INE 150 Instructor PDF

INE 150
REQUIREMENTS FOR PERFORMING

NONDESTRUCTIVE TESTING
(INSTRUCTOR)
THE TRAINING MATERIALS CONTAINED IN THIS MANUAL WERE DEVELOPED FOR THE SAUDI ARABIAN OIL COMPANY (SAUDI ARAMCO) AND ARE INTENDED
FOR THE EXCLUSIVE USE OF SAUDI ARAMCO EMPLOYEES ENROLLED IN PROFESSIONAL ENGINEERING DEVELOPMENT COURSES. ANY MATERIAL
CONTAINED IN THIS MANUAL WHICH IS NOT ALREADY IN THE PUBLIC DOMAIN MAY NOT BE COPIED, REPRODUCED, SOLD, GIVEN, OR DISCLOSED TO THIRD
PARTIES, OR OTHERWISE USED, IN WHOLE OR IN PART, FOR PURPOSES OTHER THAN FOR USE IN SAUDI ARAMCO’S PROFESSIONAL ENGINEERING
DEVELOPMENT COURSES WITHOUT THE PRIOR WRITTEN CONSENT OF THE VICE-PRESIDENT, ENGINEERING SERVICES, SAUDI ARAMCO.
INE 150 INSTRUCTOR REVISIONS
Date Description Page(s)
09/16/00 Revised Cover Page with New Corporate Logo Cover
09/17/07 Combined modules 2 and 3 and rearranged PPT slides; All

updated teaching schedules.
a
INE 150 INSTRUCTOR OBJECTIVES
OBJECTIVES
TERMINAL OBJECTIVE
Upon completion of this module, the Participant will be able to determine the
requirements for performing nondestructive testing of Saudi Aramco systems and
components, using the applicable Saudi Aramco and industry standards.
ENABLING OBJECTIVES
In order to accomplish the Terminal Objective, the Participant will:
 Identify significant base metal and weld metal discontinuities.

 Identify the codes, standards, procedures, and instructions associated with
nondestructive testing at Saudi Aramco.
 Locate the nondestructive testing requirements and acceptance criteria for
weldments in the applicable codes, standards, procedures, and instructions.
Note: definitions of words in italics are contained in the Glossary
1
INE 150 INSTRUCTOR PREPARATION
LESSON PREPARATION
The following equipment and materials will be required to teach this course. The
Instructor should give sufficient lead time to ensure that the materials are on hand in
the classroom.
Equipment
 Whiteboard and Markers.

 Power Point Projector and Computer/with PP Presentation Program loaded.
 Projection Screen for Power Point Presentation
Materials
 Power Point Transparencies of all Module Figures.

 Transparencies of topics other than figures (determined by Instructor).
 One copy of Handout 1, ASNT manual, for every Participant
 One copy of Participant Module, INE 150.01, for every Participant.
 One copy of Combined Addendum, for every Participant
 One copy of Instructor Module, INE 150.01 for Instructor and for instructor
redlines.
Additional Arrangements
 Classroom of suitable size to accommodate Participants
2
INE 150 INSTRUCTOR COURSE SCHEDULE
COURSE SCHEDULE
The following is the course schedule for this class.
SATURDAY 0X/XX/XX
7:30 – 9:00 Theory on the following NDT methods: Visual Testing (VT), Liquid
Penetrant Testing (PT), Magnetic Particle Testing (MT)
9:00 – 9:20 Coffee Break
9:20 – 10:20 Classroom exercises on the above NDT methods
10:20 – 1130 Laboratory exercises on studied NDT methods
11:30 – 12:30 Lunch Break
12:30 – 1:15 Theory on the following NDT method: Electromagnetic Testing (ET)
1:15 – 1:45 Classroom exercises on the above NDT method
2:00 – 3:30 Lab. Demonstrations of different NDT tools based on ET

principles MFL TC-5700
SUNDAY 0X/XX/XX
7:30 – 9:00 Theory on the following NDT methods: Ultrasonic Testing (UT),
Radiographic Testing (RT)
9:20 – 10:20 Classroom exercises on the above NDT methods
10:20 – 1130 Laboratory on UT method Thickness Gage Measurements P-scan
12:30 – 1:45 Radiation Safety Presentation
2:00 – 3:30 Lab. Demonstrations on RT method IR-192, X-ray
3
MONNDAY 0X/XX/XX
7:30 – 9:00 Specialized Testing Methods, Eddy Current Testing - MAD8, Infra Red ,
Pulsed Thermal Wave Imaging, Acoustic Emission, Guided Wave,
Lorus, P-Scan, Isonic, UT Strips
9:20 – 11:30 Specialized Testing Methods; Continue, Remote Field Testing, Internal
Rotary Inspection, System Magnetic Flux Leakage, LOTIS, LIZARD,
FLOOR MAP Tank Scanning, Digiray, Linear Accelerator
12:30 – 1:45 Radiation Safety Presentation
2:00 – 3:30 Laboratory Demonstrations on specialized NDT methods
TUESDAY 0X/XX/XX
7:30 – 9:10 Identifying Significant Base Metal and Weld Metal, Discontinuities
9:30 – 11:30 Codes, Standards, Procedures, and Instructions, associated with

Nondestructive Testing at Saudi Aramco
12:30 – 1:30 Codes, Standards, Procedures, and Instructions, associated with

Nondestructive Testing at Saudi Aramco; Continue
2:00 – 3:30 Nondestructive Testing Requirements and Acceptance Criteria
4
WEDNESDAY 0X/XX/XX
7:30 – 9:00 NDT Methods Overview – Film
9:20 – 10:30 General Review
10:30 – 11:30 Final Test
5
INE 150 INSTRUCTOR INFORMATION
OUTLINE OF TOPICS TO DISCUSS AIDS
Place the start time of the module introduction Place

a time in the blank time place each time you finish a
major topic, of item of instruction.
Start Time .
Display PPT1 on the screen before Participants get

PPT 1, Module Cover
into classroom. Leave it on until you start the class.
Slide
Explain the Course Schedule. Explain that if there

are personnel that have to leave at noon on PPT 2 and PPT 10,
Wednesday, their critique will be on Tuesday, last Course Schedule.
period
6
PPT 11, Objectives

INTRODUCTION
Explain the topics that will be covered during this
module.
 Identifying significant base metal and weld metal

discontinuities.
 Identifying the Codes, Standards, Procedures,
and Instructions associated with Nondestructive
Testing at Saudi Aramco.
 Locating Nondestructive Testing requirements
and Acceptance Criteria for weldments.
PPT 12, Purpose of NDT

Purpose
Explain the purpose of NDT which is:
 To prevent the premature failure of components

or weldments
 To improve the reliability and the safety of
production and maintenance operations at Saudi
Aramco.
 To check and monitor the condition of equipment
used in all aspects of oil extraction and refining
 To check during fabrication, construction, and
maintenance repair activities.
7
Use the analogy of how a doctor performs a medical

check-up to diagnose the condition of his patient to
how a NDT inspector diagnoses the condition of a
component.
Discuss the difference between NDT and NDE and Terminology

review the terms VT, PT, MT, UT, RT, and and
provide a brief description of each.
Explain that the Participant's role is to recognize when

NDT can and should be used to ensure or improve
the safety, quality, and reliability of Saudi Aramco
facilities and equipment.
Use any or all of the examples in the Instructor

Addendum A to make the point.
Advantages
PPT 13
Explain the advantages of NDT which are:
 NDT improves reliability

 NDT tested components are not destroyed
 Cost effective
 Increase in quality of fabrication
8
PPT 14
Discussion Points for Each NDT Method
NDT Methods PPT15
Visual Testing PPT 16
Visual Weld Examination

- Requirements, aids, types of weld gauges, common PPT 17- 24
applications
PPT 25, Purpose

Liquid Penetrant Testing
Advantages
PPT 26
Principles of Operation
PPT 27 - 28
Discuss classification of penetrants and removal

PPT 29
methods.
Note: Saudi Aramco uses only color constant solvent

removable dies.
Applications
PPT 30
Limitations
PPT 31
Discuss common discontinuities

PPT 32
9
PPT 33, Purpose

Magnetic Particle Testing (MT)
Advantages PPT 34
Reference Table 3-2, Page 3-9, ASNT Manual)
Principles of Operation PPT 35 -39
Common Applications PPT 40
Limitations PPT 41
Common Discontinuities PPT 42
Nonrelevant Indications PPT 43

- Refer to pages 4-18 thru 4-20, ASNT Manual
- Also pages 14-2 and 14-3, ASNT Manual
PPT 44
Electromagnetic Testing
Advantages
(not applicable at Saudi Aramco)
Purpose PPT 45 - 46
Principles of Electromagnetic Testing PPT 47
Test Equipment PPT 48 49

Refer to Figures 10:13 and 10:14, Page 10-12,
ASNT Manual

Refer to Lesson 11, ASNT Manual
10
Limitations PPT 51
- Other limitations – Lesson 11, ASNT Manual
Common Discontinuities
- Refer to “Discontinuities”, Pages 11-1 thru 11-11,
ASNT Manual
PPT 52
Ultrasonic Testing (UT)
Purpose
Advantages PPT 53-54
References for Principals of UT PPT 55 - 56
Types of Scans (CRT - cathode ray tube) PPT 57

- Refer to “Specific Applications”, Pages 7-11
through 7-20, ASNT Manual
Limitations PPT 59
- Refer to “General Considerations” in “Selection of
Method”, Pages 7-1 through 7-5, ASNT Manual
Nonrelevant Indications PPT 61

- Refer to “Ultrasonic, Nonrelevant Indications”,
Page 14-3, ASNT Manual
11
Radiographic Testing (RT)
Purpose PPT 62
Advantages PPT 63 - 66
Discuss the types of electromagnetic radiation PPT 67

used to perform radiography at Saudi Aramco
Discuss the DANGERS associated with RT. PPT 68

- Reference GI 150.003 “Saudi Aramco Radiation
Safety Guidelines”
- Reference SAEP-1141, “Radiation Safety”
Devices PPT 69
Radiation Safety PPT 70

-Refer to “Radiation Safety”, Pages 9-7 through 9-
21, ASNT Manual.
Variables of Exposure PPT 71

- Refer to “Geometry of Exposure”, Pages 8-13 and
8-14, and “Essential Variables of Exposure”, Pages
8-15 through 8-20, ASNT Manual
Film Quality PPT 72 - 74

- Discuss contrast and definition
Limitations PPT 76

- (Pages 9-24 through 9 36, ASNT Manual).
Nonrelevant Indications
- (“Radiography, Nonrelevant Indications”, Page
14-3 ASNT Manual)
12
PPT 78
Specialized Methods
Refer to “Infrared/Thermal Testing”, Pages 12-10 PPT 79 - 80

Pulsed Thermal Wave Imaging PPT 81 - 91
Acoustic Emission PPT 92 - 98

- Refer to “Acoustic Emission”, Pages 12-23
Explain the use of UT Guided Wave PPT 99 - 104
Explain the use of Lorus PPT 105 - 110
Explain the use of P-Scan PPT 111 - 114
Explain the use of Isonic PPT 115 - 118
Explain the use of UT Strips PPT 119 - 121
Explain the use of Remote Field Testing (RFT) PPT 121 - 124
Explain the use of Internal Rotary Inspection PPT 125 - 126

System (IRIS)
Explain the use of RFT & IRIS Results PPT 127
Explain the use of Magnetic Flux Leakage PPT 128 – 131
Explain the use of LOTIS PPT 131 – 132
Explain the use of LIZARD PPT 133 - 136
13
Magnetic Flux Leakage Tank Floor Scanning PPT 136 - 140

- Discuss the use of magnetic flux leakage basis
used to examine AST carbon steel floor plates.
Explain the use of Digiray to produce high PPT 141 – 144

quality digital radiography.
Discuss the use of linear accelerator to PPT 145 - 147

produce high quality inspection.
Holiday Detector: application and classes PPT 148
Instrumented Pipeline Tool PPT 149

- Discuss the use of a scraper and advantages
END OF SESSION ONE PPT 150
14
OBJECTIVES – CODES AND STANDARDS PPT 151
Discontinuities PPT 152

- Discuss base and weld metal; Ref. Lesson 14,
“ASNT Manual.
PPT 153
Base Metal Discontinuities
Explain that a discontinuity is an interruption of the
typical structure of a material such as a lack of
homogeneity in the mechanical, metallurgical, or
physical characteristics of the material or
weldment.
Base metal discontinuities are classified in accord

with the point in the manufacturing process in
which such discontinuities occur. These
discontinuities are classified as follows:
 Inherent
 Primary Process
 Secondary Process
PPT 3,
154Inherent
Inherent Discontinuities
Discontinuities
Inform the Participants that they will need to follow
along in the ASNT Manual as the following figures
are referenced in the following discussions.
Explain that inherent discontinuities result from the PPT 155

original melt, casting, or solidification of the ingot
of primary metal:
 Stringer PPT 4, Inherent

Discontinuities (Cont’d)
 Seam
 Lamination
 Pipe
Refer Participant to Table 1 and the Figures listed.
15
For each figure, discuss the following:
 Cause of the discontinuity

 Common location (surface or internal)
 Best method of detection
PPT 5, Primary Process

Primary Process Discontinuities PPT 156 - 157
Discontinuities
Explain that the primary process discontinuities
are formed during the rough shaping and forming
of metals during primary processing:
 Forging
 Casting
 Rolling
 Drawing
Refer Participant to Table 2 and the listed PPT 6, Primary Process

Figures. For each figure, discuss the following:
Discontinuities (Cont’d)
 Cause of the discontinuity
Secondary Process Discontinuities PPT 7, Secondary

Explain that the secondary process Process Discontinuities
PPT 158 – 159
discontinuities are associated with final finishing
operations such as machining and heat PPT 8, Secondary
treatments Process Discontinuities
(Cont’d)
 Refer the Participant to Table 3 and the
listed Figures. For each figure, discuss the
following: Cause of the discontinuity
16
PPT 9, Weld Metal

Weld Metal Discontinuities Discontinuities
PPT 160
Explain that there are numerous types of weld
metal discontinuities. Each will be discussed and
shown individually.
Refer Participant to 14-10 through 14-12 of ASNT.
Refer Participant to Work Aid 1 for definitions of

discontinuities.
PPT 10, Cracks in Welds

Cracks in Welds
Explain that cracks severely reduce the strength of PPT 161 - 162
a weld. only small cracks are acceptable and only
on non-critical welds. Cracks can be:
 Either longitudinal (aligned with the weld

bead) or transverse (perpendicular to the weld
bead
 Occur from stresses that are developed
during the welding process usually from
severe restraint of parts
 Surface or subsurface
 Are not reliable
 Best detected by RT, UT, MT, PT, or VT PPT 11, Cracks in Welds
Refer Participant to Figure 1. (Cont’d)
Slag Inclusions
PPT 163 - 164
Explain that slag inclusions are located within a weld
and they occur when gases, impurities, or flux
contaminate a slag weld:
 Caused by poor welding technique, welding with

inadequate heat input, or improper bead
placement
 Normally located within a weld, external slag can
be cleaned and may reveal undercut
17
 Best detected by RT and UT

Refer the Participants to Figure 2.
Lack of Fusion
PPT 165 - 166
Explain that lack of fusion has the following aspect:
 Usually caused by poor welding technique,

welding with inadequate heat input, or improper
bead placement
 Usually located at the weld metal and base
metal interface.
 Occurs when the molten weld metal does not
completely fuse with an adjacent weld bead or
with the base material
 Almost always classified as a defect because
the weld is not reliable
 Best detected by RT or UT
Refer Participants to Figure 3.
PPT 167 – 168

Incomplete Root Penetration
Incomplete root penetration is :
 Usually caused by inadequate heat or improper

weld joint fit-up
 The weld metal does not completely penetrate
into the root area and consume both base
metals
 It is usually located on the root surface
 It is unacceptable in critical applications
 This defect is best detected by RT or UT
Refer the Participant to Figure 4.
18
PPT 169 - 170

Weld Undercut
Explain that weld undercut is an area in which the
actual weld is less than the specific contour
resulting in a depression on the surface at the point
at which the weld metal contacts the base metal.
This defect is:
 Caused by poor welding technique, excessive

heat, or traveling too fast
 Located on the surface at the weld toe
 Best detected by VT, PT or MT
Cold Lap PPT 171 - 172

Explain that a cold lap occurs when the weld metal
freezes too quickly and does not fuse with the
surface of the base metal. Cold lap is most typically
found on the cover pass at the toe of the weld. This
discontinuity:
 Caused by inadequate heat or too high of a

travel speed.
 Located on the surface, most typically found on
the cover pass at the toe of the weld.
 Best detected by VT, PT or MT.
Root Concavity
PPT 173 - 174
Explain that a root concavity occurs in weld joints
that are welded from one side only. . The following
are typical causes of root concavity:
 Too much heat, which causes shrinkage

 A root opening that is too wide
 Insufficient deposits of weld metal
 Located on root surface
19
 Best detected by RT or UT
Crater Pit
PPT 175 - 176
Explain these characteristics of the crater pit
 The crater pits are located on the weld bead

surface and result from the rapid breaking of
the electric arc so that the weld puddle freezes
too quickly leaving a small void.
 The rapid freezing normally occurs with Gas
Tungsten Arc Welding
 Located on the surface of the weld
PPT 177 - 178

Arc Strike
Explain that arc strikes:
 Are caused by dragging the electrode over the

surface of the base metal in an effort to initiate
an arc for welding
 Is located on the surface of the weld or base
metal
PPT 179 - 180

Weld Porosity
Explain that weld porosity is
 Caused by inadequate flux or shielding gas

coverage, allowing oxygen to contaminate the
molten weld metal prior to solidification.
 Located within a weldment or on the weld
20
surface.
 Best detected with RT or UT.
PPT 181
Nonrelevant Indications
Explain this concept to the participants. Refer them
to pages 14-2 and 14-3 of ASNT for more
information.
 Not caused by actual discontinuities

 Examples of nonrelevant indications:
 Scratches or water spots on radiographic
film
 Inability to adequately remove all of the
surface liquid penetrant
 Can be determined to be nonrelevant by the
NDT technician based on:
 The method of NDT
 The configuration of the component being
examined
 The appearance of the indication
PPT 182
Defects
Explain that a defect in a weld is a discontinuity that
would probably result in an early failure of the weld.
The discontinuities must be compared to the
acceptance criteria to determine whether they
actually are defects. The acceptable criteria
depends upon the codes and standards for
fabrication.
Explain the two examples.
21
Review Work Aid 1.
Do Exercise 1, using Work Aid 1.
Critique Exercise 1.
PPT 183, Purpose of

CODES, STANDARDS, PROCEDURES, Welding Standards
AND INSTRUCTIONS ASSOCIATED WITH
NONDESTRUCTIVE TESTING AT SAUDI
ARAMCO
Explain the purpose of the welding standards which
is:
 To establish the minimum requirements for

welds:
 Design
 Materials
 Fabrication
 Inspection
 Testing
 To ensure a level of quality and safety that is
consistent with the intended service
Explain each of the following organizations. Briefly
explain the organizations responsible.
American National Standards Institute

(ANSI) PPT 184
 Coordinates activities of all other standard

writing organizations.
 Reviews and certifies that standards are correct
22
PPT 185 - 186

American Society of Mechanical
Engineers (ASME)
Explain that this is the main organization regarding
pressure vessels and piping in Saudi Aramco.
Explain each of the main standards that follow and
refer the Participant to the correct Addendum:
 ASME Code B31.1, Power Piping. Refer the

Participant to Addendum A1
 ASME Code B31.3, Chemical Plant and
Petroleum Refinery Piping. Refer the
Participant to Addendum A2
 ASME Code B31.4, Liquid Transportation
Systems for Hydrocarbons, Liquid Petroleum
Gas, Anhydrous Ammonia, and Alcohols.
Refer the Participant to Addendum A3
 ASME Code B31.8, Gas Transmission and
Distribution Piping . Refer the Participant to
Addendum A4
 ASME Boiler and Pressure Vessel Code,
Section I. Refer the Participant to Addendum
A5
Section IV. Refer the Participant to
Addendum A6
Section V. Refer the Participant to Addendum
A7
Section VIII. Refer the Participant to
Addendum A8
23
American Society for Nondestructive

Testing (ASNT)
Explain that ASNT organizes and distributes
technical information that is specific to NDT, such
as the manual the Participant is using in class.
PPT 187
American Welding Society (AWS)
Explain that the AWS provides standards for the
welded fabrication of structures and bridges with
structural steel and sheet metal. For the purpose
of this course, only AWS D1.1 is referenced and
provides:
 Acceptance standards and welding

requirements
 Requirements for the qualification of weld
procedures and welders
 Refer the Participants to Addendum A9
American Petroleum Institute (API) PPT 188
Explain that the American Petroleum Institute (API)
establishes guidelines that are specific to the
petroleum industry’s equipment and products.
Explain each of these standards:
 API 510. Refer the Participant to

Addendum A10
Addendum A11
Addendum A12
 API RP-2A. Refer the Participant to
Addendum A13
24
PPT 189 - 191

Saudi Aramco Engineering Procedures
Explain that as already indicated some of the
SAIPs and the GI will become SAEPs in the
immediate future. Following are some of those
concerning NDT that have already been changed.
 SAEP-1140
 SAEP-1142
 SAEP-1146
25
Review Work Aid 2
Do Exercise 2
Critique Exercise 2
PPT 192, Equipment and

LOCATING NONDESTRUCTIVE TESTING Material (NDT)
REQUIREMENTS AND ACCEPTANCE
CRITERIA FOR WELDMENTS
Explain that the applicable codes, standards,
procedures, and instructions that contain the NDT
requirements and acceptance criteria are given
under each heading for the following equipment
and materials (explain briefly as a overview). Each
point will be covered individually (refer Participants
to the Addendum Table of Contents).
 Power Piping
 Chemical Piping
 Liquid Petroleum and Anhydrous Ammonia
Piping
 Gas Transmission Piping
 Power Boilers
 Heating Boilers
 Pressure Vessels
 Buildings and Structures
 Large Low Pressure Storage Tanks
 Above Ground Atmospheric Storage Tanks
 Drilling Platforms
26
PPT 194
Power Piping
Explain that NDT requirements for power piping

welds are described in ASME B31.1, Chapter VI,
Table 136.4. Refer Participants to this table.
Explain that the weld acceptance criteria is

located in Paragraph 136.4 of ASME B31.1 of
Addendum A1. Refer the Participants to this
addendum and paragraph.
PPT 195
Chemical Piping
Explain that NDT requirements for power piping

welds are described in Table 341.3.2A of ASME
B31.3 located on page A26 of the Addendum A2
shows the acceptance criteria for welds of chemical
piping. The criteria is based on service condition:
 Normal fluid
 Severe cyclic, or
 Category D
The NDT requirements for chemical piping welds
are described in ASME B31.3, Chapter VI,
Paragraph 341.4 located in Addendum A2.
PPT 196
Liquid Petroleum and Anhydrous
Ammonia Piping
Explain that the NDT requirements for liquid
petroleum and anhydrous ammonia piping welds
are described in ASME B31.4, paragraph 434.8.5,
page A46, Addendum A3. Additional
requirements - Chapter VI, pages A47 and A48.
27
PPT 197
Gas Transmission Piping
Explain that the NDT requirements for gas
transmission piping welds are described in ASME
B31.8, Chapter II, Paragraph 826. located on page
A57 of Addendum A4. Knowledge of the weld
location class is required to properly determine the
NDT requirements.
PPT 198
Power Boilers
Explain that the NDT requirements for the
fabrication of power boilers are described in ASME
Section I, Part PW. Paragraphs PW-11 (Page A62
of Addendum A5) and Paragraph PW-41 (Page
A63) are based on component diameter, wall
thickness, and component exposure to radiant heat
or furnace gases.
The weld acceptance criteria is provided in

Paragraphs PW-51 (Page A65) and PW-52
(Page A66)
PPT 199
Heating Boilers
Explain that ASME Section IV does not require
specific NDT beyond a visual examination.

Paragraph HW-820 located on page A71 of
Addendum A6.
28
PPT 200
Pressure Vessels
The NDT requirements for pressure vessel welds
are described in ASME Section VIII, Division 1,
paragraph UW-11. located on page A84 of
Addendum A8, based
 The type of weld

 The weld category, or
 The diameter or the thickness of the weld.
Paragraph UW-51 located on page A85.
PPT 201 - 202

Buildings and Structures
The NDT requirements for structural welds that are
in statically loaded buildings and structures are
described in AWS D1.1 Paragraphs 6.7 and 8.15
located on page A113 and A114, respectively
(Addendum A9).
The weld acceptance criteria is found in AWS D1.1

at the Paragraphs listed in Error! Reference source
not found. (refer Participants to Table 4 in the
Participant Manual and to Addendum A9).
29
PPT 203 - 205

Large Low Pressure Storage Tanks
Explain that the NDT requirements for welds in
large low pressure storage tanks are described in
API 620, Section 5, Pages A125 through A129
(Addendum A11). Type and orientation of the
weld, as well as to the base material thickness, is
required to determine the NDT requirements
Table 5 gives the location of the acceptance criteria

for Large Low Pressure Storage Tanks gives the
location of the acceptance criteria for Large Low
Pressure Storage Tanks (efer Participants to Table
5 and Addendum A11.)
Above Ground Atmospheric Storage PPT 206 - 207

Tanks
The NDT requirements for welds in above ground
atmospheric storage tanks are described in API
650, Section 5, Pages A132 through A134 of
Addendum A12. The type and orientation of the
weld, as well as to the base material thickness, is
required to determine the NDT requirements
Table 6 gives the location of the acceptance criteria

(refer Participants to Table 6 in the Participant
module and Addendum A12). Explain that the
notes to the table are the same as Table 5.
30
Drilling Platforms PPT 208

Explain that the NDT requirements for drilling
platforms are described in API RP-2A, Section 13
located on pages A141 through A143 of
Addendum A13.
The Weld acceptance criteria is located in

paragraph 13.4.3b of API RP-2A, Section 13, which
references AWS D1.1 (pages A113 through A117
of Addendum 9).
Review Work Aid 3
Do Exercise 3
Critique Exercise 3
Perform Evaluation
Critique Evaluation
Stop Time:
31
INE 150.01 INSTRUCTOR EXERCISES
EXERCISE KEY
EXERCISE 1 KEY: IDENTIFY SIGNIFICANT BASE METAL AND

WELD METAL DISCONTINUITIES
Use Work Aid 1 to name the type of discontinuity that is shown in Figures 11 through
18. Briefly describe the possible causes for the discontinuity. Use the blank spaces
provided.
1. Refer to Figure 1
Lamination that results from gas cavities, blisters, or inclusions that
were made directional during rolling.
Figure 1. (To be used in Question 1)
32
2. Refer to Figure 2.
Quench crack that results from cooling during a quench cycle.
33
Grinding crack that results from localized heating of the surface.
34
Crack in weld that results from improper cooling or restraint of
the parts being welded.
35
Porosity, resulting from gas trapped in solidifying metal
during welding.
36
6. Refer to Figure 6.
Undercut, resulting from excessive heat applied during welding
operation.
37
7. Refer to.Figure 7
Incomplete root penetration, resulting from welding technique,
insufficient heat, or improper joint fit-up.
38
8. Refer to. Figure 8.
Lack of fusion, resulting from insufficient heating of base metal
surfaces.
39
EXERCISE 2 KEY : IDENTIFY THE CODES, STANDARDS,

PROCEDURES, AND INSTRUCTIONS
ASSOCIATED WITH NONDESTRUCTIVE
TESTING
For each typical welding job listed below, identify the governing code or standard, and
applicable procedures or instructions that provide the requirements for the indicated
NDT. Use Work Aid 2 as necessary to complete the Exercise.
1. NDT a weld repair on a vertical shell weld on a low pressure storage tank.
API 620
2. Perform a liquid penetrant test on a steam plant piping weld.
ASME B31.1 and SAIP-04-P
3. NDT a plug weld a boiler tube at the “mud” drum.
ASME Section I
4. NDT a weld in a new piece of steam piping to a distillation column.
ASME B31.1 or B31.3
5. NDT a weld repair to refinery process piping.
ASME B31.3
6. NDT the construction of a welded structure for catwalks.
WS D1.1
7. Perform a magnetic particle test of an Un-Fired Pressure Vessel Weld.
ASME Section VIII and SAIP-05-P
40
8. NDT the add of a welded valve to a toxic fluid pipeline (on-plot).
ASME B31.3
9. Perform a radiographic examination of crude oil pipeline (off-plot) welds.
ASME B31.4 and SAGI 448.010
10. NDT the addition of a nozzle to a heat exchanger.
ASME Section VIII
11. Perform a liquid penetrant test on a compressed gas piping weld.
ASME B31.8 and SAIP-04-P
12. Weld a tubular support structure for tank.
AWS D1.1
13. NDT the addition of an expansion loop to a cross-country crude pipeline.
ASME B31.4
14. NDT the construction of a gas storage tank and a crude storage tank in an existing
tank farm.
API 620 and 650
15. NDT the addition of a weld-o-let to a chemical handling piping system.
ASME B31.3
16. NDT the new construction of a drilling platform.
API RP-2A
41
EXERCISE 3 KEY: LOCATE NONDESTRUCTIVE TESTING

REQUIREMENTS AND ACCEPTANCE CRITERIA
FOR WELDMENTS
For each situation (1 through 3) described below, perform the following items, using
Work Aid 3. Determine the applicable code, standard, procedure, or instruction.
Locate the requirements for NDT (other than VT) and the reference paragraph.
Determine the acceptability of the given discontinuity.
1. An on-plot sour water piping system is made up of 1" socket welded pipe. The
welds are considered to be in severe cyclic stress. Weld A-1 and B-16 were found
to have a 1/4" and 2" crack respectively.
Applicable code, standard, procedure or instruction B31.3,SAIP-04-P & 05-P
NDT requirements PT or M Reference 341.4.3(b)
Weld A-1 Acceptable [ ] Rejectable [X]
Weld B-16 Acceptable [ ] Rejectable [X]
2. A tank with 1-1/4" thick shell plates stores petroleum products at 300 oF. Verticle
weld C and E have maximum weld reinforcements of 3/32" and 5/16" respectively.
Applicable code, standard, procedure or instruction API 650 & SAGI 448.010
NDT requirements RT Reference 6.1.2.1-3
Weld C Acceptable [X] Rejectable [ ]
Weld E Acceptable [ ] Rejectable [X]
3. A pressure vessel with a 3" thick shell is designed for 300 oF and 120 psi, with a
joint efficiency of 1.00. A 3/8" elongated indication (slag) was found in weld C1.
Applicable code, standard, procedure or instruction ASME VIII, Division I and
SAGI 448.010
NDT requirements RT Reference UW-11 and 12
Weld C-1 Acceptable [X] Rejectable [ ]
42
For each welding job described, determine the requirements for nondestructive testing
using Addendum A.
4. A section of 6"-XX (0.864") header, downstream of the first valve off a boiler, is to
be replaced using butt welds. The header design temperature is 750 oF at a
pressure of 1,100 psi, and the branch lines are designed for 300 oF at a pressure
of 900 psi. Several branches, both 4" sch 80 (.337") and 2" sch 80 (.218) are
connected to the header by butt welds and socket welds respectively.
What NDT is required for the 6" butt welds? VT and RT
What NDT is required for the 4" butt welds? VT
What NDT is required for the 2" socket welds? VT
5. A crude oil pipeline (off-plot) weld has been repaired. The hoop stress of the
pipeline is in excess of 20% of the specified minimum yield and the pipeline is
located in a populated industrial area.
What NDT is required for this weld? RT
If 10 repair welds were completed on this pipeline in one day, how many welds
would require NDT? 10
In which code or standard is the applicable acceptance criteria located for this type
of NDT? API 1104
6. A longitudinal weld has been repaired in a low pressure above ground tank with a
wall thickness of 1•”. A double welded butt joint was used because of anticipated
tensile stresses in excess of 10% over the specified minimum tensile strength of
the material.
of NDT? Section VIII
7. A 1/2" fillet weld connecting a column to a base plate in a statically loaded

structure is to be made. Determine the requirements for nondestructive testing.
All welds require VT, additional NDT is determined by the specification
or other information furnished to the bidder or contractor.
43
INE 150.01 INSTRUCTOR EVALUATION
EVALUATION KEY
For each welding job described, determine the requirements for nondestructive testing
using Addendum A.
1. A section of 6"-XX (0.864") header, downstream of the first valve off a boiler, is to
be replaced using butt welds. The header design temperature is 750 oF at a
pressure of 1,100 psi, and the branch lines are designed for 300 oF at a pressure
of 900 psi. Several branches, both 4" sch 80 (.337") and 2" sch 80 (.218) are
connected to the header by butt welds and socket welds respectively.
What NDT is required for the 6" butt welds? VT and RT
What NDT is required for the 4" butt welds? VT
What NDT is required for the 2" socket welds? VT
2. A crude oil pipeline (off-plot) weld has been repaired. The hoop stress of the
pipeline is in excess of 20% of the specified minimum yield and the pipeline is
located in a populated industrial area.
If 10 repair welds were completed on this pipeline in one day, how many welds
would require NDT? 10
of NDT? API 1104
3. A longitudinal weld has been repaired in a low pressure above ground tank with a
wall thickness of 1•”. A double welded butt joint was used because of anticipated
tensile stresses in excess of 10% over the specified minimum tensile strength of
the material.
of NDT? Section VIII
44
INE 150.01 INSTRUCTOR EVALUATION
4. A 1/2" fillet weld connecting a column to a base plate in a statically loaded

structure is to be made. Determine the requirements for nondestructive testing.
All welds require VT, additional NDT is determined by the specification or
other information furnished to the bidder or contractor.
45
INE 150.01 INSTRUCTOR BIBLIOGRAPHY
BIBLIOGRAPHY
API 510 (1992), Pressure Vessel Inspection Code.
API 620 (1996), Design and Construction of Large, Welded, Low-Pressure Storage
Tanks.
API 650 (1993, Welded Steel Tanks for Oil Storage. (ADDENDUM 2, 1995)
API RP-2A (1996), Recommended Practice for Planning, Designing, and Constructing
Fixed Off-Shore Platforms.
ASME Code B31.1 (1995), Power Piping.
ASME Code B31.3 (1996), Chemical Plant and Petroleum Refinery Piping.
ASME Code B31.4 (1992),Liquid Transportation Systems for Hydrocarbons, Liquid

Petroleum Gas, Anhydrous Ammonia, and Alcohol.
ASME Code B31.8 (1995), Gas Transmission and Distribution Piping System.
ASME Section I (1995), Rules for the Construction of Power Boiler.
ASME Section IV, (1995), Rules for the Construction of Heating Boiler.
ASME Section V, (1995), Nondestructive Examination.
ASME Sect. VIII, (1995), Rules for the Construction of Pressure Vessel.
ASNT Handbook
ASNT SNT-TC-1A, (1986),Recommended Practice for Personnel Qualification and

Certification in Nondestructive Testing.
AWS D1.1, (1996),Structural Welding Code.
SAEP-1140 (15 Jan 1997), Qualification and Certification of Saudi Aramco Nondestruct
Examination Personnel.
SAEP-1142 (12 Dec 1996), Qualification and Certification of Non-Saudi Aramco

Nondestruct Examination Personnel.
GI 448.010 (3 Aug 93), Radiographic Examination. (WILL BE REVISED AS SAEP-

1143).
SAIP-04-P (SAEP-1145), Liquid Penetrant Examination of Welds and Components.
46
SAIP-05-P (SAEP-1144), Magnetic Particle Examination of Welds and Components.
NOTE: A new SAEP-1147 will be developed for Ultrasonic Examination
47
INSTRUCTOR ADDENDUM
48
Examples to illustrate how NDT can prevent personnel injury, equipment or production
loss, or damage to the environment:
Example 1: Checking the integrity of flammable or toxic systems
In 1955, in an oil refinery near Philadelphia, a leak developed in the rundown line from
the crude units to the receiving house. Flow from the crude units was immediately
halted. However, gas spread to the receiving house basement and was ignited from
an unknown source. Management, maintenance, and operating personnel who were
working to repair the leak were burned. Although the fire was controlled in 45 minutes
and property damage was negligible, 18 people were injured, 6 of those people were
critically injured. A good on-going inspection program utilizing NDT may have
identified the potential of a leak before it occurred.
Example 2: Determining the affects of erosion and corrosion
Corrosion failures abound when conditions become more severe than was anticipated
at the time the pressure vessel, tank, or piping system were designed or when the
materials were originally selected. A service environment may become more corrosive
as a result of changes in the chemical environment or in the solutions that are
contained in the vessel or tank or carried in the piping. Conditions also may arise that
substantially reduce the corrosion resistance of the materials. An example of such
conditions would be the formation of heavy copper deposits on the inside of steel tanks
or pipe, resulting in galvanic corrosion.
Example 3: Identifying cracks or weak areas resulting from cyclic stress
In 1951, a thermometer well joint failed in the low pressure return oil line at the turbine
end of a 30,000 KW turbo-generator near Columbus, Ohio. The resulting leak allowed
oil to escape under 15 lb pressure and to ignite at surfaces heated to 900oF by
superheated steam. Oil discharged into the fire for 45 minutes. When the fire had
burned itself out, unprotected steel roof trusses 50 ft overhead had collapsed and
about 6000 sq ft of the concrete roof of the noncombustible building had fallen in. The
damage that results from the small leak amounted to $1.5 million. Designers and field
engineers need to pay special attention to cyclic and thermal stresses.
Example 4: Observing operating characteristics of equipment or systems
In August 1955, losses in excess of $1 million resulted from the explosion of a new
fluid catalytic hydroformer near Chicago. Flames quickly spread to surrounding gas
and oil tanks. Debris crashed into nearby houses and littered the streets. One fatality
occurred, and injury resulted to 36 persons. It was believed that the blast failure
resulted from a material failure, from abnormal stresses or pressure, or from the
introduction of water into the unit's high temperature section. Facility operators have a
tremendous responsibility to maintain system operating parameters within safe limits.
Aberrations may expedite the need to perform preventive NDT.
49

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INE 150

REQUIREMENTS FOR PERFORMING

Date Description Page(s)

09/16/00 Revised Cover Page with New Corporate Logo Cover

09/17/07 Combined modules 2 and 3 and rearranged PPT slides; All

 Identify significant base metal and weld metal discontinuities.

Note: definitions of words in italics are contained in the Glossary

 Whiteboard and Markers.

 Power Point Transparencies of all Module Figures.

 Classroom of suitable size to accommodate Participants

9:00 – 9:20 Coffee Break

9:20 – 10:20 Classroom exercises on the above NDT methods

10:20 – 1130 Laboratory exercises on studied NDT methods

11:30 – 12:30 Lunch Break

1:15 – 1:45 Classroom exercises on the above NDT method

1:45 – 2:00 Coffee Break

2:00 – 3:30 Lab. Demonstrations of different NDT tools based on ET

9:00 – 9:20 Coffee Break

9:20 – 10:20 Classroom exercises on the above NDT methods

10:20 – 1130 Laboratory on UT method Thickness Gage Measurements P-scan

11:30 – 12:30 Lunch Break

12:30 – 1:45 Radiation Safety Presentation

1:45 – 2:00 Coffee Break

2:00 – 3:30 Lab. Demonstrations on RT method IR-192, X-ray

9:00 – 9:20 Coffee Break

11:30 – 12:30 Lunch Break

12:30 – 1:45 Radiation Safety Presentation

1:45 – 2:00 Coffee Break

2:00 – 3:30 Laboratory Demonstrations on specialized NDT methods

9:10 – 9:30 Coffee Break

9:30 – 11:30 Codes, Standards, Procedures, and Instructions, associated with

11:30 – 12:30 Lunch Break

12:30 – 1:30 Codes, Standards, Procedures, and Instructions, associated with

1:45 – 2:00 Coffee Break

2:00 – 3:30 Nondestructive Testing Requirements and Acceptance Criteria

7:30 – 9:00 NDT Methods Overview – Film

9:00 – 9:20 Coffee Break

9:20 – 10:30 General Review

10:30 – 11:30 Final Test

OUTLINE OF TOPICS TO DISCUSS AIDS

Place the start time of the module introduction Place

Display PPT1 on the screen before Participants get

Explain the Course Schedule. Explain that if there

PPT 11, Objectives

 Identifying significant base metal and weld metal

PPT 12, Purpose of NDT

 To prevent the premature failure of components

Use the analogy of how a doctor performs a medical

Discuss the difference between NDT and NDE and Terminology

Explain that the Participant's role is to recognize when

Use any or all of the examples in the Instructor

 NDT improves reliability

NDT Methods PPT15

Visual Testing PPT 16

Visual Weld Examination

PPT 25, Purpose

Discuss classification of penetrants and removal

Note: Saudi Aramco uses only color constant solvent

Discuss common discontinuities

PPT 33, Purpose

Principles of Operation PPT 35 -39

Common Applications PPT 40

Common Discontinuities PPT 42