Floating & Fixed Platform, FPSO Marine & Hull, LNG, Onshore, Pipelines, Subsea, Topsides

QAM-SU-6163-A
Performance Demonstration Qualification Program for
NDE Contractors Performing Ultrasonic Weld Inspection

This document is the confidential property of Chevron U.S.A. Inc. and its affiliates. When made available to
any contractor providing services to Chevron U.S.A. Inc. or its affiliates, the contractor’s use of this
document shall be governed by the confidentiality provisions of the applicable contract or bid package.
Without limiting the foregoing, neither the whole nor any part of this document may be disclosed by the
contractor to any third party, other than an affiliate of the contractor that requires this information for
purposes of the contract with the Chevron entity, without the prior written consent of the Chevron entity that
has disclosed this document to the contractor. When requested by Chevron U.S.A. Inc. or its disclosing
affiliate, the contractor must return all copies of this document to the Chevron entity requesting such return
and delete any electronic copies from the contractor’s systems.

Any and all modifications (changes, amendments, etc.) to this document must follow approved
Chevron Engineering Standards governance processes.

Rev. Date Description Author Technology Leader

— 06/15 Initial release. M. Seiwald J. Pesonen
A 06/18 Minor revision. M. Seiwald M. Calva

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Performance Demonstration Qualification Program for
NDE Contractors Performing Ultrasonic Weld Inspection QAM-SU-6163-A

Summary of Changes
Revised technical content may be marked with change bars in the right margin as directed by Author.
The Author denotes the following technical changes to this revision as detailed below:

Author notations regarding this revision

3.2 Updated specimen size for qualification examinations

4.0 Add additional clarification for qualification validity
5.0 Add Failed Grading Criteria for pipe (Table 2), planar through wall (Table 4), and PA UT (Table 7)

Safety Critical Changes (if applicable) are noted below

n/a

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Performance Demonstration Qualification Program for
NDE Contractors Performing Ultrasonic Weld Inspection QAM-SU-6163-A

Contents
1.0 Scope............................................................................................................................................... 4
1.1 Conflict Resolution .............................................................................................................. 4
1.2 Units of Measurement ......................................................................................................... 4
2.0 References ...................................................................................................................................... 4
2.1 Owner Documents .............................................................................................................. 4
2.2 Industry Codes and Standards ........................................................................................... 4
3.0 Acronyms ........................................................................................................................................ 5
4.0 General ............................................................................................................................................ 5
5.0 Protocols ......................................................................................................................................... 6
5.1 Prerequisites ....................................................................................................................... 6
5.2 Specific Requirements ........................................................................................................ 6
6.0 Qualification Validity...................................................................................................................... 7
7.0 Testing Protocols ........................................................................................................................... 8
7.1 Ultrasonic Shear Wave for Piping (Detection) .................................................................... 8
7.2 Ultrasonic Planar Through Wall Sizing ............................................................................. 10
7.3 Ultrasonic for Structural Welds ......................................................................................... 11
7.4 Ultrasonic for Phased Array .............................................................................................. 12

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Performance Demonstration Qualification Program for
NDE Contractors Performing Ultrasonic Weld Inspection QAM-SU-6163-A

1.0 Scope
1. This specification covers the requirements for performance demonstration qualification
(PDQ) of nondestructive examination (NDE) technicians for weld inspection.
2. This document does not apply to the following:
a. Global manufacturing facilities or projects that are encompassed in other guidance.
b. The qualification of automated ultrasonic testing (AUT) for pipeline girth weld
construction, which is covered under PPL-PU-5312.
c. Ultrasonic thickness measurements are excluded and addressed in a future separate
specification.
d. Guided wave ultrasonics or long range ultrasonics.
3. This specification includes inspection of new shop and field construction welds and
existing welds inspected while in service and out of service.

1.1 Conflict Resolution

Supplier shall submit any conflicts among the inquiry documents in writing to Owner for
resolution.

1.2 Units of Measurement

This document contains both U.S. Customary and International Systems (SI) units of measure,
with U.S. units listed first.

2.0 References
1. The following documents are referenced herein and are considered an integral part of this
specification.
2. Unless otherwise specified herein, use the latest edition of the referenced documents.

2.1 Owner Documents

None.

2.2 Industry Codes and Standards

American Petroleum Institute (API)
RP 2X Recommended Practice for Ultrasonic and Magnetic Examination of
Offshore Structural Fabrication and Guidelines for Qualification of
Technicians
QUTE Qualification of Ultrasonic Testing Examiners Program

American Society for Nondestructive Testing (ASNT)

SNT-TC-1A Recommended Practice for Personnel Qualification and Certification in
Nondestructive Testing

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Performance Demonstration Qualification Program for
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American Welding Society (AWS)

D1.1 Structural Welding Code – Steel

International Organization for Standardization (ISO)

9712 Non-destructive testing – Qualification and certification of NDT
personnel

3.0 Acronyms
CRA Corrosion Resistant Alloy
CSWIP Certification Scheme for Welding and Inspection Personnel
NDE Nondestructive Examination
PA Phased Array
PCN Personnel Certification in Nondestructive Testing
PDQ Performance Demonstration Qualification
TOFD Time of Flight Diffraction

4.0 General
Note: Performance demonstration qualification (PDQ) of nondestructive examination (NDE)
technicians has been conducted for more than a decade. Testing results have
consistently shown failure rates on the order of 70 percent of personnel examined in
certain areas of the globe.

Testing across the industry has also revealed that, generally, training for in-service
examination of degradation mechanisms is not prevalent. Ultrasonic examiners tend
to be trained to examine construction welds. The absence of appropriate training
schemes for detection and characterization of in service damage mechanisms
underpins the high failure rates.
1. PDQ outlined in this document shall apply when any of the designations in item 2 are
required through an upstream business unit (BU) or major capital project (MCP).
2. Qualification shall be required by the following:
a. An Owner standard.
b. Contractual requirements.
c. A recognized and referenced industry standard, e.g., API 2X.
d. Owner BUs, as part of good practice.
e. Fitness for Service critical examinations.
f. A response to concerns around contractor performance.

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Performance Demonstration Qualification Program for
NDE Contractors Performing Ultrasonic Weld Inspection QAM-SU-6163-A

3. Candidates who successfully pass the PDQ shall receive email notification and their name
placed on an approved list. Designated personnel may receive separate monthly updates
listing individuals who have passed their site-specific PDQs.

5.0 Protocols
1. When qualification is required, the testing shall be administered by Owner or an approved
testing proctor.
2. The test blocks, protocols, and grading criteria shall be maintained confidentially with
Owner.

Note: Testing can be arranged at any location in the world.

3. Where qualification is required for piping weld quality alone on piping, the Owner shall
have the option of accepting both of the following in lieu of the Owner performance test for
ultrasonic shear wave:
a. Personnel certification in nondestructive testing (PCN) Category W.
b. API QUTE certifications.

5.1 Prerequisites
1. All NDE personnel shall be certified by their employer to a minimum of
ASNT SNT-TC-1A (or equivalent) at Level II in ultrasonic weld examination with
no limitations by their employer.
2. When individuals are attempting ultrasonic qualification to advanced methods such as
phased array (PA), time of flight diffraction (TOFD), API 2X, or AWS D1.1, individuals
shall hold additional valid certifications from their employer or nationally recognized body
in these methods.
3. Owner shall recognize ISO 9712 certification or equivalent, such as PCN and Certification
Scheme for Welding and Inspection Personnel (CSWIP). However, company-specific
certifications not equivalent to ISO 9712 issued by employers or other certification entities
shall be subject to individual review and endorsement.
4. Owner shall reserve the right to audit and accept or deny any certification systems that do
not, in the Owner’s judgement, meet the intent of this document.

5.2 Specific Requirements

1. Owner shall offer four standard qualification examinations covering the following:
a. Ultrasonic shear wave for piping for components 3 inch (75mm) and less.
b. Ultrasonic planar through wall sizing components 3 inch (75mm) and less.
c. Ultrasonic for structural welds T-K-Y (API 2X and AWS D1.1).
d. Ultrasonic for PA for component 3 inch (75mm) and less.

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Performance Demonstration Qualification Program for
NDE Contractors Performing Ultrasonic Weld Inspection QAM-SU-6163-A

2. The test blocks, protocols, and grading criteria shall be maintained confidentially with
Owner.
3. Candidates shall be required to pass ultrasonic shear wave for piping before attempting any
other examinations in item 1 above, with the exception of ultrasonic for structural.
4. Examiners qualified for automated techniques are not automatically qualified for manual
examination. Examiners qualified for automated techniques shall also hold qualification for
manual examination.
5. Basic guidelines and testing protocols shall be provided at the time of the examination for
each ultrasonic method, but an individual’s company procedures and equipment shall be
used for examinations.
6. Personnel who fail the test may be re-examined, but if an additional failure occurs, a period
of thirty (30) days shall elapse before retests can be taken.
7. Specific ultrasonic examination outside those specified in Section 5.2, item 1 shall be
created and attempted as follows:
a. The examinations may be—but are not limited to—TOFD, corrosion resistant alloy
(CRA) weld examination, and exotic metal examination (stainless steel, duplex, etc.).
b. The examination protocol for these exams shall be created and provided to the
personnel attempting the examination in advance.
8. Any candidate who, during the course of the examination, does not abide by the
examination rules or who perpetrates, or is an accessory to, fraudulent conduct shall be
excluded from all further qualification examinations for a period of at least one year.

6.0 Qualification Validity

1. Personnel who qualify per the Owner qualification test shall be qualified for a period of
three calendar years from the date they receive notification of qualification.
2. Qualification validity shall not exceed the duration of the existing validity of certification
on which the qualification is based.

Note: At any time during the validity period, Owner may withdraw qualification if the
performance of the operator does not meet requirements.
3. Individuals shall be requalified if employment changes to a different company.
Qualifications are only valid with the company with which the individual was employed
when attempting or passing the examination(s).

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Performance Demonstration Qualification Program for
NDE Contractors Performing Ultrasonic Weld Inspection QAM-SU-6163-A

7.0 Testing Protocols

7.1 Ultrasonic Shear Wave for Piping (Detection)
Personnel seeking qualification for the ultrasonic detection of flaws on carbon steel welds
3 inches (75 mm) and below shall meet the requirements of this section, including Table 1.

Table 1: Components to Be Examined for Qualification for Ultrasonic Shear Wave for Piping
Number of Items
Material Pipe Sizes Plate Sizes
for Examination
Carbon Steel 8 in. and 12 in. 0.500 in. (12.5 mm) to 2 pipes and 2 plates
(200 mm and 300 mm) 1.00 in. (25 mm)
0.500 in. (25 mm) nominal wall
nominal wall
Note: Calibration standards may or may not be provided, but candidates shall be notified before
examination date.

7.1.1 Prerequisites
1. Proof of current Level II status or higher in ultrasonics with no limitations for weld
inspection shall be provided.
2. Current equipment internal calibrations shall be provided for review as requested.

7.1.2 Exam Information

1. The testing protocols and guidelines shall be read and signed before starting the
examination.
a. The testing protocols and guidelines shall provide specific information on the
examination.
b. The candidate shall have any questions resolved before starting the examination.
c. The candidate shall have a maximum of 6 hours to complete the examination, including
calibration time and filling out all paperwork and flaw-grading sheets.
d. Questions may be asked during the examination; however, questions specific to the
content of the examination may not be asked and answers to the examination shall not
be given.
2. All indications are real weld flaws; there shall be no hidden notches or drilled holes on the
examination.
3. Candidates shall detect, characterize, plot, and record flaws if present.
4. Flaw types that may be on the examination shall be as follows:
a. Inside diameter (ID) root crack.
b. Heat affected zone crack.
c. Axial crack on the either surface.
d. Sidewall crack.

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Performance Demonstration Qualification Program for
NDE Contractors Performing Ultrasonic Weld Inspection QAM-SU-6163-A

e. Lack of penetration (single V or double V).

f. Lack of sidewall fusion.
g. Embedded centerline crack.
h. Lack of root fusion.
i. Toe crack on either surface.
j. Outside diameter (OD) crown crack.
k. Slag.
l. Porosity.
5. Candidates shall not be marked down for misinterpretation of volumetric indications, such
as calling a slag indication a porosity or a porosity indication a slag.
6. Candidates shall not be marked down for misinterpretation of planar indications, such as
calling a lack of root penetration a root crack, as long as the planar flaw is called in the
correct region (ID connected, mid-wall, or OD connected).
7. Calling a planar flaw a volumetric or vice versa shall result in a missed call. For grading
purposes, a missed call shall be considered the same as a missed flaw.
8. A missed flaw shall be defined as when a candidate does not identify a flaw in the required
examination region.
9. An overcall shall be defined as when the candidate calls a flaw when one that is over
20 percent of reference level does not exist in the examination region.

Weld geometry such as root or crown geometry shall not be considered a flaw.

7.1.3 Grading Criteria

Grading for the detection of flaws on carbon steel welds 3 inches (75 mm) and below shall be
as shown in Table 2.

Table 2: Ultrasonic Shear Wave for Piping Grading Criteria for Examinations
Total Number of Missed
Flaws, Miss Calls, Overcalls Pass/Fail
or a Combination Thereof
2 0 PASS
0 2 PASS
1 1 PASS
1 2 PASS
2 1 FAIL
2 2 FAIL
3 0 FAIL
0 3 FAIL

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Performance Demonstration Qualification Program for
NDE Contractors Performing Ultrasonic Weld Inspection QAM-SU-6163-A

7.2 Ultrasonic Planar Through Wall Sizing

Personnel seeking qualification for the sizing of planar flaws on carbon steel welds
3 inches (75 mm) and below shall meet the requirements of this section, including Table 3.

Table 3: Material to Be Examined for Qualification Title

Weld Thicknesses for Examination Number of Welds to Size Cracks
0.750 in. (19 mm), 1.000 in. (25 mm), 12
1.500 in. (37 mm)
Note: Calibration standards are not provided. Calibration standards for calibration
and examination shall be brought to the examination by the candidate.

7.2.1 Prerequisites
Candidate shall take and pass Ultrasonic Shear Wave for Piping exam before attempting
qualification.

7.2.2 Exam Information

1. The testing protocols and guidelines shall be read and signed before starting the
examination.
a. The testing protocols and guidelines shall provide examination-specific information.
b. Questions may be asked during the examination; however, questions specific to the
content of the examination may not be asked and answers to the examination shall not
be given.
c. The candidate shall have a maximum of 4 hours to complete the examination, including
calibration time and filling out all paperwork and flaw-grading sheets.

Note: All indications are real planar flaws that are ID connected.
2. The examination may contain welds that are not cracked. If a candidate calls a crack in a
non-crack location, it shall be an automatic failure.
3. For grading purposes, the examination tolerances shall be as follows:
a. Welds 1.000 inch (25 mm) thick and lower planar flaw through wall depths shall be
within ±0.050 inch (±0.0750 mm).
b. Welds greater than 1.000 inch (25 mm) thick planar flaw through wall depths shall be
within ±0.750 inch (±1.9 mm).

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Performance Demonstration Qualification Program for
NDE Contractors Performing Ultrasonic Weld Inspection QAM-SU-6163-A

7.2.3 Grading Criteria

Grading for the planar through wall sizing of flaws on carbon steel welds 3 inches (75 mm) and
below shall be as shown in Table 4.

Table 4: Planar Through Wall Sizing Pass Requirements

Total Number of Planar Flaws Total Number of Planar Flaws
Sized Within Tolerance Sized Outside Tolerance
12 0 PASS
11 1 PASS
10 2 PASS
9 3 FAIL
8 4 FAIL

7.3 Ultrasonic for Structural Welds

Personnel seeking qualification on structural welds (T, K, and Y) shall meet the requirements
of this section, including Table 5.

Table 5: Structural Components to Be Examined for Qualification

Number of Items
Material Exam Configurations Component Thicknesses
for Examination
Carbon Steel T, K, or Y as defined by May range from Minimum 3
API 2X and AWS D1.1 0.375 in. (9.5 mm) to
1.500 in. (38 mm)
Note: Calibration standards are not provided. For examinations to API 2X, calibration standards
shall meet that required for Level A per API 2X. For examinations to AWS D1.1, standards
shall meet the requirements of Section 6, Part F of the D1.1 code.

7.3.1 Prerequisites
1. Proof of current Level II status or higher in ultrasonics with no limitations for structural
weld inspection shall be provided.
2. For API 2X examinations, proof of 400 hours of actual ultrasonic examinations on
T, K, or Y configurations as defined by API 2X shall be provided.

7.3.2 Exam Information

1. The testing protocols and guidelines shall be read and before starting the examination.
a. Examinations for structural welds shall be either for API 2X or AWS D1.1.
b. The testing protocols and guidelines shall provide specific information on the
examination.
c. The candidate shall have any questions resolved before starting the examination.
d. The candidate shall have a maximum of 4 hours to complete the examination, including
calibration time and filling out all paperwork and flaw-grading sheets.

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Performance Demonstration Qualification Program for
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e. Questions may be asked during the examination; however, questions specific to the
content of the examination may not be asked, and answers to the examination shall not
be given.
2. Candidates shall be required to detect and characterize recordable flaws.
3. Calibrations shall be from a 1/16-inch (1.6-mm) side drill hole at the appropriate depth per
either API 2X or AWS D1.1.
4. For recordable flaws, candidates shall detail the following on the examination report form:
a. Location of flaw along weld (starting point from 0 reference).
b. Length of flaw.
c. Planar location of flaw.
d. Flaw type: spherical, cylindrical, or planar.
5. Candidates shall show a plot drawing of recorded flaws that shows the location and depth
in the weld.
6. A missed flaw shall be defined as when a candidate does not identify a flaw in the required
examination region, including along the weld and in the planar direction.
7. An overcall shall be defined as when the candidate calls a flaw when one that is over
20 percent of reference level does not exist in the examination region.
8. Grading shall be done as per the requirements of paragraph 5.3.4 in API 2X. The
examination results shall produce two (2) numbers:
a. P-Number, in which a candidate must have a score of 70 or more to pass.
b. R-Number, in which a candidate must have a score of 50 or more to pass.

7.4 Ultrasonic for Phased Array

Personnel seeking qualification for PA UT inspection of carbon steel welds shall meet the
requirements of this section, including Table 6.

Table 6: Possible Piping and Plating to Be Examined for Qualification

Possible Number of
Material Pipe Sizes Plate Sizes
Items for Examination
Carbon steel 8 in. and 12 in. 0.500 in. (12.5 mm) 2 pipes and 2 plates
(200 mm and 300 mm) to 1.000 in. (25 mm)
0.500 in. (12.5 mm) and nominal wall
0.688 in. (17.5 mm)
nominal wall
Note: Calibration standards are not provided. Calibration standards for calibration and
examination are required to be brought to the examination by the candidate. Other piping
and plate configurations may be chosen before the examination and shall be agreed upon
before the examination.

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Performance Demonstration Qualification Program for
NDE Contractors Performing Ultrasonic Weld Inspection QAM-SU-6163-A

7.4.1 Prerequisites
1. Proof of current Level II status or higher in ultrasonics with no limitations for weld
inspection shall be provided, with additional proof of qualification for performing
PA inspection from the candidate’s employer.
2. Candidate shall take and pass Ultrasonic Shear Wave for Piping exam before attempting
qualification.

3. Current equipment internal calibrations may be requested for review.

7.4.2 Exam Information

1. Companies shall use their own company written procedures for the examination written
specific for PA inspection.
2. Examinations may either be encoded or non-encoded and shall be agreed upon before
the examination.
3. The testing protocols and guidelines shall be read and signed before starting the
examination.
a. The testing protocols and guidelines shall provide specific information on the
examination.
b. The candidate shall have any questions resolved before starting the examination.
c. The candidate shall have a maximum of 6 hours to complete the examination, including
calibration time and filling out all paperwork and flaw-grading sheets.
d. Questions may be asked during the examination; however, questions specific to the
content of the examination may not be asked and answers to the examination shall not
be given.
4. Candidates shall be required, before examination, to have a completely empty memory card
(if used).
5. Upon completion of the exam, candidates who used memory cards shall be required to wipe
them clean.
6. If the candidate is to use software other than the inspection instrument to analyze data,
Owner may provide a laptop for this purpose, but the software shall be provided by the
candidate. Personal laptops shall not be allowed in the examination area.
7. All indications are real weld flaws; there shall be no hidden notches or drilled holes on the
examination.
8. Candidates shall detect, characterize, plot, and record flaws if present.
9. Flaw types that may be on the examination shall be as follows:
a. ID root crack.
b. Heat affected zone crack.
c. Axial crack on the either surface.

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Performance Demonstration Qualification Program for
NDE Contractors Performing Ultrasonic Weld Inspection QAM-SU-6163-A

d. Sidewall crack.
e. Lack of penetration (single V or double V).
f. Lack of sidewall fusion.
g. Embedded centerline crack.
h. Lack of root fusion.
i. Toe crack on either surface.
j. OD crown crack.
k. Slag.
l. Porosity.
10. Candidates shall not be marked down for misinterpretation of volumetric indications, such
as calling a slag indication a porosity, or a porosity indication a slag.
11. Candidates shall not be marked down for misinterpretation of planar indications, such as
calling lack of root penetration a root crack, as long as the planar flaw is called in the
correct region (ID connected, mid-wall, or OD connected).
12. Calling a planar flaw a volumetric or vice versa shall result in a missed call. For grading
purposes, a missed call shall be considered the same as a missed flaw.
13. A missed flaw shall be defined as when a candidate does not identify a flaw in the required
examination region.
14. An overcall shall be defined as when the candidate calls a flaw that is over 20 percent of
reference level when one does not exist in the examination region.
15. Weld geometry such as root or crown geometry shall not be considered a flaw.

7.4.3 Grading Criteria

Grading for the PA UT inspection of carbon steel welds shall be as shown in Table 7.

Table 7: Grading Criteria for Examinations

Total Number of Missed Flaws,
Overcalls
Missed Calls, or a Combination Thereof
3 0 PASS
2 2 PASS
3 1 PASS
1 2 PASS
2 1 FAIL
2 2 FAIL
3 0 FAIL
0 3 FAIL

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