Competency Assessment For Upstream Oil and Gas Pipeline Installation Inspectors

GUIDE
Competency Assessment for Upstream Oil and Gas Pipeline Installation Inspectors
September 2009
2009-0005
The Canadian Association of Petroleum Producers (CAPP) represents companies, large and small, that explore for, develop and produce natural gas and crude oil throughout Canada. CAPPs member companies produce about 90 per cent of Canadas natural gas and crude oil. CAPP's associate members provide a wide range of services that support the upstream crude oil and natural gas industry. Together CAPP's members and associate members are an important part of a $110-billion-a-year national industry that provides essential energy products. CAPPs mission is to enhance the economic sustainability of the Canadian upstream petroleum industry in a safe and environmentally and socially responsible manner, through constructive engagement and communication with governments, the public and stakeholders in the communities in which we operate.
Review by April 2014

Disclaimer This publication was prepared for the Canadian Association of Petroleum Producers (CAPP). While it is believed that the information contained herein is reliable under the conditions and subject to the limitations set out, CAPP does not guarantee its accuracy. The use of this report or any information contained will be at the users sole risk, regardless of any fault or negligence of CAPP or its co-funders.
2100, 350 7 Avenue S.W. Calgary, Alberta Canada T2P 3N9 Tel (403) 267-1100 Fax (403) 261-4622
403, 235 Water Street St. Johns, Newfoundland and Labrador Canada A1C 1B6 Tel (709) 724-4200 Fax (709) 724-4225
www.capp.ca communication@capp.ca
Contents
1 2 3 4 Project Scope................................................................................................................2 1.1 Definitions........................................................................................................2 Pipeline Installation Inspector Roles and Responsibilities........................................3 Qualification .................................................................................................................4 Areas of Knowledge, Skill and Competency .............................................................4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 General Pipeline Construction Overview.......................................................4 Quality Concepts for Pipeline Construction ..................................................5 Overview of Relationships Between Codes and Jurisdictional Requirements ...................................................................................................6 CSA Z662.........................................................................................................8 Owner Specifications, Drawing Interpretation & Management of Change (MOC) ..............................................................................................................9 Pipeline Safety ...............................................................................................10 Welding/Joining and Non-Destructive Testing (NDT) ...............................11 Materials: CSA Z245, API, ANSI ................................................................11 Environmental Considerations and Regulations..........................................12 Surface Rights and Reclamation...................................................................13 Crossings: Road, Highway, Railway, Water, Pipeline, Foreign Line, Heavy Equipment ..........................................................................................14 Accountability and Liability .........................................................................15 Soft Skills .......................................................................................................16 CSA B51 (ASME B31.3) ..............................................................................18 Facilities Additional Requirements ..............................................................19
September 2009
Project Scope This Guide to Competency Assessment for Upstream Oil and Gas Pipeline Installation Inspectors (Guide) is intended as a management tool for owners and constructors of pipelines, to ensure installation inspectors employed have the technical knowledge and competence to ensure new installations fully satisfy their requirements and expectations. This document provides guidance for the assessment and verification of pipeline installation inspectors knowledge and competence within the scope of application of the CSA Z662 Code for Oil and Gas Pipeline Systems. (CSA Z662) The focus of this document is pipeline installations in upstream, and midstream oil and gas production 12 diameter. Future revisions may include pipelines >12 diameter, offshore pipelines, oilfield steam distribution pipelines and gas distribution pipelines, however they are not at included in the scope of this Guide. Installation of pipeline surface facilities has been included to ensure the inspector is generally aware of the differences in requirements. This will allow the inspector to decide whether additional inspection resources are required to ensure compliance in these associated facilities. Please refer to CSA Z662 for further information. 1.1 Definitions Competence The ability to do something well, measured against a standard, relative to a specific job using his/her skills, knowledge, abilities, and qualifications. Competent A person who has the skills, knowledge, and training to consistently perform specific work activities according to predefined standards; the ability to apply skills, knowledge, and training in a specific working environment. Examination Quality control functions performed by the manufacturer, fabricator, or installer. As referenced in this document examiner is the person(s) who performs quality control examinations. Owner Owner includes a lessee, a person in charge, person who has care and control and a person who holds out that the person has the powers and authority of ownership or who for the time being exercises the powers and authority of ownership. (Alberta Safety Codes Act)
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Pipeline (see CSA Z662) Those items through which oil or gas industry fluids are conveyed, including pipe components, and any appurtenances attached thereto, up to and including the isolating valves used at stations and other facilities. Upstream Pipeline Installation Inspector Inspector is the person(s) who oversees all aspects of pipeline construction and pipeline facilities construction on behalf of the owner. The inspector should be trained and competent in the acts, codes, regulations, specifications and standards applicable to the engineered design. 2 Pipeline Installation Inspector Roles and Responsibilities The primary role of the pipeline installation inspector is to act within their assigned scope, as the owners representative to verify or ensure that the requirements as specified in the engineering design have been fully satisfied. Their responsibilities include: i) ii) iii) iv) v) vi) vii) viii) ix) Ensure that engineering and design is complete and available for review prior to construction. Ensure safe work practices are followed as outlined by Occupational Health and Safety. Create or verify documentation adequate for compliance with regulatory and engineering design requirements. Ensure corporate cost control measures are adhered to. Adhere to ground disturbance requirements. Ensure Corporate Material Receiving, identification, traceability and storage practices are adhered to. Inspect field fabrication to ensure compliance to design specifications, codes and standards (e.g. B31.3, CSA Z662). Liaise between design engineer and project engineer to ensure inspection work is completed as planned. Ensure that individuals involved with special processes such as welding, heat treatment and non-destructive testing (NDT) are qualified and certified in accordance with the requirements. Document certification and qualifications of personnel to verify demonstrated competency for all critical work. Review and evaluate contractors quality program to ensure compliance with owner requirements. Generate or ensure generation of nonconformance reports and assist in development of action plans to resolve. Monitor general awareness and compliance to Section 217.1 of the Criminal Code (Bill C-45).
x) xi) xii) xiii)
September 2009
Qualification The owner should be able to demonstrate the qualification and competence of pipeline installation inspectors has been adequately verified and documented. There is currently no requirement for certification of pipeline installation inspectors. The onus is on the owner to evaluate and ensure the inspector is competent and has the knowledge to ensure all regulatory and integrity requirements have been satisfied. Pipeline installation inspectors may not require competence in all areas of pipeline installation. Inspectors may choose to specialize in one area of pipeline installation. Documentation should be maintained by the owner demonstrating verification of competency of the inspector for all areas where the inspector is employed.
Areas of Knowledge, Skill and Competency 4.1 General Pipeline Construction Overview The pipeline installation inspector should have skills and knowledge in all aspects of pipeline construction and regulations utilized in pipeline and pipeline facilities construction. This should include:
Licensing and notifications Ground Work: Ground Disturbance, Environmental Impacts, Timber Salvage, Grading, Topsoil Stripping, Ditching, Rock Trenching Pipe handling and Stringing, Pipe Bending, Pipe Coating, Pipe Laying Back Filling, Rock Shielding, Ditch Padding Pipe Supports/Anchors Crossings, Pipe Weight Installation, Horizontal Directional Drilling (HDD) requirements Tie-ins, Hot Taps and Cold Taps Block Valve Installation Pressure Testing and Test Mitigation Plan
September 2009
Joining/Welding, Welding Repairs Composite materials Management of Change (MOC) Orders, Quality Control/Quality Control Records, Non-Destructive Testing (NDT) Interpretation De-watering, Pigging Commissioning, turn over documentation, cleanup and fence repairs, erosion control, Cathodic Protection, pipeline markers, reclamation Drawing interpretation General content and scope of the Z-662 Code General understanding of jurisdictional and regulatory involvement Materials and basic design requirements and materials selection Materials identification Fabrication, Assembly and Installation

4.2
Quality Concepts for Pipeline Construction The pipeline installation inspector should understand, in general, the concepts of Quality Control and Quality Assurance (QA/QC). Outlined below are the basic elements of QA/QC: Definition of Quality: How to meet project requirements relating to federal, provincial and owner codes standards and specifications. i) Elements of Quality including but not limited to:

September 2009
Quality system (Quality Plan and Program) Contract Review Design Change Control Document and Data Control Purchasing Item Identification and Traceability Process Control (Welding, Coating)

ii)
Inspection and Testing Inspection, Measuring and Test Equipment (IM & TE) Control of Nonconforming Product Corrective and Preventive Action Handling, Storage and Preservation of Material and Equipment
Responsibilities for monitoring and verification Quality Records
iii) Review of Contractor Quality Program 4.3 Overview of Relationships Between Codes and Jurisdictional Requirements The inspector should be familiar with the regulatory and jurisdictional requirements utilized in pipeline and pipeline facilities systems construction. This will require an understanding of various regulatory instruments issued by the applicable regulatory authority such as: legislation, regulations, guidelines, Codes of Practice, Instructions, Information Letters, Information Bulletins, and Directives. Understanding the regulatory requirements is essential as they may supersede or supplement the applicable industry code of construction requirements (e.g. CSA Z662). The inspector should be competent and have knowledge to fulfill the following responsibilities:
Determine the applicable regulatory authority Identify pertinent regulatory documents applicable to their scope of responsibility Identify and ensure pertinent regulatory approvals are in place Understand notification or hold point requirements Understand documentation, record keeping, reporting and retention requirements Determine documentation required to be submitted for regulatory authorization/approval Identify where regulatory requirements may supersede or supplement industry code of construction requirements
September 2009
Understand incident and failure reporting requirements Understand any local/municipal requirements
The inspector should be familiar with regulatory requirements based on the location of the pipeline being installed. This may include:
Canada and Offshore: National Energy Board (NEB) Alberta: Energy Resources Conservation Board (ERCB) British Columbia: Oil and Gas Commission (BC OGC) Saskatchewan: Minister of Energy and Resources (MER) Ontario: Technical Standards and Safety Authority (TSSA) Local Municipal Bylaws
The types of activities that may trigger regulatory requirements that the pipeline installation inspector should be aware of includes:
Permits to construct, license to operate Landowner notification and access, survey requirements Call before dig/line location training, certification, notification, procedures Water and road crossing restrictions Environmental restrictions and approvals Requirements for pressure testing (approvals, acceptable test fluids, disposal of test fluids, test pressures, records, charts, documentation) Non-destructive testing (NDT) additional requirements for visual examinations, test methods, test frequencies, acceptance requirements In-line inspection (ILI) tools notification, approvals Crossing of other pipelines, utilities (3rd party crossings) notification, inspection, documentation
September 2009

4.4 CSA Z662
Depth of cover requirements Pipeline marking and signage requirements
The inspector should have a general understanding of the entire CSA Z662 standard and the ability to navigate and locate any and all required information encompassed within the standard. Following are sections of direct importance to upstream oil and gas: A general understanding of: 1. Reference Publications (Clause 2) 2. Gas Distribution Systems (Clause 12) 3. Aluminum Piping (Clause 15) A detailed understanding of: 1. Design (Clause 4) 2. Materials (Clause 5) 3. Corrosion Control (Clause 9) 4. Operating, Maintenance and Upgrading (Clause 10) 5. Applicable sections of Annexes A comprehensive understanding of: 1. Scope (Clause 1) 2. Definitions (Clause 3) 3. Installation (Clause 6) 4. Joining (Clause 7) 5. Pressure Testing (Clause 8) 6. Plastic Pipelines (Clause 13) 7. Oilfield Steam Distribution Lines (Clause 14) *I MPORTANT: The above categorizations are not for the full scope of industries covered by the CSA Z-662 specification, but are for upstream oil & gas only. For applications outside of the upstream industry the categories may be very different.
September 2009
4.5
Owner Specifications, Drawing Interpretation & Management of Change (MOC) Inspectors should understand the application of owner specifications, including:
Purpose and need for owner specifications How to access specifications for project or work Specification revisions and updates Relationship between specifications, codes and jurisdictional authority Interpret and locate specifications on drawings, e.g.: vendor drawings, plot plans, tie-in and line lists, piping plans, flow diagrams Relationship between specifications, standards and best practices Specifications, management of change, change orders, revision control
1) Inspector should have a working knowledge of pipeline and pipeline facilities construction drawings. This will include the following drawing types: 1. Topographical 2. Facility plot plan and elevation drawings 3. Typical excavation detail drawings including basic pipeline anchor and support details, various creek and road crossing details and cathodic protection 4. Civil engineering drawings 5. Pipeline construction alignment drawings (construction plan/survey drawing) 6. Legal land site descriptions 7. Piping isometric and orthographic 8. Pipeline system maps 9. Process flow and Process & Instrumentation Diagrams (P & ID) 10. Detail construction and welded steel construction. 11. Welding and NDT symbols
September 2009
12. Basic electrical and instrumentation drawings The inspector should also have a general understanding of related activities such as surveying and line location. 4.6 Pipeline Safety The inspector should have a thorough knowledge of appropriate safety practices and requirements applicable to the construction of pipelines, including:
Work preparation Personal Protective Equipment (PPE) Workplace Hazardous Material Information System (WHMIS) Hazard recognition and control Front end operational hazards and controls Rigging and hoisting hazards and controls Pipe hazards and controls Pipe assembly and coating hazards and controls Specialized work hazards and controls Environmental hazards and controls Back end operational hazards and controls Vehicle operation Equipment operation and inspections Emergency response Medical service requirements Hazards related to Cathodic Protection
September 2009
10
4.7
Welding/Joining and Non-Destructive Testing (NDT) The pipeline installation inspector should understand, in general, the various welding processes utilized in pipeline and facilities construction. The pipeline installation inspector should understand the various factors that affect weld quality and the inspection and test methods used to ensure and verify acceptable weld quality. In general this will include:

4.8
Detailed knowledge of CSA Z662 Joining Clause (Clause 7) Overview of welding processes (including special processes used in pipeline construction. Basic welding metallurgy (new material/in-service materials/tie-points. Welding consumables including filler metals, fluxes, shielding gases Welding procedure specifications and qualification testing Closure weld procedures Welder Qualification Testing Practical considerations for welding in the field Weld faults and acceptance criteria Repair welding In-service maintenance welding, repair and Hot Taps Joining non-metals (mechanical/bonding) Basic NDT for welds - Visual Test (VT) , Radiographic Test (RT) , Ultrasonic Test (UT), Magnetic Particle Test (MT)
Materials: CSA Z245, API, ANSI The pipeline installation inspector should understand, in general, the various codes and standards utilized in material selection for pipeline and facilities construction.
Definitions of pipe manufacture (e.g. electric and submerged arc welded, seamless) Definitions of fitting/valve manufacture methods (e.g. forging, casting)
September 2009
11
Definitions of different organizations, including: i) Canadian Standards Association (CSA) ii) American Petroleum Institute (API) iii) ASTM International iv) American Society of Mechanical Engineers (ASME) v) Manufacturers Standardization Society (MSS) vi) American National Standards Institute (ANSI)
Definitions of testing terminology (tensile strength, yield strength stress/strain, absorbed energy impact test, drop weight tear test fracture appearance, ductility and hardness) Definitions of heat treatment (stress relief, annealing, normalizing) Material and equipment pressure ratings Material and equipment derating for temperature stress level limitations (for sour service) Deviations for materials not addressed in Z662 (sufficient technical information and acceptance) Understanding of required markings Sour service and NACE MR0175/ISO15156 Material Test 6 Reports (dual certification) CSA/ASME Requirements for gaskets and bolting (bolt-up procedures) Fibre-reinforced composite pipe and fittings (manufactured and tested to API 15HR) Effect of alloying agents on manufacture of steel (carbon, manganese, CE and effect on weldability)

4.9
Environmental Considerations and Regulations The pipeline installation inspector should, in general, to able to discuss and manage the various environmental regulations and considerations for pipeline and facilities construction. In general this will include:
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4.10
Spill control/clean up/containment Waste disposal Product, chemical and waste storage Appropriate vegetation management and surface water run-off management Compliance with atmospheric emissions policy and regulations Relevant provincial legislation, national and international legislation dealing with the environment Communication with regulatory agencies and government officials on environment issues Compliance with legislated testing and reporting of environmental issues Applicable enforcement actions (or applicable regulatory body, e.g. Alberta Environment or ERCB) Site-specific environmental issues. Inform residents on environmental issues Procedures necessary to deal with environmental incidents and the people that need to be contacted Approvals and licenses required to operate and the responsibilities that go along with the licenses Communication with the owners environmental group
Surface Rights and Reclamation The inspector should have an overall understanding of the land ownership and usage rights of all stakeholders. The inspector should also interface with some or all of the stakeholders and demonstrate due diligence in minimizing adverse impacts to the landowners and users. The inspector should be aware of the following:

September 2009
Land ownership (crown owned, privately owned/leased, aboriginal) Know the stakeholders
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4.11
Land and environment representative(s) Local and municipal regulations/approvals (development permits, road use, borrow pits, signage, stakeholder approvals) Required permits/licenses and issue agencies for the related work e.g. permit to construct Environmental guidelines, procedures and contacts Public consultation practices Clearing and timber salvage requirements Stripping and top soil handling Right Of Way (ROW) work space and extra work space Water draw and disposal locations/requirements
Crossings: Road, Highway, Railway, Water, Pipeline, Foreign Line, Heavy Equipment The pipeline installation inspector should be knowledgeable and have a thorough understanding of all applicable company specifications and provincial/federal acts, codes, regulations and standards when supervising pipeline installations in the vicinity of and or underneath roads, highways, railways, and foreign lines/utilities. The pipeline installation inspector should be able to interpret the following sections of applicable codes and standards:
Public safety Ground disturbance Crossing/proximity/tie-in agreement Emergency shut-down devices Pipeline identification and marking Weld procedures Mandatory non-destructive testing
September 2009
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4.12
Code requirements for record keeping applicable to pipeline systems Material test reports Valve requirements Valve location and spacing Erosion control on roadways Waterway and ditch erosion control Slope gradients for fine, medium and coarse textured soils Soil stability and wind erosion Unstable slopes Private/Public utility crossing Bored crossings Open cut crossings Crossings of navigable waterways Arial crossings Cased road and railway crossings Uncased road and railway crossings Clean up and restoration Cathodic protection
Accountability and Liability The pipeline installation inspector should have a good understanding of the areas of general accountability and liability as they apply to the inspection of pipeline installation. These should include:
Definition of Accountability (see Section 217.1 of the Criminal Code, Bill C-45)
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15
Understanding elements of negligence: a. Duty i. Should meet a standard of care (act as a reasonable person would act or, in the case of expertise, must act as a reasonable competent person would act) ii. Foreseeable plaintiffs (who there is or who there could be) iii. Types of duty (voluntary, involuntary imposed by law) iv. Special duty b. Breach of Duty i. Failure to meet the standard of care ii. Failure to perform or act c. Cause (direct or indirect) d. Damages
Avoidance of Personal Liability: e. Act in the publics best interest f. Adhere to adopted codes, standards and specifications g. Act in a non-discriminatory manner h. Professional and business-like conduct i. Document j. Conduct follow-up inspections as required k. Send decisions to a higher level (deviations from established (design) codes and policies)
4.13
Soft Skills The pipeline installation inspector be able to demonstrate the soft skills outlined below: i) Communications
Effective writing skills Effective interpersonal communications
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Open and timely communication (who should be told when) Interpretation of an organizational chart Identification and communication with all stakeholders (residents organizations, local media, appointed and elected government representatives, others) Reading skills and comprehension using the English language Meeting management Teamwork Effective interpersonal problem resolution

September 2009
ii) Computer Skills Basic computer literacy Basic word processing skills Send and receive e-mail Basic spreadsheet skills Use of a digital camera Proficiency with using the internet
iii) Management and Administration Description and application of risk assessment procedures Ability to prioritize tasks Understanding of company structure Track purchasing activities Liaise with trucking companies, other plants and operations Supervision of other employees Liaise with safety department Adherence to owners purchasing requirements
17
Application of Cost Control measures in the work facility Personal and work area time management (Planning and Scheduling) techniques Manual and electronic filing Identify and report all incidents and near misses, hazard identification Knowledge of Safe Operating Practices Recognize and report regulation violation or reportable incident Read and interpret a Legal Subdivision (LSD) map and a survey mapping system
iv) Community Relations
4.14
Effective public community relations
CSA B51 (ASME B31.3) The inspector should have a general understanding of the CSA B51 Boiler, Pressure Vessel and Pressure Piping Code and the ASME Code B31.3 for Process Piping. Of particular importance is how the inspection and testing requirements from each code are applied to pipelines. The inspector should have general knowledge of:
CSA Z662 provisions for the application of the B51 and B31.3 Codes General content and scope of the CSA B51 and ASME B31.3 Codes General understanding of typical jurisdictional relationships, involvement with process piping and documentation requirements Definitions of B31.3 fluid services and how this relates to the materials and basic design requirements and materials selection Basic design and materials overview should include overview of stress tables, requirements for typical materials used Materials identification
September 2009
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4.15
Detailed understanding of fabrication, assembly and erection requirements Detailed understanding of inspection, examination and testing requirements
Facilities Additional Requirements The pipeline installation inspector should be generally aware of the different requirements for pipeline associated surface facilities. This will allow the inspector to determine whether additional inspection resources are required to ensure compliance (refer to CSA Z662 Clause 1). The inspector should understand the types of facilities: well site type facilities compressors stations, dehydration, separator packages, meter skids - and the need to define jurisdictional and code boundaries/specification break. Knowledge should include:
Pressure Equipment Safety Legislation overview: i. CSA B51 ii. Provincial legislation and regulations for Boilers and Pressure Vessels iii. ASME Boiler, Pressure Vessel and Piping Codes
Authorized Inspector (a person appointed by the Provincial Regulator to administer the provincial legislation and regulations) Quality Control Program Requirements Management of Change Pressure Vessel Installation Inspections Tank codes and regulations Pressure Safety Devices Pre-commissioning and Commissioning Jurisdictional documentation requirements
September 2009
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GUIDE

Review by April 2014

x) xi) xii) xiii)

Responsibilities for monitoring and verification Quality Records

Depth of cover requirements Pipeline marking and signage requirements

Effective writing skills Effective interpersonal communications

iv) Community Relations

Effective public community relations

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