SAEP-1140

Engineering Procedure SAEP-1140

21 August 2011

Qualification of Saudi Aramco NDT Personnel Document Responsibility: Non-Destructive Testing Standards Committee

Saudi Aramco DeskTop Standards Table of Contents 1

Scope............................................................ 2

2

Conflicts and Deviations............................... 2

3

References.................................................... 2

4

Definitions...................................................... 3

5

Nondestructive Testing (NDT) Methods........ 4

6

Levels of Qualifications................................. 4

7

Qualification Requirements........................... 6

8

Responsibilities............................................. 8

9

Certification of NDT Personnel...................... 9

10

Examinations............................................... 11

11

Qualification and Certification Records....... 15

Previous Issue: 15 February 2006 Next Planned Update: 21 August 2016 Revised paragraphs are indicated in the right margin Primary contact: Qadeeb, Fathi Essa on 966-3-8720262 Copyright©Saudi Aramco 2011. All rights reserved.

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Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

1

2

3

Scope 1.1

This Engineering Procedure establishes the requirements for the qualification and certification of Saudi Aramco nondestructive testing (NDT) personnel.

1.2

This Engineering Procedure applies to all personnel whose specific tasks or jobs require appropriate knowledge of the technical principles underlying Nondestructive Testing methods for which they have responsibilities within the scope of their employment. These specific tasks or jobs include, but are not limited to, performing, reviewing, monitoring, and evaluating NDT work.

Conflicts and Deviations 2.1

Any conflicts between this procedure and other applicable Saudi Aramco Engineering Procedures (SAEPs), Materials System Specifications, (SAMSSs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Inspection Department of Saudi Aramco/Dhahran.

2.2

Direct all requests to deviate from this procedure in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Inspection Department of Saudi Aramco/Dhahran.

References The requirements contained in the following documents apply to the extent specified in this procedure. 3.1

Saudi Aramco Reference Saudi Aramco Engineering Procedure SAEP-302

3.2

Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

Industry Codes and Standards American National Standards Institute / American Society for Nondestructive Testing, Inc. ANSI/ASNT CP-189 - 2006 ASNT Standard for Qualification and Certification of NDT Personnel

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Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

British Standards Institution BS EN 473 - 2008

Qualification and Certification of NDT Personnel - General Principles

International Organization for Standardization ISO 9712 - 2005

4

NDT - Qualification and Certification of NDT Personnel

Definitions 4.1

Qualification The education, skills, training, knowledge, and experience required for personnel to properly perform the duties of a specified NDT level.

4.2

Certification Written testimony that an individual has met the applicable requirements of this procedure.

4.3

Training An organized and documented program of activities designed to impart the knowledge and skills required to be qualified to this procedure.

4.4

Experience Work activities accomplished in a specific NDT method under the direction of qualified supervision. Experience includes the performance of NDT and related activities but not time spent in organized training activities.

4.5

NDT Level III An individual possessing a currently valid ASNT NDT Level III Certificate and certified in accordance with this document. An individual possessing a certificate issued by an organization meeting the requirements of EN 473 such as the ASNT ACCP Professional Level III program can also be certified in accordance with this document.

4.6

Documented The condition of being in written form.

4.7

Education An institutionalized program, prescribed by appropriate authorities that is Page 3 of 15

Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

offered by schools institutes, organizations, colleges, or universities established for the sole purpose of providing instruction in an orderly, planned, and systematic fashion. 5

Nondestructive Testing (NDT) Methods 5.1

5.2

6

The qualification and certification of nondestructive examination personnel in accordance with this SAEP is applicable to each of the following methods and/or techniques: 5.1.1

Radiographic Testing (RT)

5.1.2

Radiographic Film Interpretation (RTFI)

5.1.3

Ultrasonic Testing (UT) 5.1.3.1

Thickness Measurement (UTT)

5.1.3.2

Manual Shear Wave (UT)

5.1.3.3

Time of Flight Diffraction (TOFD)

5.1.3.4

UT Phased Array

5.1.4

Magnetic Particle Testing (MT)

5.1.5

Liquid Penetrant Testing (PT)

5.1.6

Visual Examination (VT)

5.1.7

Electromagnetic Testing (ET)

5.1.8

Acoustic Emission (AE)

5.1.9

Infrared Testing (IR)

Individual NDT methods may be subdivided into other specialized techniques as approved by the Saudi Aramco Head NDT Level III. Performance qualification shall be required in each of the applicable specialized techniques.

Levels of Qualifications Five classifications of NDT qualification are defined in terms of the skills and knowledge required in a given method or methods to perform specific NDT activities. 6.1

Trainee A person who is not yet certified to any level shall be considered a Trainee. A Trainee shall work with a certified individual and shall not independently Page 4 of 15

Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

conduct any tests, interpret or evaluate the results of a test, or report test results. 6.2

NDT Level I NDT Level I personnel shall have the skills and knowledge to perform specific calibrations, specific tests, and with prior written approval of the NDT Level III, perform specific interpretations and evaluations for acceptance or rejection and document the results, in accordance with specific approved NDT procedures. The NDT Level I shall be able to follow approved nondestructive testing procedures and shall receive the necessary guidance or supervision from a certified NDT Level II or NDT Level III individual.

6.3

NDT Level II NDT Level II personnel shall have the skills and knowledge to set up and calibrate equipment, to conduct tests, and to interpret, evaluate and document results in accordance with procedures approved by an NDT Level III. The NDT Level II shall be thoroughly familiar with the scope and limitations of the methods to which certified and should be capable of directing the work of trainees and Level I personnel. The NDT Level II shall be able to organize and report the results of nondestructive examinations.

6.4

NDT Level III An NDT Level III shall have the skills and knowledge to establish techniques and procedures; interpret Codes, standards, and specifications; designate the particular test methods and techniques to be used; and to verify the adequacy of NDT procedures. The NDT Level III is responsible for the NDT operations for which he is qualified and to which he is assigned, and shall be capable of interpreting and evaluating NDT results in terms of existing Codes, standards, and specifications. The NDT Level III should have sufficient practical background in applicable materials, fabrication, and product technology to establish techniques and to assist in establishing acceptance criteria where none are otherwise available. The NDT Level III shall have general familiarity with other appropriate NDT methods, and shall be qualified to train and examine NDT Level I and Level II personnel.

6.5

NDT Instructor An NDT Instructor shall have the skills and knowledge to plan, organize, and present NDT classroom, laboratory, demonstration, and/or education programs in accordance with course outlines approved by the Saudi Aramco Head NDT Level III or his delegate. The NDT Instructor shall possess a currently valid ASNT NDT Level III Certificate in the method for which he is responsible and shall have a minimum of 40 hours of instruction in teaching and training Page 5 of 15

Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

techniques. The Saudi Aramco Head Level III may require a practical demonstration by the NDT Instructor of an NDT method being taught. 7

Qualification Requirements 7.1

Candidates for certification as NDT Level I or II shall complete sufficient organized training to become familiar with the principles of the method and the practices of the applicable test technique. This training shall be conducted in accordance with an approved course outline approved by the Saudi Aramco Head NDT Level III or his delegate. The course shall include all of the topics contained in ANSI/ASNT CP-189 Appendix B for the appropriate NDT method plus additional topics as deemed necessary by the Saudi Aramco Head NDT Level III or his delegate. Training programs shall include sufficient examinations to demonstrate that the necessary information has been comprehended. 7.1.1

To receive credit for training hours, the candidate shall have passed, with a minimum score of 80%, a final examination covering the topics contained in the course outline.

7.1.2

The minimum number of hours of classroom training required for NDT Level I and Level II are described in Table 1. Table 1 – Initial Training Requirements for Level I and Level II Method

Classroom Hours in Method Level I Level II

RT

40

40

RTFI

N/A

40

UT

40

40

UTT

8

16

MT

12

8

PT

8

8

VT

8

16

ET

40

40

AE

40

40

AE Valve Leakage

8

8

IR

40

40

ToFD*

40

80

UT Phased Array*

N/A

96

* Note: Candidates must hold appropriate UT Level II prior to ToFD and Phased Array courses.

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Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

7.2

7.1.3

All training shall be presented by an NDT Instructor. However, the NDT Instructor may use personnel with specialized experience, e.g., metallurgists, welding engineers, etc., who are not qualified in accordance with this SAEP to assist in the presentation of specific information.

7.1.4

Training requirements for NDT Level III personnel will be satisfied if the individual holds a current ASNT NDT Level III Certificate in the specific NDT Method. Training requirements will also be met if an individual holds a current ASNT ACCP Professional Level III Certificate in the specific NDT method.

Candidates for certification shall have acquired the practical experience to assure they are capable of performing the duties of the level in which certification are being sought. 7.2.1

The minimum number of hours of experience required for NDT Level I and Level II are shown in Table 2. Table 2 – Experience Requirements for Level I and Level II Hours in Method

Hours in NDT

Method

Level I

Level II

Level I

Level II

RT

200

600

400

1200

RTFI

N/A

600

N/A

1200

UT

200

600

400

1200

UTT

N/A

80

N/A

160

MT

65

200

130

400

PT

65

135

130

270

VT

65

135

130

270

ET

65

600

130

1200

AE

200

600

400

1200

IR

200

900

400

1800

ToFD

200

600

400

1200

UT Phased Array

200

600

400

1200

Notes: 1. Experience shall be based on the actual hours worked in the specific method. 2. A person may be qualified directly to NDT Level II with no time as a certified Level I, providing the required experience consists of the sum of the hours

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Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel required for NDT Level I and Level II. 3. The required minimum experience shall be documented by method and by hour with supervisor or NDT Level III approval. 4. While fulfilling total NDT experience requirements, experience may be gained in more than one (1) method. Minimum experience hours must be met for each method.

7.2.2

8

Experience requirements for NDT Level III will be satisfied if the individual holds a current ASNT NDT Level III certificate in the specific NDT method. Experience requirements will also be met if an individual holds a current ASNT ACCP Professional Level III Certificate in the specific NDT method.

7.3

For Level I and Level II, a candidate's previous training and experience may be accepted by the Saudi Aramco if verified and documented in writing by the previous employer(s) or, for training, by the previous training agency(ies). Any claimed training and experience which cannot be verified and documented to the satisfaction of the responsible NDT Level III shall be considered invalid.

7.4

For Level III personnel, the Inspection Department shall verify and document the current validity of a candidate's ASNT Level III Certificate or ACCP Professional Level III certificate.

7.5

An NDT Instructor shall be designated by the Saudi Aramco Head NDT Level III or delegated authority. The designation shall be in writing and annotated in the individual's qualification records.

Responsibilities 8.1

Saudi Aramco Head NDT Level III Qualification and certification of all levels of NDT personnel is the responsibility of the Saudi Aramco Head (Corporate) NDT Level III as designated by the Manager, Inspection Department. The Saudi Aramco Head NDT Level III may delegate other NDT Level III's to provide services as necessary. The CNDT&PS Unit of Operations Inspection Division shall administer the NDT personnel qualification and certification program as governed by this document.

8.2

NDT Level III An NDT Level III is responsible for evaluating questionable test results and resolving problems in interpretation of test results. He is ultimate technical authority for Saudi Aramco regarding the acceptance or rejection of items based on NDT findings when evaluated in accordance with his interpretation of Page 8 of 15

Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

existing Codes, standards, and specifications. The Level III is responsible for determining the particular test methods, techniques, and procedures to be used to examine specific items and is responsible for providing specialized test procedures and training in the use of these procedures whenever required. 8.3

NDT Instructor An NDT Instructor is responsible for training and examining NDT Level I and II personnel in preparation for qualification examinations.

9

Certification of NDT Personnel 9.1

Certification Certification of NDT personnel shall be based on demonstration of satisfactory training, experience, and examinations as determined by the requirements outlined in this document. Prior to performing, reviewing, or evaluating NDT, all personnel shall be certified in accordance with this SAEP. Note:

9.2

NDT Level I and Level II certifications obtained through internationally recognized certification programs/organizations, i.e., PCN, CSWIP, etc., that meet the requirements of this SAEP should be adequate and accepted and waive further examination requirements.

Expiration Individual certification shall expire when:

9.3

9.2.1

Employment with Saudi Aramco is terminated.

9.2.2

At the end of five years for NDT Level I and II personnel (excluding certification for RTFI & UT).

9.2.3

The certification for RTFI & UT methods shall expire at the end of three years.

9.2.4

The ASNT Level III or ACCP Professional Level III certificate has expired for Level III personnel.

Re-certification 9.3.1

NDT Level I and Level II personnel shall be re-qualified for certification by examination in accordance with Section 9 of this document.

9.3.2

NDT Level III personnel shall be re-certified every five years by verifying that the ASNT Level III or ACCP Level III certificate is current in each method for which certification is sought. Page 9 of 15

Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

9.4

9.5

9.6

Individual certification shall be suspended if: 9.4.1

The vision examination interval exceeds one year. Certification is reinstated concurrently with passing the vision examination; or

9.4.2

The individual has not performed the duties in the method(s) for which certified during any six month period; or

9.4.3

The individual's performance is determined to be deficient in the method or technique for specific documented reasons; or

9.4.4

For NDT Level III personnel, when the ANST Level III certificate has not been renewed.

Note:

An employee's supervisor is responsible for tracking requirements of paragraph 9.4 and 9.5 and communicating any deficiencies to the CNDT&PS Unit of ID.

Individual certification shall be revoked when: 9.5.1

The individual has not performed the duties in the method(s) for which certified during any consecutive twenty-four month period; or

9.5.2

For NDT Level III personnel, the ASNT NDT Level III or ACCP Professional level III certificate has been revoked; or

9.5.3

The individual's performance is determined to be deficient in the method or technique for specific documented reasons; or

9.5.4

An individual's conduct is deemed by the Saudi Aramco Head NDT Level III, or his designee, to be or has been unethical or incompetent.

Reinstatement 9.6.1

Suspended Certifications Reinstatement of suspended certifications for NDT Level I, Level II or Level III shall be determined by the Saudi Aramco Head NDT Level III, or his designee. The requirement for ASNT NDT Level III certification may not be waived.

9.6.2

Expired or Revoked Certifications Certifications which have expired or have been revoked may only be reinstated by complying with Section 10.

9.7

At the discretion of the Saudi Aramco Head NDT Level III, or his designated representative, NDT personnel may be re-examined any time. Page 10 of 15

Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

10

Examinations The Head NDT Level III or his designated representative shall administer and grade all examinations. The examinations to verify physical and technical qualifications shall consist of the following: 10.1

10.2

Vision 10.1.1

The candidate shall be capable of reading a minimum of Jaeger Number 1 or equivalent type and size letters at a distance of not less than 12 inches (30.5 cm) on a standard Jaeger test chart with at least one eye. The ability to perceive an OrthoRater minimum of 8 or similar test pattern is also acceptable.

10.1.2

NDT personnel for all methods shall demonstrate the capability of distinguishing and differentiating contrast between colors or shades of gray used in the NDT method as determined by the Saudi Aramco Head NDT Level III.

10.1.3

Vision examinations, including color differentiation, shall be administered on the initial certification date and on an annual basis thereafter.

10.1.4

Vision examinations shall be conducted in accordance with an approved written procedure and conducted by personnel approved by an NDT Level III designated by the Saudi Aramco Head Level III.

General (Written) for NDT Levels I and II A general “closed book” examination, approved by the Saudi Aramco Head NDT Level III, shall be administered in accordance with paragraph 10.7 of this procedure. The minimum number of questions required for each method is listed in Table 3. The examination, representing a cross section of the basic principles of the applicable NDT method, shall be administered to the Level I or Level II candidate. The General written examinations shall be administered without access to reference material (closed book) except that necessary data, such as graphs, tables, specifications, procedures, and codes, will be provided.

10.3

Specific (Written) for NDT Levels I and II A specific “open book” examination, approved by the Saudi Aramco Head NDT Level III, shall be administered in accordance with paragraph 10.7 of this procedure. The minimum number of questions required for each method is listed in Table 3. The examination, representing a cross section of the various types of equipment, operating procedures, and test techniques that the applicant may encounter during specific assignments, shall be administered to each Page 11 of 15

Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

candidate. The specific examination shall address the specifications or Codes and acceptance criteria used in the applicable NDT method as used by Saudi Aramco. Table 3 – General and Specific Examination Question Requirements General

10.4

10.5

Specific

Level I

Level II

Level I

Level II

RT

40

40

20

20

RTFI

N/A

40

N/A

20

UT

40

40

20

20

UTT

40

40

20

20

MT

40

40

20

20

PT

40

40

20

20

VT

40

40

20

20

ET

40

40

20

20

AE

40

40

20

20

IR

40

40

20

20

ToFD

N/A

40

N/A

20

UT Phased Array

N/A

40

N/A

20

Practical examination for NDT Level I 10.4.1

A practical examination, approved by the Saudi Aramco Head NDT Level III or his delegate, shall be administered to each Level I candidate.

10.4.2

The candidate shall demonstrate proficiency using the applicable NDT method and technique to examine at least one test sample for each technique to be used in the candidate's job.

10.4.3

A checklist containing sufficient checkpoints demonstrating an understanding of test variables and Saudi Aramco NDT procedural requirements shall be included in this practical examination.

Practical Examination for NDT Level II 10.5.1

A practical examination, approved by the Saudi Aramco Head NDT Level III or his delegate, shall be administered to each Level II candidate. Page 12 of 15

Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

10.5.2

The candidate shall demonstrate proficiency using the applicable NDT method and/or technique to examine at least one test sample per technique and a minimum of two samples per method and by interpreting, evaluating, and documenting the results of the examination. The test samples shall be representative of the products that the candidate will encounter in performing the job functions. Note:

10.5.3

10.6

For ToFD and Phased Array examinations, the candidate shall demonstrate proficiency using at least two test samples.

A checklist containing sufficient checkpoints demonstrating an understanding of test variables and Saudi Aramco NDT procedural requirements shall be included in this practical examination.

Level III Examinations 10.6.1

Prior to Saudi Aramco certification examinations, the Level III candidate shall hold an ASNT Level III or ACCP Professional Level III Certificate with a currently valid endorsement for each method for which certification is sought.

10.6.2

The Inspection Department shall administer a written specific examination for each method for which certification is sought consisting of at least thirty questions relating to the comprehension of the NDT related requirements of specifications and/or standards used by Saudi Aramco. Copies of the applicable specifications and/or standards shall be available as reference material during the examination.

10.6.3

The Level III candidate shall, as a practical examination, prepare an NDT procedure for each method for which certification is sought appropriate to Saudi Aramco requirements. However, if documented experience demonstrates that the candidate has previously prepared acceptable NDT procedures in the method using the specifications, Codes, and standards applicable to the Saudi Aramco requirements, a written practical examination is not required. If experience is substituted for the written practical examination, the pertinent practical experience shall be documented.

10.6.4

An NDT Level III required performing tests or evaluating test results (including RTFI) shall sit and pass the Level II practical examination demonstrating his ability to perform the method.

10.6.5

The administrator of a Level III examination (the Level III Examiner) shall possess a current ASNT Level III or ACCP professional Level III

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Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

certificate in the applicable method and shall be designated as a Level III Examiner in writing by the Saudi Aramco Head NDT Level III. 10.7

10.8

11

Administration and Grading of Examinations 10.7.1

An NDT Level III shall be responsible for the administration and grading of examinations for NDT Level I and II personnel for those methods in which the NDT Level III has a valid ASNT Level III or ACCP Professional Level III certificate. The administration and grading of multiple choice questions may be delegated by the NDT Level III in writing. For the practical examination, the individual administering the examination must be an NDT Level III in the respective test method; or somebody delegated by NDT level III in the respective test method.

10.7.2

When an examination is administered for qualification, each candidate shall achieve a grade of at least 70% on each section of the examination and an average grade of 80% to be eligible for certification. All examinations shall have equal weight in determining the average grade.

10.7.3

All portions of a certification examination, i.e., general, specific and practical shall be completed within six months.

Reexamination 10.8.1

Candidates that fail to attain the required passing grades must receive additional documented training or wait at least 30 days for reexamination. The additional training shall address the deficiencies which caused the failure. A candidate shall not be reexamined using the examination and/or specimen previously failed.

10.8.2

Candidates will be permitted three attempts for certification per NDT method, i.e., a candidate will not be permitted to sit NDT certification examination (in the particular NDT method) after three failed attempts.

10.8.3

Candidates may re-sit the failed portion(s) only, i.e., general, specific or practical of a NDT certification examination provided that the score of the failed portion(s) is 60% or higher.

Qualification and Certification Records 11.1

The Saudi Aramco Inspection Department CNDT&PS shall be responsible for the administration and documentation of the Personnel Qualification and Certification Program in accordance with the policies established by the Saudi Page 14 of 15

Document Responsibility: Non-Destructive Testing Standards Committee SAEP-1140 Issue Date: 21 August 2011 Next Planned Update: 21 August 2016 Qualification of Saudi Aramco NDT Personnel

Aramco Head NDT Level III with concurrence by the Inspection Department Manager. 11.2

21 August 2011

The NDT records of the certified NDT individuals shall include the following: 11.2.1

Name and Saudi Aramco or Subcontractor Company ID # of certified individual;

11.2.1

Level of certification and NDT method including the techniques covered;

11.2.1

Educational background and documented history of training identifying the NDT training received, the organization providing the training, dates of training, hours of training, evidence of satisfactory completion of training, and the instructor's name;

11.2.1

Current experience showing continuing experience in the methods for which certified;

11.2.1

Previous experience for verifying initial certification;

11.2.1

Results of the vision examination;

11.2.1

Results of all, and copies of the most recent examination taken;

11.2.1

Dates of certification and/or recertification and expiration;

11.2.1

Signatures of the Saudi Aramco Head NDT Level III, or designated NDT Level III, and Superintendent, OID.

Revision Summary Revised the "Next Planned Update." Reaffirmed the content of the document, and reissued with minor revision.

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