Institute of Materials, Malaysia

Transcription

1 Institute of Materials, Malaysia M. Azmi M. Noor FIMM, AFiCHEME MIQA Forum, KGNS 17 th Mar, 2016

2 Content Preamble & Background of Welding Industry Welding Challenges in O&G industry Business Case for CWCS Industry initiatives AWF & IMM Objectives & Implementation of CWCS Moving Forward

3 PREAMBLE WELDING INDUSTRIES DIVIDED INTO:- 1. General Industries gates, fences, grills 2. Automotive Industries 3. Building & Construction Industries 4. Marine & Shipbuilding Industries 5. Manufacturing OEM Industries 6. Oil & Gas, Chemical & Energy Industries Certified Welders under (1) no need for qualification. Certified Welders under (2)-(6) must undergo qualification, re-qualification from project to project or change of Welding Code

4 NOSS & SKM NOSS : National Occupational Skills Standards under Ministry of Human Resources (MOHR) SKM : Sijil Kemahiran Malaysia based on NOSS Skills Certification issued by MOHR Welders qualified and certified by SKM only suitable for (1) General Industries but not for industries under categories (2) (6).

5 Welder Certification Welders in Industry Categories (2) (6) currently must undergo Qualification & Certification under following International Codes:- American Welding Society ( AWS ) American Society of Mechanical Engineers ( ASME ) American Petroleum Institute ( API ) British Standard ( BS ) European Standard ( EN ) German Standard ( DIN )

6 BUSINESS CASE WELDING CHALLENGES Current Training Centres Produce General Welders (SKM) - O&G Industry Have To Re-train & Re-Certify All Such Welders Extra Costs! Current Practice Welders Need To Re-certify & Re-qualify for every New Project and New Welding Code High Costs & Down-Time! Numerous Industry Failures attributed to Poor Welding No Current Mechanism to Monitor Quality (Performance) Of Certified Welders

7 BUSINESS CASE : Welder Re-Qualification Costs

8 BUSINESS CASE Consequential Costs Poor Quality Welds = Pipes & Structures Failures Welding Failures = Lost of Containment, Production Loss & Fire Total costs to Facility Owner = RM Billions Total mandays lost = Millions mandays BIG SAVINGS & HSE IMPROVEMENT IF CWCS IMPLEMENTED IN MALAYSIAN O&G INDUSTRY!

9 BUSINESS CASE WELDING SURVEY

10 BUSINESS CASE WELDING SURVEY

11 BUSINESS CASE Welding Quality Welder Performance Monitoring System & Database Certified & Qualified Welders can perform bad welds! Serious Need to emplace a Worker Performance Monitoring System to ensure poor quality welders are traceable and upskilled. Facility failures can be significantly reduced. Improved Safety, Health & Environment

12 Asian Welding Federation (AWF) Incorporated on 16 July 2004 in Osaka Non-profit Professional Society Promotion of a Common Welder Certification Scheme (CWCS) for Asia based on ISO international standard in Asia. Reduce Costs & Improve Welding Quality. Enable a more Level Playing Field for Asian & ASEAN welding practitioners against Western counterparts.

13 AWF membership Welding societies from 11 member nations Malaysia China India Indonesia Japan Korea Mongolia Myanmar Philippines Singapore Thailand

14 OBJECTIVES OF CWCS Migrate from western-dominated welding codes & standards to ISO (covers ASME, AWS, API, BS, etc) Reduce Costs of Re-Qualification & Re- Certification of Welders from Project-to-Project Ensure Welders are properly Trained & Certified to Correct Industry Standards & Codes Ensure Welders are Regularly Monitored on their Performance for better Quality Assurance

15 AWF-CWCS Requirements for Implementation Local Authority to establish Quality Management system Authorised Certification Body (ACB) Authorised Training Bodies (ATB) Authorised Testing Centres (ATC)

16 Authorised Certification Body (ACB) Each country member appointed 1 ACB Malaysian protem ACB was formed in 2011 Spear-headed by IMM Committee Members in ACB Representatives from Professional Societies (IMM, MWJS, etc) Representatives from Government Authorities (DOSH, CIDB, SIRIM, NIOSH, etc) Representatives from O & G Operators (PETRONAS, Shell, etc) Reps from O&G service providers Academicians

17 Authorised Certification Body (ACB) - Malaysia IMM established Malaysia Protem ACB in October 2011 Draft Quality Manual & ACB application submitted to AWF Secretariat in January 2012 Provisional approval as AWF ACB for Malaysia in May 2015 Propose CIDB to take over Role of MAS-ACB

18 CWCS Organisation Structure

19 AWF 10 YEARS ON SINCE 2015, AWF TECHNICAL COMMITTEES HAVE DEVELOPED NUMEROUS OPERATING PROCEDURES DOCUMENTS FOR THE IMPLEMENTATION OF THE AWF CWCS SINGAPORE 1 ST COUNTRY TO TRIAL THE AWF- CWCS IN PETROCHEMICAL INDUSTRIES MALAYSIA WILL BE 2 ND COUNTRY TO IMPLEMENT AWF-CWCS MALAYSIA IS THE FIRST ACB TO BE APPOINTED BY AWF.

20 MONITORING PERFORMANCE Manpower Optimization System (MOS) One stop storage and provider of skilled workers information e-system key modules Registration Test Results Assignment Worker Performance Monitoring Reporting & Billing

21 Manpower Optimisation System (MOS) Oversees Continuous Work Experience of Certified Welders Easily Accessible to Project Owners, Clients, Fabricators and Contractors Performance Records up-to-date Allows Welder to Maintain Certification without Re-qualification & Re-certification every New Project Enable Verification & Validation of Certificates

22 MOVING FORWARD Government Agency (CIDB?) to lead the MAS-ACB for transparency & credibility. CWCS will reduce Costs & Wastage in Re-qualification & Re-certification of Welders. Quick Implementation of CWCS will benefit the O&G Industry in Malaysia. O&G Operators (PETRONAS?) encouraged to Recognize a Common Standard in Welder Certification based on ISO MAS-ACB to develop a Malaysian-based Manpower Monitoring Software Program (MyMOS?) for Quality Assurance of welders and possibly all other skills.

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