2012 Standards ConferenceSC18 Committee on Quality Standards
Westminster, COJune 14, 2012
API Monogram ProgramStatus Report
W. Don WhittakerManagerMonogram Program/[email protected]
Aaron DukeCertification & Audit Program DevelopmentMonogram Program/[email protected]
API Monogram/APIQRProgram Status Report
1. Monogram Program Statistics2. Audit Program3. Monogram Standards Update4. Fraud & Product Complaints5. API Conference & Expo – Beijing - 2013
2003
2004
2005
2006
2007
2008
2009
2010
2011
YTD0
1000
2000
3000
4000
3546
1093
API Monogram Licensees APIQR Certified Companies
API Monogram/APIQR Certified Companies
5-12
3812 Active Certified Companies.
3546 Licensed Companies.1093 Companies Certified with APIQR.
827 Companies With Both. 5-12
API Monogram Licensed CompaniesTop Countries
1. China – 14412. USA – 5903. India – 2134. S. Korea – 1335. Canada – 986. Italy – 927. UK – 718. UAE – 669. Indonesia – 6210. Japan – 5211. Germany – 5012. Mexico – 4013. Malaysia – 3914. Singapore – 3615. Brazil – 33 3546 Licensees. 77 Countries.
Asia PacificNorth AmericaEuropeSouth AsiaSE AsiaMiddle EastSouth AmericaAfricaAustralasiaCentral Asia
5-12
API Monogram LicensesTop Countries
1. China – 22492. USA – 8853. India – 4034. Italy – 2005. S. Korea – 1886. UAE –1647. Canada – 1528. Indonesia – 1109. UK – 10610. Germany – 9911. Japan – 9012. Singapore – 8913. Mexico – 6914. France – 6415. Malaysia – 63
5859 Licenses.
Asia PacificNorth AmericaEuropeSouth AsiaMiddle EastSE AsiaSouth AmericaAfricaAustralasiaCentral Asia
5-12
Top Specifications
API-5CT
API-6D
API-6A
API-5L
API-7-1
API-7K
API-16A
API-5DP
API-4F
API-16C
0
200
400
600
800
1000
5-12
Top Licensed Products
5-12
API-6D Ball Valves 638 API-5L PSL 1 Line Pipe 552 API-5CT Threader 528 API-6D Gate Valves 486 API-6D Check Valves 483 API-7-1 Threading 475 API-6A Flanges 468 API-5L PSL 2 Line Pipe 452 API-6A Valves 429 API-6A Tees and Crosses 385
APIQR ISO 9001 Certified CompaniesTop Countries
1. China – 2742. USA – 2663. Canada – 574. India – 455. Indonesia – 346. S. Korea – 327. UAE – 258. Singapore – 249. Mexico – 2210. Russia – 2111. UK – 1712. S. Arabia – 1513. Venezuela – 1314. Egypt – 1215. Italy – 11 1037 Companies. 63 Countries.
North AmericaAsia PacificEuropeSE AsiaMiddle EastSouth AsiaSouth AmericaAfricaCentral AsiaAustralasia
5-12
APIQR API Spec Q1 Certified CompaniesTop Countries
1. China – 2792. USA – 2543. Canada – 514. India – 465. Indonesia – 336. S. Korea – 337. Singapore – 268. UAE – 259. Russia – 1910. Mexico – 1811. UK – 1712. Egypt – 1413. S. Arabia – 1414. Turkey – 1115. Italy – 11
1023 Companies. 64 Countries.
North AmericaAsia PacificEuropeSE AsiaMiddle EastSouth AsiaSouth AmericaAfricaCentral AsiaAustralasia
5-12
API Monogram ApplicationsTop Countries
1. China – 2942. USA – 903. India – 484. Indonesia – 365. Italy – 306. S. Korea – 227. UAE – 198. UK – 199. Canada – 1810. Singapore – 1711. Germany – 1112. S. Arabia – 1113. Turkey – 1014. Mexico – 1015. Russia – 8
737 Applications at 516 Companies.
Asia PacificNorth AmericaEuropeSE AsiaSouth AsiaMiddle EastSouth AmericaAfricaAustralasiaCentral Asia
5-12
APIQR ISO 9001 ApplicationsTop Countries
1. China – 712. USA – 623. Canada – 174. Russia – 95. Malaysia – 76. Australia – 67. Singapore – 68. UK – 69. India – 510. Mexico – 511. Italy – 412. Romania – 313. S. Korea – 314. Spain – 315. UAE – 3
242 Applications.
North AmericaAsia PacificEuropeSE AsiaAustralasiaMiddle EastSouth AsiaAfricaSouth AmericaCentral Asia
5-12
APIQR API Spec Q1 Applications
257 Applications.
North AmericaAsia PacificEuropeSE AsiaAustralasiaMiddle EastSouth AsiaAfricaSouth AmericaCentral Asia
Top Countries
1. China – 732. USA – 623. Canada – 174. Russia – 105. Australia – 96. Singapore – 87. Malaysia – 78. UK – 69. India – 510. Mexico – 511. Italy – 412. UAE – 413. Romania – 314. S. Korea – 315. Spain – 3 5-12
API-6D
API-6A
API-5L
API-5CT
API-7-1
API-4F
API-7K
API-5DP
API-8C
Other
0
50
100
150
200
250
300
350
400
Frequency
Freq
uenc
y (C
ount
)
Audit Nonconformities by Specification
7.5 8.2 7.4 4.2 7.6 7.3 6.2 7.1Othe
r0
200
400
600
800
1000
1200
1400
1600
Frequency
Freq
uenc
y (C
ount
)
Audit Nonconformities by Clause
2012 Standards ConferenceSC18 Committee on Quality Standards
Westminster, COJune 14, 2012
Audit ProgramStatus Report
Aaron DukeCertification & Audit Program DevelopmentMonogram Program/[email protected]
41%
42%
14%2%
MonogramDualRegistrationOther
1045 Audits Performed
Audits by Program: Monogram Only – 433 Dual – 444 Registration – 144 Other – 24
Audits by Country: China – 320 (30%) USA – 228 (22%) India – 54 (5%) Canada – 44 (4%)
2012 To DateTotal Certification Program Audits
5-12
API Monogram Audits by Type
Initial Renewal Re-Audit Other0
50
100
150
200
250
300
93
274
42 24
5-12
Dual (API Monogram/APIQR) Audits by Type
Initial Surveillance Recertifica-tion
Re-Audit0
50
100
150
200
250
300
108
247
67
16
5-12
APIQR Registration Audits by Type
Initial Surveillance Recertifica-tion
Re-Audit0
1020304050607080
53
72
136
5-12
First 6 Months Previous 12 Month Period (June-June)0
250500750
1000125015001750200022502500275030003250
2009201020112012
2009 – 2012 Audits Performed Historical Comparisons
6-12
Registration-Recerts
Dual Surveillance-Recerts
Monogram Renewals
0 100 200 300 400 500 600 700 800 900
Complete
Scheduled for June Completion
To Schedule
2012 Audits Due – Status
5-12
2006 2007 2008 2009 2010 2011 2012 20130
500
1000
1500
2000
2500
3000
3500
3535 3780
1620
15351230 1445
570675
Total Audits
Linear (Total Audits)
Monogram
Dual
Registrations
2012 - 2013 Audits Due
5/23/12
Active API Monogram/APIQR Auditors
2005
2006
2007
2008
2009
2010
2011
2012
0
20
40
60
80
100
120
140
160
143 Active Auditors• 138 QMS-Monogram• 20 Auditors in training• 16 EMS-OHSAS• 11TPCP• 15 Perforator Witness
5/23/12
Auditors Auditor Training Session – Singapore – February 2012 19 Auditor Observations Due in 2012 2012 Auditor Summit – Sanya, China – November 12-15, 2012 2013 Auditor Summit – Phoenix, Arizona – February 18-21, 2013 API Spec Q2 – training & resource planning Continue to develop resources in key areas
Working to foster relationships with sub-contract providers USA, Central Asia, Japan
Audits More audit questions and tools – all priority specs done end 2012 Develop better technical audit & training tools for auditors New myCerts audit module implemented Q4 2012
Audit Program
5/23/12
New / Revised SpecificationsAPI Spec Q1
Quality Programs for the Petroleum, Petrochemical and Natural Gas Industry, 9th Edition
Effective TBD
API Spec 2C Specification for Pedestal Mounted Cranes, 7th Edition Published March 2012-Effective September 2012
API Spec 5CT Casing and Tubing, 9th Edition Published July 2011-Effective Jan 2012
New / Revised SpecificationsAPI Spec 6AV1
Verification Test of Wellhead Surface Safety Valves and Underwater Safety Valves for Offshore Service, 2nd Edition
Effective TBD
API Spec 8C Specification for Drilling and Production Hoisting
Equipment (PSL 1 and PSL 2), 5th Edition Published April 2012-Effective October 2012
API Spec 11AX Subsurface Sucker Rod Pumps & Fittings, 13th Edition Effective Fourth Quarter 2012/First Quarter 2013
New / Revised SpecificationsAPI Spec 11E
Pumping Units, 19th Edition Effective Fourth Quarter 2012/First Quarter 2013
API Spec 17E Subsea Umbilicals, 5th Edition Effective TBD
API Spec 20A Carbon Steel, Alloy Steel, Stainless Steel and Nickel Base
Alloy Castings for use in the Petroleum and Natural Gas Industry, 1st Edition
Published March 2012
11IW Specification Withdrawn Document will no longer be considered as active and maintained within
the API Standards document list, but will remain as historical document Ballot concluded May 3rd 2012 11IW licenses to be withdrawn on November 3rd, 2012
11V1 – 19G1-G2 Transition 19G1 / 19G2 initial / transition audits still underway 4 facilities transitioned / 6 audited and under review / 6 facilities have not
completed transition request Transition period ends July 1, 2012 – 11V1 licenses to be withdrawn
on July 1, 2012
Program Updates
Program Updates
• myCerts 2 • Q2• Application process /content changes• Quality manuals• Audit reports• Composite list upgrade
Fraud and Complaints Overview
Number of Fraud Cases
2009 2010 2011 2012 Total0
10
20
30
40
50
60
70
80
32
1916
12
79
0 3 4 613
32
2220 18
74
No. of closed cases No. of open cases Total no. of cases
39
22
9
4
4
32
21 1 1 1 1 1
China-39 USA-22India-9UK-4Canada-4Singapore-3 Spain-2 Egypt-2Kazakhstan-1South Africa-1Indonesia-1Colombia-1Thailand-1UAE-1
Fraud Distribution 2009-2012
Actions Taken
74
7
7
132
Resolved
Still Open
Withdrawn Applications
Listed as Non-licensed org. in the composite list
Cancelled/Suspended
2012 Recent Product Complaints API Spec 6D Ball Valves with multiple leaks discovered after gas
commissioning. Product inspection demonstrated that the Valves were not fitted with internal sealant injection fittings.
API Spec 5CT Pipe delivered with clear nonconformities identified in Mill Cert. Pipe tested and several defects found throughout pipe length (butt welds, jointers, cross welds, pipe length) When welding procedures were requested by client, they received no response.
Periodic audits
Major Complaint
Tests performed to assess mechanical integrity yielded that in addition to poor finish, the impact strength of Pipe was far below requirements.
Periodic Audit
API Spec 5L Pipe delivered with major signs of corrosion and rust which raised questions regarding quality of product . During the cleaning of corrosion, pieces of metal broke off from inner pipe surface.
Corroded metal piece
Major Complaint API Spec 8A/8C/4F Facility with multiple complaints. One end user
received 4F Mast which shipped with structural damage. Records were requested regarding structural and mechanical integrity of 4F Mast, API Licensee refused to release documentation.
One end user received 8A Bails that became bent in the field.
Periodic audit
Pad eye damage
2012 Periodic Audit Outcomes
Two Facilities cancelled
Two 4F Facilities approached consultants affiliated with Monogram Program to provide designs and engineering for 4F products. Consultants alerted API that the facilities do not have capability nor equipment to test or assemble. One audit so far performed with early recommendation from auditor of immediate cancellation.
Potential client of 16A licensee performed an Audit as part of a purchase agreement, discovered evidence that licensee did not have minimum capability to Design, Weld, and Heat Treat 16A products. API notified, periodic audit yielded credible evidence to substantiate complaint. License now suspended.
Beijing Exposition and Conference
Sept, 2013
Upstream Downstream
MeasurementTraining – Q1 and Q2
