Ndt Manual Revised 01 21-12-2013
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Vietnam Airlines Corporation VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL Manual Code: VAECO NDTM
Hanoi Main Facility: V48Y426B Noibai International Airport Tel: 84-4-38.84.32.90 Fax: 84-4-38.86.51.76 Sita: HANEEVN
Hochiminh City Satellite Facility: V48Z426B Tan Son Nhat International Airport Tel: Fax: Sita:
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 1 - GENERAL
PART 1
GENERAL
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 1-1
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 1 - GENERAL
1.1
TABLE OF CONTENTS
PART 1
GENERAL .......................................................................................................... 1-1
1.1 1.2 1.3 1.4 1.5 1.6 1.7
TABLE OF CONTENTS ..................................................................................... 1-2 RECORD OF REVISIONS ................................................................................. 1-3 SUMMARY OF AMENDMENT ........................................................................... 1-4 LIST OF EFFECTIVE PAGES ........................................................................... 1-5 DISTRIBUTION LIST ......................................................................................... 1-8 ABBREVIATION................................................................................................. 1-8 REVISION PROCEDURE .................................................................................. 1-9
PART 2
MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION ................... 2-1
2.1 2.2 2.3 2.4 2.5 2.6 2.7
GENERAL .......................................................................................................... 2-2 APPLICABLE NDT METHODS .......................................................................... 2-2 NDT FACILITIES ................................................................................................ 2-3 PRIVILEGES OF NDT STAFF ........................................................................... 2-6 REQUIREMENTS TO NDT PERSONNEL ......................................................... 2-8 QUALIFYING PROCEDURE FOR NDT PERSONNEL ..................................... 2-8 EQUIVALENT ASSESSMENT OF NDT EQUIPMENT AND MANUFACTURE STANDARD BLOCK .......................................................................................... 2-9
PART 3
WRITTEN PRACTICE ....................................................................................... 3-1
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8
SCOPE............................................................................................................... 3-2 NORMATIVE REFERENCES ............................................................................ 3-3 TERMS AND DEFINITIONS .............................................................................. 3-3 GENERAL REQUIREMENTS ............................................................................ 3-6 QUALIFICATION AND CERTIFICATION LEVELS ............................................ 3-9 TRAINING AND EXPERIENCE ....................................................................... 3-11 EXAMINATIONS .............................................................................................. 3-14 CERTIFICATION .............................................................................................. 3-18
PART 4
NDT SPECIFIC PROCEDURES & WRITTEN INSTRUCTIONS ....................... 4-1
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9
EDDY CURRENT INSPECTION PROCEDURE ................................................ 4-2 MAGNETIC PARTICLE INSPECTION PROCEDURE ....................................... 4-6 PENETRANT INSPECTION PROCEDURE .................................................... 4-35 WRITTEN INSTRUCTIONS FOR PT METHOD .............................................. 4-55 ULTRASONIC INSPECTION PROCEDURE ................................................... 4-65 VISUAL INSPECTION PROCEDURE ............................................................. 4-69 VISUAL INSPECTION INSTRUCTION ............................................................ 4-73 THERMOGRAPHY AND INFRA-RED INSPECTION PROCEDURE .............. 4-75 RADIOGRAPHIC TESTING PROCEDURE ..................................................... 4-79
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 1-2
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 1 - GENERAL
1.2
RECORD OF REVISIONS Upon receipt of the request for document update, remove the obsolete page(s), insert revised page(s) in the manual, enter the information, and sign in the appropriate column: Issue Number
Revision Revision Date Insertion Date Number
Revised by VAECO QAD
01
00
28 Oct 2010
28 Oct 2010
01
01
22 Nov 2010
22 Nov 2010
01
02
14 Feb 2011
14 Feb 2011
VAECO QAD
01
03
14 Jun 2011
14 Jun 2011
VAECO QAD
01
04
11 Jul 2011
11 Jul 2011
VAECO QAD
01
05
22 Sep 2011
22 Sep 2011
VAECO QAD
02
00
15 Dec 2011
15 Dec 2011
VAECO QAD
02
01
21 Dec. 2013
21 Dec. 2013
VAECO QAD
VAECO QAD
The “Revision Date” is the date printed on the revised page; “Insertion Date” is the date performing the insertion.
Issue: 02, Revision: 01, Date: 21 Dec. 2013
Page 1-3
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 1 - GENERAL
1.3
SUMMARY OF AMENDMENT The following table shows the summary of the latest amendment of the VAECO NDTM. Manual Name
: Non Destructive Testing Manual
Manual Code
: VAECO NDTM
Issue Number
: 02
Revision Number
: 01
Part
Removed Pages
Inserted Pages
1
1-3
1-3
To update Record of revision
1
1-4
1-4
To update Summary of changes.
1
1-5; 1-6; 1-7
1-5; 1-6; 1-7
To update List of effective pages
2
2-3
2-3
To update HAN NDT Shop Layout
2
2-8
2-8
Content changes
3
Reason For Amendment
3-2, 3-5, 3-7, 3-8, 3-2, 3-5, 3-7, 3-8, Content changes 3-11, 3-22 3-11, 3-22
3
NIL
3-50 to 3-53
To add Course Outline for Thermography Method
3
NIL
3-54 to 3-57
To add Ultrasonic Phased Array Inspection of Aircraft Course Contents List
4
4-41, 4-45
4-41, 4-45
Content changes
This page is updated whenever there is any amendment. The Quality Assurance Department keeps all revision information.
Issue: 02, Revision: 01, Date: 21 Dec. 2013
Page 1-4
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 1 - GENERAL
1.4
LIST OF EFFECTIVE PAGES
Pages
1.
The pages listed here are identified in the format of: Chapter Number - Page Number.
2.
The Revision Date here is identified in the format of: dd mmm. yyyy.
Issue Revision Revision Date
Pages
Issue Revision Revision Date
1-1
02
00
15 Dec 2011
3-11
02
01
21 Dec 2013
1-2
02
00
15 Dec 2011
3-12
02
00
15 Dec 2011
1-3
02
00
21 Dec 2013
3-13
02
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15 Dec 2011
1-4
02
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21 Dec 2013
3-14
02
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15 Dec 2011
1-5
02
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21 Dec 2013
3-15
02
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15 Dec 2011
1-6
02
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21 Dec 2013
3-16
02
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15 Dec 2011
1-7
02
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21 Dec 2013
3-17
02
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15 Dec 2011
1-8
02
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3-18
02
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15 Dec 2011
1-9
02
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15 Dec 2011
3-19
02
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15 Dec 2011
2-1
02
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15 Dec 2011
3-20
02
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15 Dec 2011
2-2
02
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15 Dec 2011
3-21
02
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15 Dec 2011
2-3
02
01
21 Dec 2013
3-22
02
01
21 Dec 2013
2-4
02
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15 Dec 2011
3-23
02
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2-5
02
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15 Dec 2011
3-24
02
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15 Dec 2011
2-6
02
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15 Dec 2011
3-25
02
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15 Dec 2011
2-7
02
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15 Dec 2011
3-26
02
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15 Dec 2011
2-8
02
01
21 Dec 2013
3-27
02
00
15 Dec 2011
3-1
02
00
15 Dec 2011
3-28
02
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15 Dec 2011
3-2
02
01
21 Dec 2013
3-29
02
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15 Dec 2011
3-3
02
00
15 Dec 2011
3-30
02
00
15 Dec 2011
3-4
02
00
15 Dec 2011
3-31
02
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15 Dec 2011
3-5
02
01
21 Dec 2013
3-32
02
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15 Dec 2011
3-6
02
00
15 Dec 2011
3-33
02
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15 Dec 2011
3-7
02
01
21 Dec 2013
3-34
02
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15 Dec 2011
3-8
02
01
21 Dec 2013
3-35
02
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15 Dec 2011
3-9
02
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15 Dec 2011
3-36
02
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15 Dec 2011
3-10
02
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15 Dec 2011
3-37
02
00
15 Dec 2011
Issue: 02, Revision: 01, Date: 21 Dec. 2013
Page 1-5
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 1 - GENERAL
Pages
Issue Revision Revision Date
Pages
Issue
Revision Revision Date
3-38
02
00
15 Dec 2011
4-11
02
00
15 Dec 2011
3-39
02
00
15 Dec 2011
4-12
02
00
15 Dec 2011
3-40
02
00
15 Dec 2011
4-13
02
00
15 Dec 2011
3-41
02
00
15 Dec 2011
4-14
02
00
15 Dec 2011
3-42
02
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15 Dec 2011
4-15
02
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15 Dec 2011
3-43
02
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15 Dec 2011
4-16
02
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15 Dec 2011
3-44
02
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15 Dec 2011
4-17
02
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15 Dec 2011
3-45
02
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15 Dec 2011
4-18
02
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15 Dec 2011
3-46
02
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15 Dec 2011
4-19
02
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15 Dec 2011
3-47
02
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15 Dec 2011
4-20
02
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15 Dec 2011
3-48
02
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15 Dec 2011
4-21
02
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15 Dec 2011
3-49
02
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15 Dec 2011
4-22
02
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15 Dec 2011
3-50
02
01
21 Dec 2013
4-23
02
00
15 Dec 2011
3-51
02
01
21 Dec 2013
4-24
02
00
15 Dec 2011
3-52
02
01
21 Dec 2013
4-25
02
00
15 Dec 2011
3-53
02
01
21 Dec 2013
4-26
02
00
15 Dec 2011
3-54
02
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21 Dec 2013
4-27
02
00
15 Dec 2011
3-55
02
01
21 Dec 2013
4-28
02
00
15 Dec 2011
3-56
02
01
21 Dec 2013
4-29
02
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15 Dec 2011
3-57
02
01
21 Dec 2013
4-30
02
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15 Dec 2011
4-1
02
00
15 Dec 2011
4-31
02
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15 Dec 2011
4-2
02
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15 Dec 2011
4-32
02
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15 Dec 2011
4-3
02
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15 Dec 2011
4-33
02
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15 Dec 2011
4-4
02
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15 Dec 2011
4-34
02
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15 Dec 2011
4-5
02
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15 Dec 2011
4-35
02
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15 Dec 2011
4-6
02
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15 Dec 2011
4-36
02
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15 Dec 2011
4-7
02
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15 Dec 2011
4-37
02
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15 Dec 2011
4-8
02
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15 Dec 2011
4-38
02
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15 Dec 2011
4-9
02
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15 Dec 2011
4-39
02
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15 Dec 2011
4-10
02
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15 Dec 2011
4-40
02
00
15 Dec 2011
Issue: 02, Revision: 01, Date: 21 Dec. 2013
Page 1-6
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 1 - GENERAL
Pages
Issue Revision Revision Date
Pages
Issue
Revision Revision Date
4-41
02
01
21 Dec 2013
4-65
02
00
15 Dec 2011
4-42
02
00
15 Dec 2011
4-66
02
00
15 Dec 2011
4-43
02
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15 Dec 2011
4-67
02
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15 Dec 2011
4-44
02
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15 Dec 2011
4-68
02
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15 Dec 2011
4-45
02
01
21 Dec 2013
4-69
02
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15 Dec 2011
4-46
02
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15 Dec 2011
4-70
02
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15 Dec 2011
4-47
02
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15 Dec 2011
4-71
02
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15 Dec 2011
4-48
02
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4-72
02
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15 Dec 2011
4-49
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4-73
02
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15 Dec 2011
4-50
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02
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4-51
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4-75
02
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4-52
02
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15 Dec 2011
4-76
02
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4-53
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4-54
02
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4-78
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4-55
02
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15 Dec 2011
4-79
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4-56
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4-57
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4-81
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4-84
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4-61
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15 Dec 2011
RESPONSIBLE LEVEL 3
QUALITY ASSURANCE DIRECTOR
Date of Approval: 21 December 2013
Date of Review: 21 December 2013
George V. Crowe
Ha Tien Dung
Issue: 02, Revision: 01, Date: 21 Dec. 2013
Page 1-7
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 1 - GENERAL
1.5
DISTRIBUTION LIST NDT manual will be distributed to following holders and updated whenever there is a revision:
No
1.6
FUNCTIONARY AND ADDRESS
FORMAT
1
VAECO CEO/Accountable Manager
PDF
2
Responsible Level 3
PDF
3
Quality Assurance Director
PDF
4
Technical Library
PDF
ABBREVIATION Abbreviations used in the NDTM are listed in the following table: No
ABBREVIATION
MEANING
1
CMD
Component Maintenance Director
2
ET
Eddy Current Testing
3
HAN
Hanoi Main Facility
4
HCM
Ho Chi Minh City Satellite Facility
5
MOE
Maintenance Organization Exposition
6
MT
Magnetic Particle Testing
7
NDT
Non Destructive Testing
8
NDTM
Non Destructive Testing Manual
9
NDTS
Non Destructive Testing Shop
10 PT
Penetrant Testing
11 RSM
Repair Station Manual
12 RSTP
Repair Station Training Program
13 RT
Radiographic Testing
14 SOP
Standard Operating Procedure
15 TT
Thermographic Testing
16 UT
Ultrasonic Testing
17 UV
Ultra-violet
18 VAECO
Vietnam Airlines Engineering Company Ltd.
This table of abbreviation will be updated if any abbreviation used.
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 1-8
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 1 - GENERAL
1.7
REVISION PROCEDURE 1.
The NDT Manual is revised on an as-needed basis.
2.
Gathering information and preparing revised pages: a. Revisions to the NDT Manual may result from:
Requests for quality or procedural improvements;
Regulatory requirement or guidance changes;
Changes in policies or procedures that affect NDT activities;
Feedback from employees or customers regarding improvements;
Authority audits, quality audits or inspector reports;
Any other request that may affect NDT activities.
b. The Quality Assurance Department will evaluate the related information and propose the revision page(s). All revised text will be identified by using a revision bar “|” at the margin, indicating the revised portion. When a whole paragraph is deleted, it is indicated by a line with the word “[Deleted]” and a revision bar “|” at the margin. These marks are only applied for the latest revision. 3.
Review and submit for approval: a. The revised pages of the NDT Manual will be submitted to the Quality Assurance Director for review of the revised content before being sent to the Responsible Level 3 for approval. b. For minor changes to the NDT Manual that have no effect on the policies and procedures related to NDT, such as spelling errors, sentence amendments, minor corrections, minor modifications to clarify procedures, etc, the Quality Assurance Director will authorize the use of Temporary Revision Pages. The Temporary Revision Pages will be yellow in color to differentiate between the temporary and formal revision pages. The revised text will be identified as in Paragraph 1.7.2.b. VAECO will incorporate these changes into the next formal revision of the NDT Manual.
4.
Distribution and update: a. The approved NDT Manual in an electronic type (PDF format) will be sent to the related persons and Technical Library as specified in Paragraph 1.5. b. Upon receiving the Request for Document Update, the users will complete the VAECO Form 2018 to confirm the acknowledgment of the latest revision of manual and send it back to the Technical Library. The Technical Library will be responsible for ensuring the NDT Manual is updated within 10 working days.
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 1-9
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 2 - MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION
PART 2
MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 1-1
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 2 - MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION
2.1
2.2
GENERAL 1.
VAECO has two NDT shops, one belongs to the HAN Component Maintenance Center and the other belongs to the HCM Component Maintenance Center. The NDT shops are major supporting shops for the maintenance tasks performed in VAECO. The role of the NDT shops is to provide NDT inspection to aircrafts, engines and parts in accordance with manufacturer’s or regulatory specifications.
2.
The VAECO NDT shops comply with EN 4179 and NAS 410 for the qualification and approval of NDT personnel.
3.
The VAECO NDT shops shall follow manufacturer’s procedures when provided and strictly obey the NDT written instructions approved by the Responsible Level 3 described in this manual when no manufacturer procedures are available.
4.
VAECO has appointed an external Responsible Level 3 who is responsible for the technical supervision of NDT and the internal/ external audit functions.
APPLICABLE NDT METHODS VAECO NDT shops have the capability to perform NDT inspections using the following methods: 1.
Penetrant Testing (PT)
2.
Magnetic Particle Testing (MT)
3.
Eddy Current Testing (ET)
4.
Ultrasonic Testing (UT)
5.
Radiographic Testing (RT)
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 1-2
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 2 - MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION
2.3
NDT FACILITIES
2.3.1
HAN NDT Shop Facilities
2.3.1.1
HAN NDT Shop Layout
Issue: 02, Revision: 01, Date: 21 Dec. 2013
Page 2-3
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 2 - MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION
2.3.1.2
NDT Equipment The main NDT equipment of the HAN NDT shop consists of: 1.
Magnetic Particle Test Bench
2.
De-magnetizer
3.
Water wash cabinet
4.
Ultrasonic cleaner
5.
Penetrant Station.
6.
Eddy current equipment.
7.
Ultrasonic equipment.
8.
Hardness testing equipment.
9.
Calibration standards
10. Probes 11. Accessories
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 2-4
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 2 - MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION
2.3.2
HCM NDT Shop Facilities
2.3.2.1
HCM NDT Shop Layout
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 2-5
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 2 - MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION
1. Desk
7. Equipments and Acessories rack
2. Technical Data Cabinet
8. Document for training Cabinet
3. Labor Protection Cabinet
9. Calibration standard rack
4. Wait for inspection rack
10. Prepare Table
5. Wait for delivery rack
11. Unserviceable Cabinet
6. Batery charging area 2.3.2.2
NDT Equipment The main NDT equipment of the HCM NDT shop consists of: 1.
Magnetic Particle Test Bench & De-magnetizer
2.
Ultrasonic cleaner
3.
Penetrant Station.
4.
Eddy current equipment.
5.
Ultrasonic equipment.
6.
Hardness testing equipment.
7.
Calibration standards
8.
Probes and accessories
2.4
PRIVILEGES OF NDT STAFF
2.4.1.1
Level 1 In the method in which authorized, Level 1 staff are permitted to:
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 2-6
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 2 - MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION
2.4.1.2
1.
Process parts, document results and perform equipment standardization in accordance with approved work instructions.
2.
Carry out the necessary preparation of parts before or after inspection in accordance with approved work instructions.
3.
Conduct system performance checks in accordance with the applicable process standard.
4.
Carry out NDT inspections when provided with a Level 3 approved instructions or being directly supervised by a Level 2 authorized in the method.
Level 2 In the method in which authorized, Level 2 staff are permitted to:
2.4.1.3
1.
Set up and standardize equipment, process parts, interpret and evaluate for acceptance or rejection, and document results.
2.
Conduct system performance checks in accordance with the applicable process standard.
3.
Provide the necessary guidance and/or supervision to trainees and Level 1 personnel.
4.
Develop work instructions from approved general procedures. However, such instructions shall require final approval by a Level 3 authorized in the method.
Level 3 In the method in which authorized, Level 3 staff are permitted to:
2.4.1.4
1.
Interpret codes, standards, and other contractual documents that control the NDT method(s) used by VAECO.
2.
Select the method and technique for a specific inspection.
3.
Prepare and verify the adequacy of procedures and work instructions.
4.
Approve NDT procedures and other NDT-related work instruction for technical adequacy
5.
Provide or direct training, examination, and certification of NDT personnel.
Responsible Level 3 In addition to the privileges of the Level 3 staff mentioned above, the Responsible Level 3 also has the following privileges:
2.4.1.5
1.
Approve, implement the Written Practice and do the overall administration of the NDT qualification and certification program.
2.
Do the overall administration of the NDT Shops, establish policy, procedure and programs related to NDT.
3.
Carry out internal audits and/or outside agency audits to ensure the necessary requirements are met.
NDT Auditors NDT Auditors, who is nominated by the Quality Director, are permitted to perform: 1.
Internal audits related to NDT following instructions issued by the responsible Level 3.
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 2-7
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 2 - MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION
2.4.1.6
2.
External supplier technical NDT audits, surveys or assessments.
3.
Performance review of NDT personnel – see FORM AU01.
NDT Supervisor NDT Supervisor is responsible to direct and/or oversee the work performed by NDT personnel to ensure the compliance with NDT method, technique and procedure.
2.5
REQUIREMENTS TO NDT PERSONNEL
2.5.1
Level 1, 2, 3 NDT personnel In additional to the minimum prerequisite requirements specified in the SOP 10.1.2.5.3, the Level 1, 2, 3 NDT personnel must satify the requirements detailed in the item 3.6 of this manual.
2.5.2
NDT Supervisor In additional to the prerequisite requirements specified in the SOP 10.2.2, the NDT Supervisor personnel must be authorized as level 2 by the VAECO Quality System.
2.5.3
NDT Auditor NDT auditors shall have the education, training, skills and knowledge to understand the processes and procedures utilized in the application of NDT processes. The individual shall be familiar with the applicable codes, standards, and other contractual documents that control the applicable method(s).
2.6
QUALIFYING PROCEDURE FOR NDT PERSONNEL
2.6.1
Level 1, 2, 3 NDT personnel
2.6.2
1.
The general qualifying process and the detailed qualifying process of company/ customer procedures are carried out in accordance with the SOP 10.1.
2.
The qualifying process of NDT technique is carried out in accordance with the items 3.7 & 3.8 of this manual.
3.
A Responsible Level 3 nominated by VAECO is responsible to do the overall administration of NDT Shops, NDT qualification and certification program.
NDT Supervisor NDT supervisors are qualified by the related component maintenance center and the information about recommended supervisors shall be forwarded to the QA Department for acceptance and monitoring as specified in the SOP 10.2
2.6.3
NDT Auditor The Quality Director shall nominate the Responsible Level 3 as NDT Auditor.
2.6.4
NDT Roster A NDT Roster shall be issued and updated whenever there is any change in function of NDT personnel. The information of the roster consists of: name of NDT personnel, qualified NDT methods, NDT level, title and location.
Issue: 02, Revision: 01, Date: 21 Dec. 2013
Page 2-8
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 2 - MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION
2.7
EQUIVALENT ASSESSMENT OF NDT EQUIPMENT AND MANUFACTURE STANDARD BLOCK 1.
NDT equipment can be varied to suit the available equipment and Aircraft configuration. However, any such changes must still guarantee the same level of defect detection as the original procedures.
2.
Where the manufacturer/OEM details specific equipments to be used for NDT tasks by manufacturer and part number, the use of equivalent equipment (tool, standard, probe, cable...) for a NDT task has to be permitted/approved by the NDT Level 3 (in accordance with the ASSESSMENT OF EQUIVALENT NDT EQUIPMENT/METHOD (VAECO Form 7028)) or by the OEM unless otherwise stated.
3.
A NDT Level 2 can only assess equivalent equipment for UT and ET (where the NDT task allows substitute equipment), the assessment is recorded in the NDT REPORT (VAECO Form 7042). The equivalency is normally demonstrated by the screen signal from the conforming NDT calibration reference block(s) being presented on the instrument and matching as shown in the NDT task.
4.
In general, only aircraft manufacture’s NDT calibration blocks can be used. In some cases, where detailed drawings are provided by A/C manufacture or any OEM, it is permissible for VAECO to manufacture its own NDT calibration blocks. For reasons of audit and traceability, NDT calibration blocks produced by VAECO or manufacturing contractor should have a C of C or equivalent certified document, with a part number and serial number shown. These blocks should be tested and certified by a NDT level II (minimum) to show that the block is fit for purpose
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PART 3
WRITTEN PRACTICE
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3.1
SCOPE
3.1.1
Purpose
3.1.1.1
1.
This document is the written procedure (written practice) for the Qualification and Certification of NDT personnel of VAECO. The document meets or exceeds the minimum requirements for the qualification and certification of personnel involved in the application of non-destructive testing (NDT) in accordance with EN4179:2009 and NAS 410 Issue 3 March 2008.
2.
Except when otherwise specified in the written practice, certification includes operating approval.
Responsible Level 3 VAECO has appointed an external Responsible Level 3 in accordance with the requirements of EASA FAR Part 145. The Responsible Level 3 is responsible to the VAECO Quality Assurance Director for the technical supervision of NDT. The Outside Agency Level 3 may be replaced by a Level 3 employed full time by VAECO subject to their compliance with EN4179.
3.1.2
3.1.3
Applicability 1.
This document applies to personnel using NDT methods to test and/or accept materials, products, components, assemblies or subassemblies. It also applies to those individuals directly responsible for the technical adequacy of the NDT methods used, as well as personnel performing external NDT technical audits or providing technical NDT training.
2.
This document is not intended to apply to individuals who only have administrative authority over the personnel identified above, nor does it apply to research personnel developing technology for subsequent approval by a certified Level 3.
3.
Personnel performing specialized inspections using certain direct readout instruments as determined by a Level 3 certified in the method do not require qualification or certification to this document.
Implementation Personnel certified to previous revisions of the VAECO Written Practice do not need to recertify to the requirements of this document until their current certification expires.
3.1.4
Common methods The NDT methods used are: Penetrant, Magnetic Particle, Eddy Current, Ultrasonic, Radiography, Visual, Thermography and Hardness Testing.
3.1.5
Other methods When invoked by engineering, quality, cognizant engineering organisation or prime contractor requirements, this procedure applies to other current and emerging NDT methods used to determine the acceptability or suitability for intended service of a material, part, component, sub-assembly or assembly. Such methods may include, but are not limited to, acoustic emission, neutron radiography, leak testing and holograpy. The requirements for personnel training, experience and examination for these other methods shall be established in accordance with paragraph 3.6.4 and documented by VAECO.
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3.2
NORMATIVE REFERENCES
3.2.1
Standards The current revisions of the following documents as of the date of this document were used as the foundation for this document:
3.2.2
1.
EN4179:2009 Aerospace Series - Qualification and Approval of Personnel for Non-destructive Testing.
2.
NAS 410 Issue 3 March 2008.
3.
BINDT PCN/AERO A0 PCN Qualification and Certification of NDT Personnel for the Aerospace Multi-sector.
4.
BINDT PCN/GEN Qualification and Certification of NDT Personnel.
Order of Precedence In the event of a conflict between the text of this document, EN 4179:2009 and the references in paragraph 3.2.1, the requirements of EN 4179:2009 take precedence. Nothing in this document or EN 4179:2009 supersedes applicable laws and regulations unless a specific exemption has been obtained.
3.3
TERMS AND DEFINITIONS For the purposes of this document the following terms and definitions apply.
3.3.1
Certification: A written statement by an employer that an individual has met the applicable requirements of this standard.
3.3.2
Closed book examination: An examination administered without access to any reference materials.
3.3.3
Cognizant engineering organization: The engineering or NDT organization of the prime contractor or end user authorized to make NDT-related decisions and give NDT-related approvals.
3.3.4
Direct observation: Direct observation is when the observer is able to come to the immediate aid of the trainee and remains within a distance that permits uninterrupted, unaided visual and verbal contact with the trainee.
3.3.5
Direct readout instrument: Instruments that physically display measurements in dimensional or electrical units (e.g. inches, millimeters or %IACS, etc.) either as digital readout or an analog display, such as a scale/pointer configuration and do not require special skills or knowledge to set up the instrument and do not involve adjusting signal displays such as gates, delays, gain, or phase to obtain measurements. For example, common direct readout instruments include basic ultrasonic thickness gauges without an oscilloscope display, and eddy current coating thickness gauges.
3.3.6
Documented: The condition of being recorded in written or electronic form.
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3.3.7
Employer: A government, prime contractor, sub-contractor, supplier, or outside agency employing or contracting the services of one or more individuals who perform NDT. Self-employed individuals are included in this definition.
3.3.8
Evaluation: A review following interpretation of the indications noted during an NDT inspection to determine whether the indications meet specified acceptance criteria or to determine the significance of the indication.
3.3.9
Examination: Formal, controlled, documented testing conducted in accordance with a documented written practice to verify a candidate's visual capability, skill or knowledge of an NDT method.
3.3.10
Examiner: A Level 3 certified to this standard and designated by the Responsible Level 3 or NANDTB to administer all or part of the qualification and certification process, excluding vision examinations, in the NDT method(s) in which the Examiner is certified.
3.3.11
Experience: Actual performance of an NDT method conducted in the work environment resulting in the acquisition of knowledge and skill. This does not include formal classroom training, but may include laboratory and on-the-job training as defined by the employer's written practice.
3.3.12
Formal training: An organized and documented program of learning activities designed to impart the knowledge and skills necessary to be qualified to this standard. Formal training may be a mix of classroom, practical and programmed self-instruction as approved by the Responsible Level 3, Examiner or, NANDTB.
3.3.13
General examination: A written examination addressing the basic principles and theory of an NDT method.
3.3.14
Indication: The response or evidence of a condition resulting from an NDT inspection that requires interpretation to determine its significance.
3.3.15
Instructor: An individual designated or approved by the Responsible Level 3 or NANDTB to provide training for NDT personnel.
3.3.16
Interpretation: The determination of whether indications are relevant or non-relevant.
3.3.17
Method: One of the disciplines of non-destructive testing (e.g. ultrasonic, radiography, etc) within which different techniques may exist.
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3.3.18
National Aerospace NDT Board (NANDTB): An independent national aerospace organization representing a nation's aerospace industry that is chartered by the participating prime contractors and recognized by the nation's regulatory agencies to provide or support NDT qualification, examination, and/or certification services in accordance with this standard.
3.3.19
On-the-job training: Training in the work environment to gain experience in learning instrument setup, equipment operation, applying the process, and recognition, interpretation and evaluation of indications under appropriate technical guidance.
3.3.20
Open book examination: An examination administered with access to specific reference material that is provided with or referenced in the examination.
3.3.21
Operating approval: Written statement issued by the employer, based upon the scope of certification, authorizing the individual to carry out defined tasks. Such authorization can be dependent on the employer having provided job or task-specific training.
3.3.22
Outside agency: An independent company or organization outside the employer who provides NDT services to implement the requirements of this standard, such as training and examination of NDT personnel. Consultants and self-employed individuals are included in this definition. The Outside Agency shall be a properly formed company and the NDT personnel working within the Outside Agency for VAECO shall have certification issue by their employer.
3.3.23
Practical examination: An examination to demonstrate an individual's ability to conduct an NDT method as used by the employer. Questions and answers need not be written, but a checklist must be used and observations and results must be documented.
3.3.24
Prime contractor: An organization having overall responsibility for design, control and delivery of a system, component or product.
3.3.25
Procedure: A written general "how to" instruction for conducting a given process. Procedures are then used to develop work instructions, as defined in 3.3.32.
3.3.26
Qualification: The skills, training, knowledge, examinations, experience and visual capability required for personnel to properly perform to a particular level.
3.3.27
Responsible level 3: A Level 3 designated by the employer with the responsibility and authority to ensure that the requirements of this standard are met and to act on behalf of the employer.
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3.3.28
Specific examination: A written examination to determine an individual's understanding of operating procedures, codes, standards, product technology, test techniques, equipment and specifications for an NDT method as used by the employer.
3.3.29
Sub-contractor: An organization responsible to the prime contractor for the manufacture or maintenance of aerospace products. For the purposes of this standard, this includes suppliers and processors.
3.3.30
Technique: A category within a method; for example, ultrasonic immersion testing or ultrasonic testing of composites. Specific techniques within a method are defined by the employer or NANDTB.
3.3.31
Test sample: A part or image containing one or more known and documented natural or artificial discontinuities, flaws or conditions used in the practical examination to demonstrate the candidate's proficiency in an NDT method. Test samples can refer to actual hardware, fabricated test parts, or, when applicable, images of actual hardware such as radiographs.
3.3.32
Work instruction: A document detailing the NDT technique and testing parameters to be used for the inspection of a specific component, group of parts (e.g. "aluminium extrusions" or "steel brackets"), or assembly. These are sometimes referred to in the industry as "technique sheets" or "data cards". Such 'work instructions are based on procedures defined in 3.3.25.
3.3.33
Written: Retrievable electronic or hard copy.
3.3.34
Written practice: A procedure that describes an employer's requirements and methodology for controlling and administering the NDT personnel qualification and certification process.
3.4
GENERAL REQUIREMENTS
3.4.1
Written Practice This Written Practice has been developed in accordance with EN4179:2009 (which is equivalent in technical content to AIA NAS 410:2008) and includes the following requirements: 1.
Levels of qualification
2.
Personnel duties and responsibilities
3.
Training programme
4.
Experience requirements
5.
Examination practices
6.
Records and administration
7.
Recertification requirements
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3.4.1.1
Additional requirements [Deleted] Surveillance When an individual has not completed any NDT work in a method for a period exceeding 12 weeks, then he shall be monitored at his first inspection to ensure that he is completing the inspection correctly. This surveillance shall be in accordance with the following process. Certified Level 1’s or Level 2’s shall demonstrate the proficiency of carrying out the task in their applicable test method as required. The review shall include the ability of the individual to process hardware in accordance with approved procedure and/or evaluate and disposition hardware in accordance with customer requirements. The FORM AU01 (Performance Review of NDT Personnel) shall be used by the Responsible Level III (or designated Level II) to document the performance review of NDT personnel. Personnel failing to achieve a satisfactory surveillance shall receive corrective training to overcome the failing observed. This training shall be recorded on the FORM AU02 (NDT Personnel Surveillance Report) and countersigned by the level 3 as satisfactory.
3.4.1.2
NDT Techniques The following specific techniques used are: 1.
Penetrant – Fluorescent – Water Washable
2.
Penetrant – Fluorescent – Solvent Removable
3.
Penetrant – Fluorescent – Post Emulsified
4.
Magnetic Particle – Fluorescent – Stationary bench
5.
Magnetic Particle – Fluorescent - Yoke
6.
Eddy Current – High Frequency
7.
Eddy Current – Low Frequency
8.
Ultrasonic – Compressional Wave
9.
Ultrasonic – Shear Wave
10. Ultrasonic – Resonance Bond Testing 11. Ultrasonic – Phased Array 12. Radiography – Xray Examination with film 13. Thermography (Thermal Infrared) 14. Hardness Test 15. Visual Testing 3.4.1.3
Training Outlines 1.
The NDT Training Outlines are included as Appendix B to this procedure.
2.
The Responsible Level 3 shall verify that the Outside Agency providing the training meets the company requirements.
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3.4.1.4
Examination Practices Aerospace Inspection Training Ltd is the Outside Agency responsible for administering examinations. The examination requirements are detailed in paragraph 7 - Examinations. The specific visual examination method is detailed in Table 5 – Vision Requirements.
3.4.1.5
Administration The Responsible Level 3 identified in Appendix A is responsible for administering and maintaining the certification program of VAECO.
3.4.1.6
Records The VAECO Quality Director is responsible for maintaining the qualification and certification records.
3.4.2
Methods For the methods listed in paragraph 3.1.4 of this document, the requirements for training, experience and examination are detailed in paragraphs 6 and 7 of this procedure. No Initial Phased Array UT examination is required for an experienced level 2 UT inspector after attending a level 3 approved UT Phased Array training course. However, Phased Array Examinations may be included in level 2 qualification renewal at the discretion of the level 3
3.4.3
Level 1-Limited Level 1 Limited is not authorised.
3.4.4
3.4.5
Responsibility 1.
VAECO is responsible for implementation of, and compliance with, this written practice and for certifying qualified personnel. VAECO uses an Outside Agency for training and examining their personnel and performing other Level 3 functions as appropriate. VAECO is responsible for assuring that the appropriate requirements of the Written Practice are met by documenting the suitability of the Outside Agency and identifying in writing the name of the Responsible Level 3 from the Outside Agency who is Level 3 certified.
2.
The Outside Agency and Responsible Level 3 is identified in Appendix A.
3.
VAECO is solely responsible for the certification of its employees and cannot certify for another employer.
Responsible Level 3 1.
The Responsible Level 3 shall be: a. certified in accordance with EN4179:2009 as a Level 3 in one ore more NDT methods; b. have a thorough knowledge of the written instructions, codes, specifications and standards used by VAECO; c. have a thorough knowledge of the materials, components, product technologies, NDT methods and NDT techniques used by VAECO.
2.
The Responsible Level 3 shall approve any NDT certification by VAECO.
3.
The Responsible Level 3 having responsibility for the implementation of the Written Practice and overall administration of the qualification and certification program is identified in Appendix A.
4.
The Responsible Level 3 shall be certificated by their employer.
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3.4.6
Outside Agency 1.
The functions of the Outside Agency are: a. to develop a certification program b. to act as the Responsible Level 3 c. to examine NDT personnel d. to perform any other qualification Level 3 function
2.
VAECO shall document the suitability of the Outside Agency to perform any function in meeting the requirements of the Written Practice. The documentation shall be of sufficient detail to justify the Outside Agency’s ability to perform the required Level 3 function(s).
3.5
QUALIFICATION AND CERTIFICATION LEVELS
3.5.1
Levels of Qualification and Certification 1.
VAECO uses three levels of certification: a. Level 1 b. Level 2 c. Level 3
2. 3.5.1.1
NDT Personnel shall not independently perform the functions listed below if not certified to the appropriate level in the applicable technique/method.
Trainee A trainee is an individual who is participating in a training program for an NDT method and is in the process of becoming qualified for certification. In the technique/method in which they are preparing for certification, trainees shall:
3.5.1.2
1.
be documented as a trainee and be actively participating in a training program for a stated NDT method for a limited and specified period of time;
2.
obtain experience under the direct observation of a Level 2 or Level 3 in the same method;
3.
obtain experience under the direct observation of a Level 1 or Instructor only when approved by the Responsible Level 3;
4.
not make accept or reject decisions;
5.
not independently conduct tests;
6.
not independently perform any other NDT function.
Level 1 In the method in which certified, Level1 individuals shall: 1.
be able to follow work instructions;
2.
have the skills and knowledge to process parts, document results and perform equipment standardization in accordance with approved work instructions;
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3.5.1.3
3.
have the skills and knowledge to carry out any necessary preparation of parts before or after inspection in accordance with approved work instructions;
4.
have the skills and knowledge to conduct system performance checks in accordance with the applicable process standard;
5.
receive guidance or supervision from a certified Level 2 or Level 3 in that method when necessary;
6.
only be approved for carrying out NDT inspections when provided with a Level 3 approved instruction or be directly supervised by a Level 2.
Level 2 In the method in which certified, the Level 2 individuals shall:
3.5.1.4
1.
have the skills and knowledge to set up and standardise equipment, process parts, interpret and evaluate for acceptance or rejection, and document results;
2.
be thoroughly familiar technique/method;
3.
have the skills and knowledge to conduct system performance checks in accordance with the applicable process standard;
4.
be capable of providing the necessary guidance and/or supervision to trainees and Level 1 personnel;
5.
be familiar with the codes, standards, and other contractual documents that control the method as utilized by VAECO;
6.
have a basic knowledge of relevant product manufacturing and inspection technology;
7.
be capable of developing work instructions from approved general procedures. VAECO approves the Level 2 to develop work instructions, however such work instructions shall require final approval by a Level 3 certified in the method;
with
the
scope
and
limitations
of
the
Level 3 In the method in which certified, the Level 3 individuals shall: 1.
have the skills and knowledge to interpret codes, standards, and other contractual documents that control the NDT method(s) used by VAECO;
2.
be capable of assuming technical responsibility for the NDT facility and staff;
3.
be capable of selecting the method and technique for a specific inspection;
4.
be capable of preparing and verifying the adequacy of procedures and work instructions;
5.
approve NDT procedures and other NDT-related work instruction for technical adequacy;
6.
have a general knowledge of other NDT methods and product manufacturing and inspection technologies used by VAECO,
7.
be capable of providing or directing training, examination, and certification of personnel;
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8.
conduct NDT for the acceptance of parts and document the results if a demonstration of proficiency in this ability was included in the practical examination.
3.6
TRAINING AND EXPERIENCE
3.6.1
Training 1.
Candidates for certification to all levels shall complete sufficient organised training to become proficient with the principles and practices of the applicable test method and technique(s) and be capable of carrying out the duties specified in Paragraph 3.5. Wherever possible the source of training shall be approved by a National Aerospace NDT Board (NANDTB) but in all cases must be approved by the Responsible Level 3.
2.
Formal training shall be conducted prior to, or in conjunction with, on-the-job training. All NDT training shall be documented.
3.
The minimum training hours for Levels 1 and 2 are provided in Table 1 for the specified NDT methods.
4.
Individuals cannot certify to Level 3 without prior certification to Level 2 or performance equivalent to a Level 2 except in accordance with Paragraph 3.6.4
5.
General, specific and practical training may be obtained with VAECO or Outside Agency but shall always be supplemented by on-the-job training with VAECO. Table 1 - Minimum Formal Training Hours, Levels 1 and 2
3.6.1.1
Method
Level 1
Level 2 with Level 1 certification
Level 2 without Level 1 certification
PT
16
16
32
MT
16
16
32
ET
40
40
80
UT
40
40
80
RT
40
40
80
VT
8
16
24
TT
20
40
60
HT
-
8
8
Training Outlines 1.
All training shall be conducted in accordance with a detailed course outline approved by the Responsible Level 3. The outline shall include a list of references from which the training material is derived. As a minimum the training shall include: a. Basic theory; b. Test Principles, including choice of NDT methods, relevance to different materials and part and test variables; c.
Product forms and materials; defect formation and characterization;
d. Equipment operation and standardization;
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e. The importance of process controls; f.
The importance of appropriate processing steps and parameters;
g. Safety; h. Applicable techniques and the advantages and disadvantages of each;
3.6.1.2
i.
Limitations and capabilities of each method and technique;
j.
Applicable specifications, codes, operating procedures and work instructions;
k.
If applicable, evaluation, interpretation and documentation of inspection results.
2.
The Responsible Level 3 shall verify that the training provided by the Outside Agency meets the requirements of VAECO.
3.
Course outlines as provided by BINDT PCN/AERO A0 are provided as Appendixes to the Written Practice.
Previous Training For personnel credited with previous training or personnel not certified within 12 months of their training, refresher training must be provided. Previous training must be documented to be accepted by VAECO. At a minimum, refresher training shall cover:
3.6.1.3
1.
products,
2.
equipment set-up,
3.
operation and standardization,
4.
specific operating procedures,
5.
applicable techniques,
6.
interpretation and evaluation of NDT results,
7.
safety, and
8.
applicable codes, standards and specifications.
Equivalent training For personnel previously certified under NAS 410, EN4179 or other recognised NDT qualification program, the adequacy and equivalency of their previous training to the requirements of Table 1 shall be determined and documented by the Responsible Level 3.
3.6.1.4
Health and safety training All regulations relating to hazardous substances, accident prevention and safe working practices shall be strictly adhered to. Safety-related training requirements shall be determined by VAECO in accordance with local codes and regulations. Prior to certification, all candidates seeking radiography qualification shall have received instruction on the hazards and safety requirements associated with ionizing radiation and are knowledgeable of, and comply with, the applicable regulations and laws.
3.6.1.5
Training facilities 1.
Training facilities and classrooms shall provide and environment conducive to learning and shall be sufficiently well equipped with training aids, models,
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samples, etc., to ensure that all aspects of the training course requirements are met. In addition, a sufficient number of representative test samples containing natural or artificial features and/or flaws shall be available to cover the range of testing to be conducted by the candidate.
3.6.2
2.
Test samples used for practical examinations shall not be used for training purposes.
3.
To ensure the candidate fully benefits from the practical exercises, equipment used for training shall be sufficiently comparable to that which the candidate will use in the performance of their job. Production parts and NDT equipment may be used for training.
Training and Examination Personnel The Responsible Level 3 shall maintain overall control and cognizance over the NDT training program, including designating and approving Examiners, instructors and outside agencies.
3.6.2.1
3.6.2.2
3.6.2.3
3.6.3
Examiners 1.
When necessary, Level 3 examiners shall be designated in writing by the Responsible Level 3. All examiners shall be certified in accordance with BSEN4179. As determined and documented by the Responsible Level 3, an Examiner can prepare, administer and grade written or practical NDT examinations, and administer all or part of the certification process in the method in which certified.
2.
The designated Level 3 Examiners are identified in Appendix A.
Instructors 1.
Instructors shall have the skills and knowledge to plan, organise, and present classroom training and practical exercises in accordance with approved course outlines. Instructors shall be designated or approved by the Responsible Level 3.
2.
The designated instructors are identified in Appendix A.
Outside Agencies 1.
When an outside agency is used, the outside agency shall provide the VAECO with the names, evidence of qualifications and, if applicable, evidence of certifications held by the personnel conducting the training and examinations.
2.
In its capacity as a BINDT Accredited Outside Agency provider, Aerospace Inspection Training Ltd has been designated as the Outside Agency and identified in Appendix A.
Experience 1.
Candidates for certification at Level 1, Level 2, or Level 3 shall have sufficient practical experience to assure that they are capable of performing the duties of the level for which certification is sought.
2.
The minimum experience requirements for Levels 1 and 2 are provided in Table 2. The requirements for Level 3 are in Table 3 and 3.6.4.2, as applicable.
3.
As documented in the written practice, on-the-job training for the purpose of gaining experience shall be conducted by personnel certified in accordance with EN4179.
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3.6.3.1
Previous experience A candidate’s documented experience with a previous employer may be accepted by VAECO only if such experience is documented and approved by the Responsible Level 3.
3.6.3.2
Equivalent experience For personnel certified under NAS 410, EN 4179 or other NDT qualification program, the adequacy and equivalency of their previous experience to the requirements of Tables 2 or 3 shall be determined and documented by the Responsible Level 3. Table 2 - Minimum Experience Requirements in Hours for Levels 1 and 2 Experience Tine in hours * Method
Level 1 (Trainee experience)
Level 2 with previous Level 1 certification
Level 2 without previous Level 1certification
PT
130
270
400
MT
130
400
530
ET
400
1200
1600
UT
400
1200
1600
RT
400
1200
1600
VT
70
140
210
TT
200
600
800
HT
-
24
24
* Experience in multiple methods may be accumulated simultaneously. Experience in method must be at least half this time when remaining time is spent working or training in other NDT methods when approved by the responsible Level 3
Table 3 - Minimum Experience Requirements for Level 3 in penetrant and magnetic particle, ultrasonic, eddy current and radiographic testing College or University
3.6.4
Level 2 or Equivalent Experience
None
4 years
Two years of engineering or science study at a technical school, college or university
2 years
Three to four years science or engineering undergraduate degree
1 year
Emerging NDT Methods The minimum required training and experience hours for methods used by VAECO that are not listed in paragraph 1.3, Table 1 and Table 2 shall be established by the Responsible Level 3.
3.7
EXAMINATIONS
3.7.1
Purpose 1.
Examinations to verify technical qualifications of candidates shall consist of a general, specific and a practical examination for each method in which the candidate is to be certified.
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VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 3 - WRITTEN PRACTICE - VAECO.NDT.WP01
3.7.1.1
2.
An examination for visual acuity shall also be conducted prior to the candidate’s first certification and periodically thereafter.
3.
The requirements for the vision examination, the questions or question database used for the general and specific examinations and the checklist for the practical examination shall be available for review by VAECO customers.
4.
Examination and test samples shall be made available to candidates only during administration of the examinations.
Vision Examination 1.
The vision examination for Level 1, Level 2, and Level 3 personnel shall assure that the applicant’s near vision and colour perception meet the requirements of Table 4. Vision Requirements do not apply to instructors or auditors.
2.
Near vision tests shall be administered annually and colour perception tests shall be administered at least every five years. These tests shall be administered by trained personnel designated by the Responsible Level 3 or by qualified medical personnel.VAECO shall ensure the flow-down of the Table 4 vision requirements to all necessary personnel and/or facilities.
3.
When vision correction is necessary to pass the visual acuity exam, vision correction shall be worn during all testing/inspections.
4.
Any limitations in colour perception shall be evaluated by the Responsible Level 3 prior to certification and must be approved in writing. Table 4 – Vision Requirements Examination Requirements
3.7.1.2
Near vision
20/25 (Snellen) at 42 cm (16”) +/- 25.4 cm (1”) in at least one eye, natural or corrected, or Times Roman N4.5 point/Jaeger No. 1 at not less than 30 cm/12 inch in at least one eye, natural or corrected.
Colour perception
Personnel shall be capable of adequately distinguishing and differentiating colours using the Ishihara test and the number of plates presented is to be documented.
General 1.
The general examination for all levels shall be a closed book examination consisting of questions that cover the cross-section of the applicable method at the appropriate level.
2.
A minimum of 40 questions shall be administered for the general examination for Level-1 Limited.
3.
A minimum of 40 questions shall be administered for the general examination at Levels 1, 2 or 3. For the Level 3, the general examination questions will address the general knowledge of other methods used by the employer as well as the method for which certification is sought. Passing a “basic” examination covering the other NDT methods used before passing any NDT method examination shall be considered satisfactory evidence the other NDT methods have been satisfactorily covered.
Issue: 02, Revision: 00, Date: 15 Dec. 2011
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VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 3 - WRITTEN PRACTICE - VAECO.NDT.WP01
4.
3.7.1.3
3.7.1.3.1
3.7.1.3.2
Possession of a current EN 473, i.e PCN/GEN or PCN/AERO, or ASNT NDT certificate at the appropriate level by the candidate is satisfactory evidence that the general examination requirement is satisfied as defined in Written Practice.
Specific 1.
The specific examination for all levels shall be an open book examination covering the requirements and use of the specifications, codes, equipment, operating procedures, and test techniques the candidate may use in the performance of his/her duties with VAECO.
2.
A minimum of 30 questions shall be administered for the specific examination at Levels 1, 2 and 3.
3.
Reference materials such as specifications, tables, formulas, etc. may be provided as determined by the Responsible Level 3 or Examiner. Questions utilising such material shall require the understanding of the information contained therein rather than merely finding its location.
Practical 1.
The practical examination shall consist of a demonstration of proficiency in performing tasks that are typical of those to be accomplished in the performance of the candidate’s duties..If the candidate is required to demonstrate proficiency in the application of the process as well as interpretation of results, hardware test samples shall be used. The location and severity of flaws in the test sample shall not be apparent to the candidate.
2.
If the candidate is only required to interpret the results and not perform the process of generating the image, the test samples may be images, such as radiographs or other resultant test data.
3.
A written checklist covering the topics detailed in the following subparagraphs shall be developed by the Responsible Level 3 or Examiner to assure adequate coverage and to assist in the administration and grading of the examination. In addition to using the checklist, the Responsible Level 3 or Examiner shall determine how the examination results obtained by the candidate are to be documented (e.g. part maps, drawings, sketches, written descriptions, etc.). All such documentation shall become part of the examination and filed accordingly.
4.
Possession of a current EN 473, i.e. PCN/GEN or PCN/AERO, or ASNT NDT certificate at the appropriate level by the candidate is satisfactory evidence that the practical examination requirement is satisfied as defined in Written Practice for the Penetrant and Magnetic Particle methods and techniques.
Level 1 1.
The candidate shall demonstrate proficiency by using a detailed written instruction to process at least two test samples of differing configurations for each method, with at least one test sample for each technique for which certification is sought. When only one configuration of hardware is to be inspected on certification, both test samples may be of the same configuration. The test samples shall meet the definition in 3.3.31 and be representative of the specific product to be encountered by the candidate in the performance of their duties with VAECO.
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 3-16
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 3 - WRITTEN PRACTICE - VAECO.NDT.WP01
2.
3.7.1.3.3
3.7.1.3.4
3.7.2
The candidate shall document the NDT results. The checklist shall include proficiency in the use and standardisation of equipment and materials, adherence to procedural details, and the documentation of results. If the Level 1 candidate is to accept products, the checklist shall also include proficiency in the interpretation and evaluation of indications
Level 2 1.
The candidate shall demonstrate proficiency by using a written instruction to process at least two test samples of differing configurations for each method, with at least one test sample for each technique for which certification is sought. When only one configuration of hardware is to be inspected on certification, both test samples may be of the same configuration. The test samples shall meet the definition in 3.3.31 and be representative of the specific product to be encountered by the candidate in the performance of their duties with VAECO.
2.
The candidate shall document the NDT results in accordance with the applicable acceptance criteria. The checklist shall include proficiency in the use and standardisation of equipment and materials, adherence to procedural details, the accuracy and completeness of interpretation and evaluations of indications, and the ability to develop work instructions.
Level 3 1.
The candidate shall demonstrate proficiency by preparing an NDT procedure or work instruction appropriate to the current requirements of VAECO for the method. The procedure or work instruction shall be developed in conjunction with the general and/or specific examination(s) required for certification or recertification, as applicable. A procedure or work instruction developed within the previous three months by the candidate may be used with the approval of the Responsible Level 3.
2.
When the candidate’s duties will include processing and/or acceptance/ rejection of products, proficiency in performing such tasks shall be demonstrated by a hands-on practical examination equivalent to Level 2 in accordance with 3.7.1.3.2.
3.
The results of the practical examination shall be documented and a checklist shall be used to address the practical and technical adequacy of the procedures or work instructions prepared by the candidate. When the candidate is to accept/reject hardware, the adequacy of the interpretation and evaluation of indications shall be documented.
4.
The additional practical examination to accept/reject hardware is not required for Level 3 who write or approve work instructions even if those instructions are used by personnel to accept/reject hardware.
Administration of Examination The administration and grading of all examinations shall be the responsibility of the Responsible Level 3or Examiner. The Responsible Level 3 may delegate in writing the administration and grading of all examinations using multiple choice or true/false questions to non-Examiner personnel. All practical examinations shall be administered by the Responsible Level 3 or Examiner. Responses to essay and fill-in questions must be evaluated by the Responsible Level 3 or Examiner to verify the certification candidate’s adequate understanding of the subject matter. In no case can an examination be administered by VAECO or by a subordinate.
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 3-17
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 3 - WRITTEN PRACTICE - VAECO.NDT.WP01
3.7.2.1
Administration by an Outside Agency When an outside agency is used to administer examinations, VAECO shall ensure that all individuals involved in the examinations meet the requirements of this document. In all cases, the ultimate responsibility for compliance to this procedure shall remain with VAECO.
3.7.2.2
3.7.3
Grading 1.
The candidate for certification must achieve a minimum score of 70 % on each individual examination. In addition, the candidate must detect all discontinuities, flaws or conditions specified by the Level 3 during the practical examinations and achieve a minimum score of 70%. The candidate must have an average score of no less than 80% in order to be eligible for certification. All examination scores shall be of equal weight in determining the average score. For example, if only specific and practical examinations are administered for recertification, only those scores shall be factored into the average score. If a general examination is also given for recertification, the general score shall be factored into the average score.
2.
For a Level 3 recertified under paragraph 3.8.6, the score for the practical hands-on, if administered, will be used as the average score.
3.
Scores for ASNT, EN473, ISO 9712 NDT certificates scored as “pass/fail”, and used in lieu of the general examination per 3.7.1.2 shall be assigned a value of 80%.
Re-examination Candidates failing any general, specific or practical examination shall receive additional training before attempting re-examination of the failed exam. The additional training shall be documented and shall address those areas found deficient in the candidate’s skill or knowledge. The re-examination shall not use the same written tests or test samples that were used in the initial examination. The re-examination test must contain a minimum of 25% new questions.
3.8
CERTIFICATION
3.8.1
General
3.8.2
1.
Personnel who have demonstrated that they possess the appropriate qualifications are eligible for certification by VAECO in accordance with this document. Certification is not required for personnel who are trainees, NDT auditors, or personnel performing specialised inspections using direct readout instruments.
2.
Certification shall be approved by the Responsible Level 3.
Records VAECO shall maintain personnel certification records as long as the certification is in effect. The records maintained shall include, as a minimum: 1.
Name of the certified individual;
2.
Level, method, and technique(s) for which the individual is certified;
3.
The latest written and practical examinations and the scores from immediately previous exams;
4.
Date and expiration of current certification(s);
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 3-18
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 3 - WRITTEN PRACTICE - VAECO.NDT.WP01
3.8.2.1
5.
NDT training history, which identifies source, type of training, dates of training, and course hours, and if applicable, the documentation required by 3.6.1.2 and 3.6.1.3;
6.
NDT experience history, including any previous certifications, both with VAECO and previous employers sufficient to justify satisfaction of experience requirements for qualification, and, if applicable, the documentation required by 3.6.1.2 and 3.6.1.3;
7.
Results of most recent (i.e. current) visual acuity and colour perception examinations;
8.
Extent and documentation of formal education when used to meet qualification requirements;
9.
The name and signature of the VAECO representative authorising the certification.
Record Availability All training, qualification, and certification records shall be maintained in accordance with this procedure and shall be made available for audit by VAECO customers or regulatory agencies. All such records, except for actual examinations, shall be made available to the applicable employee upon request or upon leaving the company for any reason. Examinations are to be made available for audit at the outside Agency Examination Centre.
3.8.3
Loss of Certification NDT Certification may expire, be suspended, or be revoked.
3.8.3.1
Expiration Certifications for all levels shall expire when the certification interval has lapsed with no re-certification issued. Certification for all levels is considered to expire at the end of the corresponding month in which the certification began.
3.8.3.2
Suspension Certification shall be suspended when employment is terminated, the visual acuity examination is overdue, the individual does not perform in the method certified for at least 12 consecutive months, or when the individual's performance is found to be deficient in any manner
3.8.3.3
Revocation Certification shall be revoked when the individual does not perform in the certified method for at least 24 consecutive months or when the individual’s conduct is found to be unethical or incompetent.
3.8.4
Reinstatement of certification Certifications that have been suspended may be reinstated when the cause for the suspension has been corrected and the correction verified by the employer, or the individual’s proficiency is verified by the responsible Level 3. Certifications that have expired or been revoked may only be reinstated by specific and practical examination equivalent to initial certification.
3.8.5
Recertification Personnel are eligible for recertification as follows:
Issue: 02, Revision: 00, Date: 15 Dec. 2011
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VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 3 - WRITTEN PRACTICE - VAECO.NDT.WP01
3.8.5.1
Level 1/2 Personnel Level 1/2 personnel certified to this document shall be recertified at intervals not to exceed five years. Recertification shall be accomplished by successful completion of practical and specific examinations equivalent to those required for initial certification.
3.8.5.2
Recertification for Level 3 Personnel Level 3 personnel certified to this document shall be recertified at intervals not to exceed five years. Recertification shall be accomplished in accordance with paragraph 3.8.6 or by successful completion of specific and practical reexamination equivalent to initial certification.
3.8.5.2.1
Hands-on Practical Examination If equipment operation or accepting hardware is required as part of the Level 3’s duties, an additional hands-on practical examination equivalent to Level 2 is required.
3.8.6
Credit System for Recertification of Level 3 NDT Personnel This section specifies requirements for re-certification of the Level 3 NDT personnel without examination. It applies only to those persons holding a valid Level 3 NDT certification at the time of recertification.
3.8.6.1
Requirements: Documentation for recertification shall be made to the Responsible Level 3 at least 14 days prior to the expiration date of the certification. Application for recertification by the Responsible Level 3 shall be made to the employer. The candidate shall have been employed in a Level 3 function for a minimum of 36 months (at least 12 of which are in the last 24 months) within the previous five years in the method(s) for which recertification is sought. The number of months is cumulative and does not need to be consecutive months for validation purposes. Candidates shall provide objective evidence that they have kept up to date with current NDT technology in the method(s) for which they are seeking recertification by obtaining a minimum of 24 points during the five year period of certification, irrespective of the number of certifications (methods) obtained, by engaging in one or more of the activities listed in Table 5.
3.8.6.2
Definitions 1.
Committee or Panel Meetings: Meetings, conference, symposia, seminars, trade association meetings, panels, etc. organized or sponsored by a regional, national or international NDT organization or technical society. Foreign or international meetings qualify if the sponsor(s) are national or international.
2.
Committee Projects: Specific identifiable official activities of regional or national technical societies, committees or work groups, such as round robins or individual studies, preparation of guidelines, appendices, specifications, recommended practices, procedures, codes or standards, etc. Documentation may include memos or reports, drafts of committee output documents, or official written comments submitted by the candidate on such documents.
Issue: 02, Revision: 00, Date: 15 Dec. 2011
Page 3-20
VIETNAM AIRLINES ENGINEERING COMPANY LTD.
NON DESTRUCTIVE TESTING MANUAL PART 3 - WRITTEN PRACTICE - VAECO.NDT.WP01
Table 5 Level 3 Awarded Credited Activity (to BS EN 4179:2009)
Activity
Criteria
Point Allocation
Max Points per 5 years
Authorizing or co-authoring technical NDT papers, presentations or white papers
Sole Author Co-Author (contribution >30%) Co-Author (contribution
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