysis, and then implement a series of corrective actions related to the identified potential root cause.
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From page 101... ...
Following this effort, the root cause for any inclusion now found by a supplier and its confidence level is anonymously included in the annual JETQC feedback to the suppliers, thus allowing all suppliers to assess their processes against known industry inclusion sources. Differentiating between certain elements in an inclusion, especially nitrogen and titanium, at the microscopic level is very difficult, and Woodfield said that NIST has begun to help JETQC and the industry to improve measuring practices and methods to study individual inclusions.
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From page 102... ...
Woodfield said it was encourag ing that the oil and gas industry has defined critical bolts and critical applications, which helps designers, investigators, and standards bodies understand where to direct their attention, and just as importantly, where not to. Third, measuring and publishing problems, near misses, and absence of prob lems is essential, Woodfield said.
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From page 103... ...
Collier noted that the FAA issues certificates and production approvals to ensure the design and production of the product or article meets applicable standards. FAA orders contain detailed information for FAA personnel; the aviation industry also refers to FAA orders to establish its own procedures and controls.
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From page 104... ...
Risk assessments are based on three pillars: exposure of their products to the National Airspace System, organizational assessment, and facility assessment. Mechanisms for Preventing Defective Bolts The aviation industry and deep-sea offshore drilling industry share a common ality on defective fasteners (bolts)
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From page 105... ...
Woodfield detailed how the aviation industry dramatically improved the quality of premium titanium parts for airplanes and offered several lessons that could assist the oil and gas industry. Collier summarized how the FAA exercises its authority to ensure the safety of civil airplanes through mechanisms including regulations, certifications, orders, advisory circulars, and audits.
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From page 106... ...
He also reiterated the importance of being able to define your level of confidence in the root cause identified. Candi Hudson asked Woodfield about the processes used to characterize inclu sions in titanium.
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From page 107... ...
Woodfield replied that traceability of the part was the critical data that determined its root cause. As for engine performance, record keeping then was very rudimentary, and the best they could do at the time was coordinate a count of the engine's cycles with the fatigue level at the time of the failure.
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From page 108... ...
Esaklul asked Woodfield how the aviation industry handles the adoption of updates to standards. Woodfield replied that aviation component manufacturers must use the latest editions of all standards, and there is a short window of time, typically 6 months, between the release of new standards and the date by which companies are expected to adopt them.
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From page 109... ...
Woodfield agreed that hard alpha inclusions may be easier to eliminate than the types of cracks workshop participants are grappling with. Although there are more than 100 known sources of inclusions, the list of known sources provides a valuable framework for investigators to use during root cause analyses.
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From page 110... ...
Collier reflected that the FAA is perhaps more involved, and the aviation industry is perhaps more heavily regulated, because public safety is irectly at risk when airplanes crash. In response, Fleece stressed that in his view d the oil and gas industry is indeed heavily regulated.
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From page 111... ...
Horton added that in the design review, the Navy takes a checks-and-balances approach to any changes, ensuring that a subject matter expert is involved in the process and has the final say on any configuration change. Counterfeit and Nonconforming Fasteners Johnson asked whether other industries have had experience with counterfeit bolting, and if the potential for counterfeit bolts to find their way into critical applications should be a concern for oil and gas.
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From page 112... ...
He emphasized that API works strenuously to ensure compliance, such as through noncompliance reporting requirements in every specification, noncompliance reporting systems within API, and the API quality Monogram program. To his knowledge, he added, counterfeit bolts have made their way into consumer products but not manufacturing.
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From page 113... ...
For example, side outlet valves on BOPs have eight critical bolts per flange. The bolts used in these applications are smaller and softer than most of the bolts discussed at the workshop, and they are very close to anodes for the CP system.
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