4th Middle East NDT Conference and Exhibition, Kingdom of Bahrain, Dec 2007 For all papers of this publication click: www.ndt.net/search/docs.php3?MainSource=57
CSWIP (Certification Scheme for Welding and Inspection Personnel ) APPROVED TRAINING AND INDEPENDENT CERTIFICATION FOR PERSONNEL ENGAGED IN DRILLSTEM INSPECTION BJ (Bill) Brown, Training Manager, Eurotechnology-Incon, Eurotechnology-Incon, Aberdeen, Scotland, UK Gerry Glover, Chief Examiner, TWI (The ( The Welding Institute) Cambridge, England, UK
Abstract Twenty years ago Companies involved in the Servicing of the Drilling Industry had very well documented documented and formal internal training schemes. The Inspection Inspection personnel were subject subject to formal, well managed, managed, training and certification. Unfortunately the Industry has has changed and with it the formal training and certification. With very few exceptions exceptions the Service Industry has broken up into small Companies offering Inspection / NDT Personnel in a very competitive market. Today, in the United Kingdom it is the norm for Personnel Training and Certification to be conducted in accordance with the SNT-TC-1A scheme. The management and control of these schemes tend to lean towards general Magnetic Particle Inspection and Liquid Penetrant Inspection Inspection with wit h some knowledge of ultrasonic thickness measurement using digital t hickness meters. These schemes, schemes, in general terms, do do not formally address the specific specific requirements requirements of the Product, neither do they address the visual and dimensional controls called for in the relevant Standards or Specifications. We are all a ll aware of how important visual and dimensional inspection methods are to the t he Industry.
Brief History
In an oil or gas well, the Drillstem is the collective name for all the drilling tubulars extending from the drilling rig to t he drill bit. A typical well may contain 400 pipes, pipes, each approximately 9metres (30ft) long. Near the drill bit, and comprising roughly 10% of the total length length of the t he drillstring, is the Bottom Hole Assembly (BHA). The BHA consists primarily of drill collars which pro vide the weight on the drill bit and is normally in compression. Above the BHA is the drill string, consisting of much thinner and more flexible drill pipe which extends upwards to the drilling r ig and is normally in tension. Common Common to all components components of the Drillstem are rotary shouldered connections. connections. These are coarse, tapered, male and female threads with a sealing shoulder, machined onto the ends of each component component and which permit rapid addition or removal of individual components components from the Drillstem. The stresses imposed on the Drillstem during drilling operations can result in rapid accumulation of fatigue damage and frequent inspections are performed to detect mechanical damage and cracking in the rotary shouldered connections and in the tubes of drill pipe. Typically, Typically, rotary r otary shouldered connections are subjected to visual, dimensional and either magnetic particle or penetrant inspections. inspections. Drill pipe tubes are subjected to the same types of inspection as rotary shouldered connections, but additional inspections using ultrasonics (compression and shear wave) and electromagnetic
(diverted flux) methods are performed.
Development of Scheme:
Eurotechnology was requested to revise their existing BINDT Approved training schemes and bring them up to date to meet the requirements of the Standards & Specifications currently being applied by the Industry. Several meeting were held whereby representatives of Major Oil Companies, Service Sector, Training Establishments and Certifying Bodies were represented. A core technical committee was for med and given the task of establishing: Current requirements of the Industry Resources necessary to meet these requirements Willingness of TWI Certification Ltd, a UKAS Accredited Certification Body, to support the scheme and conduct the appropriate audit programme. Willingness of recognised Industry Experts to advise on current practices, supply relevant technical procedures, oversee the relevance of the samples to be used for training and master same. The core committee consists of TWI, Eurotechnology & Bruce McPherson. Firstly, the committee agreed that the remit was certainly too extensive to have a one-fit- all Training and Certification Scheme. The Scheme was split into the Industry Sectors:
Rotary Tool Connections or BHA (Bottom Hole Assembly) and Drillpipe
The two sectors were t hen sub-divided into t he relevant Inspection / NDT categories. Rotary Tool Inspectors Rotary Tool Inspector Supervisor. Drill Pipe Inspector. Drill Pipe Inspection Supervisor. Magnetic Particle Inspection of Drillstem components Liquid Penetrant Inspection of Drillstem components Senior Drillstring Inspector (Level 3). The Rotary Tool Inspector category was to be the base unit. In the UK, the majority of Inspection / NDT application is applied to Rotary Tool Connections.
Once achieved then additional categories may be undertaken such as; Drillpipe Inspector incorporating ultrasonic methods for material evaluation, thickness measurement and manual end area inspection. Whole body Electromagnetic (EMI Buggy) inspection of dr illpipe to incorporate Magnetic Flux Leakage applications to be offered as a separate category as was the individual methods of Magnetic Particle Inspection, Liquid Penetrant I nspection and Ultrasonic Inspection.
All these training courses were to include general and specific theory together with specific practical application to Drillstem components. The theoretical and practical material had to match the Inspection / NDT methods to be applied in accordance with the Industry Specific Standards and Specifications. Two main Industry specifications exist for In-Service Inspection of Drillstem. Standard DS-1, Drill Stem Design and Operation. TH Hill Associates Inc. NS-2, Drill String Inspection Standard, Fearnley Proctor Group These Specifications are in addition to the current API Standards, A.P.I. Specification 5D - Specification for Drill Pipe: API Specification 7 – Specification for Rotary Drill Stem Elements: A.P.I. Recommended Practice 5A5 (API RP 5A5): A.P.I. Recommended Practice 7G (API RP 7G): Each Inspection / NDT task was reviewed and assessed as to the criticality of its application. A Tutorial, complete with details of each task and its methodology was compiled and reviewed for technical accuracy and relevance to its practical application.
The Verification Process.
This was indeed detailed and exacting. Under the guidance of the Training & Examination Services Division of TWI the format for the training course was devised. EN 473 and ISO 9712 were the standards to be applied. Training Course Format and Material.
The first thing that had to be done was to compile a comprehensive set of course notes to cover the Product Technology as well as the Inspection / NDT methods to be applied. The notes include the following topics: Introduction & Overview Drillpipe: Manufacturing Processes, Drill Tube, Tool Joints (Box & Pin), Drill Pipe Operating Conditions, Drillpipe Failures & Causes of Failure, Bottom Hole Assembly (BHA), Heavy Weight Drillpipe (HWDP): Manufacture of Heavy Weight Drillpipe, Heavy Weight Drillpipe Operating Conditions, Heavy Weight Drillpipe Failure Modes. Drill Collars:Drill Collar Manufacture, Drill Collar Operating Conditions, and Drill collar Failure Modes, Stabilisers:Manufacturing Process, Stabiliser Operating Conditions, Failure Modes. Subs: Manufacturing Process, Operating Conditions, Failure Modes. Rotary Shouldered Connections: Technical Description, Main Features, Number Style, Other Features of Rotary Shouldered Connections, Manufacture of Rotary Shouldered Connections, Operating Conditions, Failure Modes. Non-Magnetic Drilling Tubulars. Use of Downhole Mud Motors Drillpipe Tube Inspection Methods: Visual Inspection, Dimensional Inspection, Ultrasonic Wall Thickness Measurements, Electromagnetic Inspection (EMI), Magnetic Particle Inspection, Ultrasonic End Area Inspection. Drillpipe Tool Joint Inspection Methods: Visual Inspection, Dimensional Inspection, Magnetic Particle Inspection. Preparation for Connection Inspection. Heavy Weight Drillpipe Inspection Methods: Visual Inspection,
Dimensional Inspection, Magnetic Particle Inspection. Drill Collar Inspection Methods: Visual Inspection, Dimensional Inspection, Magnetic Particle Inspection, Elevator Groove Inspection. Electromagnetic Inspection (EMI): Basic Principles, Magnetising Methods, Magnetic Flux Leakage sensors, Search Coil Sensors, Applications of Parallel Search Coils, Buggy Type EMI Units, Fixed Head EMI Units, Buggy & Fixed Head Equipment, Drillpipe & BHA Inspection Standards Inspection Equipment Requirements Reporting of Inspections.Audit Formats by Third Part y Companies Each Tutorial and lecture was vetted for technical accuracy set against verifiable procedures – all traceable to the relevant Standards / Specifications. Summary Outline of Rotary Tool Inspector Training Course:
Introduction to the Drillstem. Bottom Hole Assembly – Overview, Visual & Dimensional Inspections – Overview, Visual & Dimensional Applications. Rotary Shouldered Connections – Overview, Visual & Dimensional Inspection Procedures, Environmental Conditions & Potential Causes of Failure. Drillpipe & BHA Inspection Standards – Detailed Review. Review of MPI. Review of Liquid Penetrant Testing. Theory Assessments, General & Specific Papers.Practical Assessment, Visual & Dimensional Applications. Practical Assessment, MPI & DPI Samples
Relevant and Verifiable Samples
Of course, the availability of such samples was critical to the outcome of the Scheme. Eurotechnology has built up an impressive range of Drillstem related samples over the years and agreed that these should be used if found acceptable by the Industry experts. Examples of samples.
Drillpipe with known Defects
Samples with relevant In-Service Defects.
Examples of external wear & Washouts
Visual and Dimensional Samples.
Traditional Strip Chart Recording and PC Based Data-Logging from the Electromagnetic (EMI) Inspection
Standard Set-Up with EMI Buggy Unit Well categorised Training Aids
Independent Competency Examinations:
The competency levels are quite separate to the end of training examination. In order to meet EN473 / ISO 9712 requirements it is necessary to test each candidate in the method applied from an Independent source – in this case TWI / CSWIP. As a result, for the Rotary Tool Inspector it is necessary for the personnel to:
Successfully undergo an approved course as described above. Test a minimum of two areas on mastered samples e.g. Two dimensional and visual checks on typical samples e.g. box and / or pin. Two MPI and two Dye Pen areas. Could be same samples e.g. MPI on the boxes, dye pen on the pins. One ferromagnetic one not so. Theory will consist of general and specific – multiple choice 50 questions for the general paper and 30 for the specific. The examination samples are specific to examination. Each sample was verified as relevant to In-Service inspection and typical of what would be found in the field by the Industry Experts. The master reports were audited and verified by TWI. In order to prove the scheme was, indeed, practicable the initial Certification was performed initially under the CSWIP Employer Specific EN 473 scheme. CSWIP Employer Specific Certification enables organisations to satisfy the requirements of the various Standards by conducting job specific qualifications on realistic test pieces. The CSWIP Scheme is managed by TWI Certification Ltd, a UKAS accredited Certification Body. The Scheme has been successfully utilised in the Rail, Metal manufacturing and Line Pipe manufacturing sectors of Industry. After issuing some 100 certificates, CSWIP was formally requested to consider adopting the scheme.
The Route to CSWIP Approval.
Following on from the pilot scheme involving some 100 examinations carried out under the CSWIP Employer Specific Training & Examination Scheme, it was decided to place the Scheme within the generic CSWIP programme. This entailed producing a document DS-16-06 for approval by the Certification Management Board. The document details specific topics such as: Amounts of Training Necessary experience The Certification Levels Examination content for the Certification Levels Examination exemptions Rules for certificate renewal and re-certification. Plus the general rules for administration of the scheme. The Certification Management Board approved the Scheme document in March 2007. The document also requires that Training Providers, programmes and facilities are approved by TWI Certification Ltd. Course approval was gained in May 2007. Examiners qualified at Level 3 are also required to mark and grade examinations. Currently, a minimum of two Level 3 examiners are specified in EN & ISO Standards. Two well experienced personnel successfully undertook the Level 3 examinations and are in place for the Scheme.
The examinations were compiled and conducted by TWI Tra ining & Examination Services. TWI Training & Examination Services monitored the conduct of the examinations by the Level 3 examiners as complying with the Scheme requirements. In addition, TWI Training & Examination Services validated the examination marking scheme as being in compliance with the Standards. A training & examination programme for 2007 is now in place. Examination validation by TWI Certification Ltd in conjunction with TWI Examination Services will continue in accordance with the CSWIP rules.
CSWIP Scheme Outline:
The CSWIP document DS-16-06 can be downloaded from www.cswip.com
References Standard DS-1, Drill Stem Design and Operation. TH Hill Associates Inc. NS-2, Drill String Inspection Standard, Fearnley Proctor Group A.P.I. Specification 5D - Specification for Drill Pipe: API Specification 7 – Specification for Rotary Drill Stem Elements: A.P.I. Recommended Practice 5A5 (API RP 5A5): A.P.I. Recommended Practice 7G (API RP 7G):Document No. CSWIP-DS-16-06, Requirements for the Certification of Personnel Engaged in the Inspection of Drillstem Components (Rotary Tool & Drillpipe)
