12 ways the oil and gas sector makes quality work

There is a reason quality standards are so important in the dynamic and complex environment of the oil and gas industry: the consequences of getting things wrong are enormous. Personal safety, environmental protection, profitability and efficiency all pivot around the implementation of an effective quality assurance or quality control management system. Here, we take look at some of the best practices that keep the energy flowing in this vital industry.

Training and skills

Investing in the skills and competence of a workforce through continuous training is of paramount importance. People are at the heart of this industry and they must be equipped with the knowledge and skills to handle complex processes and equipment.

Activities such as welding, brazing and non-destructive testing are critical, as is knowledge of pressure equipment and corrosion. Those undertaking work in these areas should hold the relevant quality assurance and control certifications from one of the various organisations that issue relevant quality assurance and control certifications.

This is a dynamic, fast-paced industry, so it is important to keep abreast of the latest technical developments.

Regulatory compliance and standards

Quality is built on standards, nowhere more so than in the oil and gas sector. Organisations must keep up to date with regulations imposed by bodies such as the American Society of Mechanical Engineers, the American Petroleum Institute and ISO. Compliance ensures not only legal standing, but also a commitment to the highest standards of quality.

Robust information and data management

To achieve the highest standards of quality in the oil and gas sector, organisations must excel at record keeping – maintaining meticulous records of processes, inspections, and maintenance activities. Such data provides valuable insights into the performance of equipment and processes, enabling proactive measures to prevent problems from arising in the first place.

There are many great tools out there to help with this essential element, including Microsoft’s Power BI and other power apps.

By transforming information into performance metrics, and measuring these against meaningful key performance indicators, insights can be gained into the effectiveness of quality management practices, and areas for improvement can be identified.

"Engage and empower employees and you will get a more open style of communication, encourage new ideas, and create a unified approach to maintaining quality."

Govind Tiwari CQI MCQI

Implement a quality management system

A well-structured quality management system, such as ISO 9001, is the key to maintaining consistency and excellence in operations. It pulls together everything we have talked about so far: it can streamline processes, monitor performance, and ensure compliance with industry standards, as well as help with continuous improvement.

Other examples include:

• ISO 29001:2020 Petroleum, petrochemical and natural gas industries – this is a specific quality management system for the oil and gas industry that clearly states additional requirements that can be considered best practice for oil and gas organisations.
• API Spec Q2 – introduced by the American Petroleum Institute, this provides a standardised approach to quality management in service supply organisations for the petroleum and natural gas industries. Certification signifies a commitment to quality, risk management, and continual improvement.
• API Spec Q1 – a quality management standard for product manufacturers, geared towards the oil and gas industry. It meets many of the ISO 9001 requirements, plus additional elements deemed valuable to the oil and natural gas industry.

Supply chain management

Quality goes beyond one single organisation, so it is important to work with suppliers to establish stringent quality standards for the entire supply chain, too. This involves thorough vendor assessments, quality audits, reviews of supplier performance, and continuous communication.

Continuous improvement

Improving quality is not a one-off exercise; it is a part of everyday operations. Kaizen, the philosophy of continuous improvement, is fundamental to operational excellence. By encouraging employees at all levels to embrace change and implement improvements, an organisation can become more dynamic – able to adapt to the road ahead.

Regular reviews and feedback help, as do approaches such as the Gemba walk and idea-development dashboards.

Managing risks

Risk can never be completely eliminated, but it can be managed. There are many ways of doing this that are interrelated parts of quality management.

Risk management provides the framework for oil and gas organisations: process and principles that help with economic resilience, environmental and safety outcomes, and professional reputation.

Lessons learned help identify and register the experience gained during various operations and projects, preventing organisations from repeating the mistakes of the past.

Benchmarking, both internal and external, is imperative and an absolute foundation of any quality management system.

Preservation and Built

The oil and gas sector exists in a highly complex environment, carrying out high-risk operations. A preservation programme is the cornerstone of a smooth start-up of projects and for their completion.

It is one of the key components of a quality and flawless execution programme, which aims to deliver uninterrupted start-up for successful project completion. Failure to stick to a robust preservation programme can result in the repurchasing of equipment or materials, construction repeats, and delays in starting up.

A build it clean programme ensures all waste and debris is removed from process equipment and piping before closure, to minimise the cost of commissioning new infrastructure. All systems should be handed over to stakeholders as ‘clean’ as possible for smooth completion and start-up.

Inspecting and assessing

Preventive maintenance and routine equipment inspections are non-negotiable in the oil and gas industry. The condition of machinery, pipelines and other assets is regularly assessed to prevent potential issues before they escalate. Addressing maintenance needs promptly can prevent costly downtime and safety hazards.

Investigating incidents

It is important to get the views and assessment of an auditor from outside the company, for a new, different perspective. These professionals can identify areas where improvements are needed, helping compliance with industry standards and regulations. Such insights are invaluable for maintaining quality control and can give organisations a competitive advantage.

When things do go wrong, it is important to investigate and establish why. Using root-cause analysis and other quality tools, it is often possible to get to the bottom of things and make sure problems do not happen again. A methodical approach allows the source of the problem to be addressed, not just the symptoms.

Embrace technology

Leveraging technology and automation will enhance the accuracy and efficiency of your quality management systems. Implementing such as Quality 4.0, data analytics, IoT sensors, Microsoft’s Power BI, and predictive maintenance tools can help to manage a quality management system, and monitor equipment health in real-time. They will also help to improve and enhance productivity and efficiency of processes.

Collaboration

Quality management is not the sole responsibility of a single quality department. Foster a culture of quality by collaborating across departments, sharing responsibility, and listening to input from all parts of an organisation.

Engage and empower employees and you will get a more open style of communication, encourage new ideas, and create a unified approach to maintaining quality.