Training Services

Inspection Training Course

Refinery NDE

Introduction/Training Objectives
Nondestructive examination (NDE) in the refinery industry is used to examine
materials, welds, or components to assess their quality or integrity without
impairing their future use or serviceability. As refinery inspectors or engineers, you
will be involved with NDE, even if you dont perform the actual examination or
interpret results. Performance and interpretation of any NDE method requires
specific training and certification in the method. Additional training should be
obtained if job responsibilities will include these functions.
This section will cover general information about refinery NDE. Subsequent
sections will address radiographic, ultrasonic, liquid penetrant, magnetic particle,
and visual examination methods used in the refinery industry.
The objective of this section is to:

Provide general information about NDE that you will need to know or
consider as a refinery inspector.

Refinery NDE Topics

The Role of NDE in the Refinery

Classification of NDE Methods
NDE Definitions
Inspection vs. Examination
NDE Selection
NDE Steps and Actions
InIn-Process NDE
NDE Demonstrations
NDE Codes and Standards
NDE Results

The topics listed above will be covered in this section.

Role of NDE in the Refinery

Quality Control During Fabrication

Mechanical Integrity Programs

Fitness-For-Service Evaluations

During fabrication, NDE is used in quality control checks to assure the quality of
materials and welds. It can be applied to incoming materials, work in progress, or
work which is completed. Detection of defects can identify fabrication problems, so
corrective action can be taken to prevent reoccurrence.
NDE is used extensively in mechanical integrity programs as an in-service inspection
tool to detect and monitor deterioration to refinery process equipment that could lead
to failure. It can also be used to determine the quality of in-service repairs and
alterations made by welding.
NDE is also a primary component in fitness-for-service evaluations of refinery
pressure equipment that may be corroded, cracked, or contain original fabrication
defects. Results from NDE are used in fracture mechanics models to determine
critical flaw size and remaining life. When evaluation allows equipment to remain
in-service, NDE is used to monitor the indications for growth and re-evaluation.

Classification of NDE Methods

Refinery NDE

Standard NDE Methods

Advanced NDE Methods

The refinery industry uses a mix of NDE methods and techniques. Refinery NDE
can be divided into two categories, standard and advanced methods. Standard
methods include radiography (RT), ultrasonics (UT), magnetic particle (MT), liquid
penetrant (PT), leak testing (LT), and visual examination (VT). The methods are
classified as standard because of their widespread use in the refinery industry.
Advanced NDE applies to specialized NDE methods that can be used to examine
refinery pressure equipment for gross or localized deterioration. These methods
typically require proprietary testing equipment. The cost usually limits their use to
key mechanical equipment whose failure could result in an uncontrolled release that
could pollute or cause a fire or explosion. Advanced methods include acoustic
emission of metallic materials, advanced ultrasonic techniques such as ultrasonic
imaging or sizing, tank floor scanning devices, internal tubular inspection devices for
tubular and air cooled exchangers, neutron back scatter radiation technique to detect
wet insulation, infrared-thermal testing techniques, to many other specialized
methods. Advanced methods are typically provided by NDE companies that
specialize in these methods and services. Their use is supplemental to required
inspections mandated by in-service inspection codes.

NDE Definitions

Nondestructive Examination

Indication (Types)

Interpretation

Evaluation

Discontinuity

As previously mentioned, NDE is used to assess integrity or quality of engineering

materials without impairing their future use or serviceability. It is used to detect,
locate, measure, and evaluate indications found during examination.
An indication may be relevant, nonrelevant, or false. Interpretation of the indication
will determine its significance. A relevant indication is caused by some kind of
condition or a discontinuity and requires evaluation. A nonrelevant indication is
caused by the same conditions, but has no relationship to a discontinuity that might
constitute a defect. A false indication is an indication that is interpreted to be caused
by a discontinuity at a location where no discontinuity exists. False indications are
also classified as nonrelevant.
A discontinuity is an indication where there is interruption in the normal physical
structure or configuration of a material, weld, or component that causes a detectable
indication or signal during the examination. A discontinuity is not rejectable, if it
does not exceed the specified criteria for acceptance. Discontinuities can include
cracks, lack of penetration or fusion, inclusions, porosity, laminations, or pits.

NDE Definitions
(continued)

Defect

NDE Technique

NDE Procedure

A defect is a discontinuity or a group of discontinuities whose indications do not

meet specified acceptance standards. Defects are unacceptable and cause for
rejection of the material, weld, or component. They may be repaired depending
upon the circumstances.
The NDE technique is special way of utilizing one of the NDE methods. For
example RT = Method. X-ray or Gamma ray = Technique.
An NDE procedure describes the equipment and sequence of events that are to be
followed to perform a given examination using a particular method or technique.

Inspection vs. Examination

Duties of the Authorized Inspector

Refinery process equipment goes through various stages of inspection and

examination over its life span. It starts during construction and continues on
throughout the service life of the equipment. One thing most codes do is to
differentiate between inspections and examinations, and personnel performing them.
In general, the term inspection applies to the functions of the Authorized
Inspector identified in the applicable construction or in-service code. The term
examination applies to those quality control or in-service functions where standard
or advanced NDE methods are used.
One of the functions of the authorized inspector is to review NDE reports and
results to applicable codes. In some cases, the inspector may be required to witness
NDE for procedure compliance.

NDE Selection
?????

ND E T o
o l Bo x

NDE selection can be difficult and may require help when choosing the best method
or technique to be applied. Help can be obtained from qualified Level III
individuals, but they will need enough information to make a proper
recommendation. Remember to ask questions and convince yourself that the method
and technique recommended or offered is capable of detecting what needs to be
discovered. When in doubt, get a second or even a third opinion. It is increasingly
popular to have NDE technology demonstrated to prove it is capable of detecting
discontinuities and defects in materials and welds prior to awarding contracts.
Errors in results of some advanced NDE technology can range from plus or minus
20% and must be taken into account when evaluating their use in the refinery. Some
methods work well on certain materials while being impractical or unusable on
others.

NDE Selection
(continued)
What are we trying
to detect?

What is the material type

and thickness?

What are the

limitations of the
method or
technique?

What is the extent

and coverage?
What acceptance standards
are to be used?

Is access limited?

What preparations
are needed?
Economics?

There are several considerations that should be taken into account when selecting an
examination method or technique. The first question should be, What are we trying
to detect? Cracks, corrosion, laminations? Some methods or techniques are
better at finding certain types of discontinuities or defects than others. Proper
selection is important to obtain desirable results.
What type of material is to be examined and its thickness? Some methods or
techniques are limited by material or thickness or may require more than one method
of examination.
What is the extent and coverage of the examination required? More is not always
better. Efforts should be concentrated on areas of concern. Global volumetric
methods may indicate potential problem areas, but need follow- up with standard
NDE methods.
Is access limited? If yes, then other methods or techniques may be considered.
What acceptance standards are to be used? This may make a difference on what is
or is not acceptable.

NDE Selection
(continued)
What are we trying
to detect?

What is the material type

and thickness?

What are the

limitations of the
method or
technique?

What is the extent

and coverage?
What acceptance standards
are to be used?

Is access limited?

What preparations
are needed?
Economics?

What are the limitations of the method or technique? Certain methods or

techniques may not be suited for the material or the type of discontinuity or defect
that is to be detected.
What are the surface preparation requirements? Power or hand brushing may be
acceptable for some examinations, but specific cleaning and/or preparation may be
required for others.
Economics? How expensive is the method or technique compared to other methods
that can be used? Some methods are more costly than others and may not be the
best choice. In some cases, there may be no alternative, but to use the more costly
methods because of their capabilities.

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NDE Steps and Actions

NDE Technique

Nonrelevant/False

Nonrecordable

Indication

Interpretation

Relevant

Discontinuity

Evaluation To
Acceptance
Standard

Recordable

Acceptance

Defect

Rejected

The flowchart above illustrates the steps and actions for any NDE method or
technique. The NDE technician who performs NDE will interpret indications to
determine if they are relevant, nonrelevant, or false. Nonrelevant and false
indications are nonrecordables, but may be noted in the remark section of an NDE
report.
Relevant indications are recorded and evaluated to acceptance standards by the NDE
technician.
Evaluation will determine if the indications are acceptable
discontinuities or a rejectable defect. The final report should document all
recordable indications and their evaluation. The report is submitted for final review
and acceptance by the construction or in-service AI.

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In-Process NDE

Hold Point Inspection

Witnessing NDE

Quality assurance inspection plans may identify if NDE is to be witnessed by the

inspector. This is called a hold point inspection. That is, no work will precede
beyond a certain point of construction or repair until the required examination is
performed and witnessed by the inspector.
To ensure that NDE is being done in accordance with the NDE procedure, inspectors
can witness the examination. By witnessing, the inspector can ensure the sequence
of steps described in the NDE procedure is being followed and the extent of
coverage is correct. NDE technicians are less likely to deviate from the established
procedure if they know they are being watched.

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NDE Demonstrations

Procedure Demonstration

Advance NDE Methods

When standard NDE procedures are modified for special situations, they should be
demonstrated to show they are capable of producing interpretable examination
results. For the same reason, advanced NDE methods should be demonstrated to
prove their capabilities. As with any NDE method, the limitation of the advanced
methods must be evaluated for proper selection and use.

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Codes and Standards

SNT-TC-1A

Written Practice

Qualification and certification requirements for NDE personnel differ between Codes
and Code Sections. Recommended Practice, No. SNT-TC-1A, Personnel Qualification
and Certification in Nondestructive Testing is commonly referred to as a guide for
establishing an employers written practice for qualification and certification of their
NDE personnel. It is published by the American Society for Nondestructive Testing in
Columbus, Ohio. When permitted by a code section, the manufacture may only be
required to certify the competency and eye examination of its NDE personnel.
A written practice is a stand alone document which describes the NDE methods used, the
education, training, examination, certification and recertification of NDE personnel and
the responsibilities for each level of certification. Most U.S. based refineries typically
require NDE personnel to be qualified and certified by their employer to SNT-TC-1A.
The written practice is usually subject to audit, as are the qualification records of the
NDE technicians. Most major NDE contractors are in compliance with SNT-TC-1A.
Auditing will determine discrepancies in compliance requirements.

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Codes and Standards

SNT-TC-1A

Trainee

Levels of Certification
Level I
Level II
Level III

There are typically three levels of certification, Level I, Level II, or Level III.
However, these levels may be further divided by the employer in accordance with
their written practice.
A trainee can assist a certified NDE technician, but they are not permitted to
perform, evaluate, or report results. Level I individuals may perform certain
calibrations and examination and even interpret results when certified to do so, but
may not be allowed to report results unless specifically trained and certified to do so.
Certification to Level II is typically required for performing examinations,
interpreting and reporting results.
Level III individuals typically do the training and write NDE procedures.
Certification is done by the employer. ASNT does provide certification for Level II
and Level III individuals, but the employer still must certify them in accordance with
their written practice. The American Welding Society also has its own program for
certifying NDE technicians but, again, these technicians must be certified by their
employer.

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Codes and Standards

ASME Boiler and Pressure Vessel Code

Section V, Nondestructive Examination

Methods Covered
Subsection A
Subsection B

The ASME Boiler and Pressure Vessel Code is an internationally recognized code
used in the construction of boilers and pressure vessels. Section V of this code
contains requirements and methods for NDE. These are code requirements to the
extent they are specifically referenced and required by other code sections. The other
code sections describe the extent of the examination, acceptance criteria and
qualification of NDE personnel. The NDE methods in this section are intended to
detect surface and internal discontinuities in materials, weld, and fabricated parts and
components.
Section V is divided into two subsections, A and B. Subsection A describes the NDE
methods to be used by the referencing code sections. Articles in this subsection cover,
among other items, such subjects as general NDE requirements, radiographic
examination, radiographic examination of metallic castings, ultrasonic examinations
for in-service inspections, ultrasonic examinations for materials and fabrications,
liquid penetrant examinations, magnetic particle examinations, eddy current
examinations of tubular products, visual examination, leak testing, and acoustic
emission examinations of fiber reinforced plastic vessels.
Subsection B contains articles covering a number of standards that have been adopted
by Section V from the American Society for Testing Materials (ASTM). They range
from standard practices and guides to standard test methods. They are for information
only, unless referenced in subsection A or other code sections.

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Standards and Codes

ASME Boiler and Pressure Vessel Code
Section VIII, Division 1, Pressure Vessels
NDE Requirements For Welds

Method
RT
UT

Written
Procedure
No
Yes

Acceptance
Criteria
Part UW
Appendix 12

Personnel
Certification
By employer1
By employer1

Eye
Examination
Not Covered
Not Covered

PT

Yes

Appendix 8

By employer

Yes

MT

Yes

Appendix 6

By employer

Yes

VT

Yes

See Code

By employer

Not Covered

SNT-TC-1A used as guideline.

The above table lists the NDE requirements for Section VIII. When Article 1 in
Section V is referenced by other code sections for qualification of personnel, then the
requirements of that article need to be satisfied. Article 1 requires personnel to be
qualified in accordance with SNT-TC-1A or a system specifically accepted by the
referencing code section.
Section VIII, Division 1 requires the manufacturer to certify that personnel
performing or evaluating radiographic examinations be qualified and certified in
accordance with their employers written practice. SNT-TC-1A is referenced as a
guide for written practice development. Provision for training, experience,
qualifications, and certifications are required to be described in the Manufactures
Quality Control Manual.
For UT, the manufacturer must certify personnel in accordance with their written
practice. SNT-TC-1A is referenced as a guide. Provision for training, experience,
qualifications, and certifications are also required to be described in the
Manufacturers Quality Control Manual.
For MT, PT, and VT, see the chart above.

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Standards and Codes

ASME B31.3 Chemical Plant
and Petroleum Refinery Piping
NDE Requirements For Welds

Method
RT
UT

Written
Procedure
Yes
Yes

Acceptance
Criteria
B31.3
B31.3

Personnel
Certification
By employer1
By employer1

Eye
Examination
Not Covered
Not Covered

PT

Yes

B31.3

By employer1

Not Covered

Not Covered
Not Covered

MT

Yes

B31.3

By employer

VT

Yes

B31.3

By employer1

SNT-TC-1A used as guideline.

NDE examiners are required by ASME B31.3 to have training and experience
commensurate with the needs of the specified examinations. For this purpose, SNTTC-1A is listed as a guide. The employer is also required to certify and maintain
records of the examiners employed, showing dates and results of personnel
qualifications. These records are required to be available to the Inspector.
ASME B31.3 requires all examinations to be performed in accordance with written
procedures. This includes visual examinations, magnetic particle examinations,
liquid penetrant examinations, radiographic examinations, ultrasonic examinations,
and in-process examinations contained in Types of Examination. Procedures are
required to be written to ASME Section V.
Examiners are required by B31.3 to have training and experience commensurate with
the needs of the specified examinations. For this purpose, SNT-TC-1A is listed as a
guide. The employer is also required to certify and maintain records of the
examiners employed, showing dates and results of personnel qualifications. These
records are required to be available to the Inspector identified in B31.3.

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Codes and Standards

API-510 Pressure Vessel Inspection Code

NDE Supplements Visual Inspection

NDE Certification Is Not Required

Examiner Is Not Qualified Under APIAPI-510

NDE Procedures

The API-510 Pressure Vessel Inspection Code covers vessels after they have been
placed into service. NDE is routinely performed to monitor pressure vessels for inservice deterioration and to examine materials and welds when repairs or alterations
are made by welding. Most refineries in the United States require NDE technicians
to be certified and examinations performed in accordance with written procedures.
The requirements contained in SNT-TC-1A are typically cited. Under the owneruser organization responsibilities in API-510, the owner-user is responsible for
documenting and maintaining inspection and quality assurance inspection
procedures. This would include procedures for NDE. The owner-user is also
responsible for maintaining controls necessary so that the work of contract inspection
and repair organizations meets the same requirements as the owner-user. The best
way this is achieved is by making the requirements known and by auditing for
compliance.

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Codes and Standards

API-570 Piping Inspection Code

Examiner Assists Inspector

Examiner Not Qualified Under APIAPI-570

NDE Certification Required

Certification Records

SNTSNT-TCTC-1A

American Welding Society

The API-570, Piping Inspection Code covers piping systems after they have been
placed in service. This code distinguishes between inspection and examination.
Inspection applies to the functions of the authorized piping inspector. An examiner
is a person who assists the inspector by performing specific NDE on piping systems.
API-570 does not require the examiner to be qualified under API-570 or be an
employee of the refinery, but does require the examiner to be trained and qualified in
the applicable procedures used. API-570 does require the employer of the examiner
to maintain certification records of the examiners employment, including dates and
results of personnel certifications and to make them available to the Inspector for
review. API-570 identifies SNT-TC-1A and the American Welding Society Weld
Inspection as examples of other certifications for examiners.

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Codes and Standards

National Board Inspection Code

NDE Requirements

NDE of Repairs and Alterations by Welding

Alternative Methods

The National Board Inspection Code covers boilers and pressure vessels after they
have been placed in service. It requires NDE requirements, including technique,
extent of coverage, procedures, personnel qualifications, and acceptance criteria to
be in accordance with the original code of construction used for the construction of
the pressure retaining item. Weld repairs and alterations are required to be subjected
to the same NDE requirements as the original welds. Where this is not practical,
alternative NDE methods acceptable to the Authorized Inspector (AI) and the
jurisdiction may be used.
An example of when alternative NDE methods could be applied is when its
impractical to use radiography. The alternative to radiography would be ultrasonic
examination using straight and angle beam techniques.

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Codes and Standards

Company Standards

Requirements

Company standards for NDE can supersede Code requirements when they are more
stringent. If not stated in the project specifications, the choice is left to the
manufacturer.

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NDE Results

Validating Results

Follow-Up Actions

Results should be validated whenever there is a question or doubt in the technique,

equipment operation, or the ability of the technician. Re-examination or other NDE
methods or techniques may be used to validate results when questions or doubts
arise. Destructive sampling may also be used to validate results. This may include
coupon removal or removal of a tube or pipe and splitting it.
NDE results may indicate that the examination needs to be expanded. A good
example is when a spot radiograph shows the weld segment radiographed contains
flaws or when thickness measurements indicate corrosion at one or more thickness
measurement locations (TMLs).
For in-service examinations, results may indicate that the inspection frequency needs
to be adjusted to monitor an in-service deterioration. They may indicate repairs or
replacements are required or they may trigger a fitness-for-service evaluation to
determine a course of action.

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NDE Results
(continued)

Validating Results

Follow-Up Actions

As the inspector in the refinery, you are responsible for reviewing NDE reports for
equipment in your area of responsibility. If your review raises a flag, then take
appropriate action to resolve the issue. If this means having the examination redone
or expanded, so be it. You may not be popular, but you will be correct.

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