Pressure Equipment Regulations - the introduction of a new category of AIA and the impact on SAQCC Certified Competent PersonsAIA Meeting November 2010

Changes in responsibilities for periodic inspection from VUP to PER

VUP Responsibility for periodic inspectionsVUP Responsibility for periodic inspections

Responsibility squarely on the shoulders of the User.Constraints applying to User were:

Had to use an SAQCC CP certified inspector

Obligated to ensure inspector had appropriate knowledge and experience for the specific job of inspection

PER Responsibility for periodic inspectionsPER Responsibility for periodic inspections

Regulation 11: User may inspect Category 1 Equipment (SANS

347 categorisation) Higher categories must be inspected by an AIA In-

Service (AIA-IS) – From April 2011 Inspection task has to be performed by an

authorised person

AIA-IS has to ensure the authorised person: Is certified by SAQCC CP Has appropriate experience and knowledge for the

specific task

PER Responsibility for periodic inspectionsPER Responsibility for periodic inspections

Notes of caution:

There is a shift of responsibility (and accountability) to the AIA-IS as a body specialising in periodic inspections

Not permissible for an AIA-IS to use a ‘non-certified’ inspector to perform work which is ‘signed-off’ by a certified CP

Requirements for approval as an AIA-IS

Requirements for AIA-IS approval?Requirements for AIA-IS approval?

Requirements for appointment as an AIA-IS by Dept. ofLabour not yet clarified but it is likely that:

SANAS accreditation will be required prior to DoL approval

SANAS will use SANS 10227 as the standard for AIA-IS assessments

Requirements for AIA-IS approval?Requirements for AIA-IS approval?

SANS 10227 is appropriate to an AIA-IS because:

An AIA-IS deals with complex in-service issues including down rating of equipment

AIA-IS will need to have most of the competencies associated with ‘traditional AIAs’ including a design evaluation capability

Can an individual CP become an AIA-IS?Can an individual CP become an AIA-IS?

Likely requirements for accreditation as an AIA-IS are beyond the capabilities of virtually all individual CPs

Reality is vast majority of CPs will need to find employment with an AIA-IS from April next year

What changes to the SAQCC CP system have the PER prompted?

Will there be any changes to the SAQCC CP Certification Will there be any changes to the SAQCC CP Certification scheme?scheme?

Certification criteria remain the same:

Physical capability

Successful completion of approved training course

Supervised practical training

Will there be any changes to the SAQCC CP Certification Will there be any changes to the SAQCC CP Certification scheme?scheme?

Certification categories remain the same:

Pressure vessels: Unlimited scope Limited scope – air receivers with and without

physical access, accumulators, medical or other small autoclaves

Boilers (renamed Steam Generators): Unlimited scope

Will there be any changes to the SAQCC CP Certification Will there be any changes to the SAQCC CP Certification scheme?scheme?

Training course requirements are being changedsignificantly to address:

longstanding concerns about the inadequacy of the scope and depth of training

the clear allocation of responsibilities of the AIA-IS and the CP in job of work

Will there be any changes to the SAQCC CP Certification Will there be any changes to the SAQCC CP Certification scheme?scheme?

There is one change to supervised practical training requirement:

When a certification candidate is already certified in one of the unlimited categories of equipment the duration of supervised experience required for certification in the other unlimited category is reduced to 1 year irrespective of the educational qualification level

What are the new SAQCC CP training requirements?

New SAQCC CP PV and SG training requirementsNew SAQCC CP PV and SG training requirements

CP PV CP PV

Existing Syllabus New SyllabusProcess Plant

1 Week 4 Weeks

for limited for unlimited PV PV certification Plus Certification

Foundation CourseWelding and NDT

New Syllabus1 Week

CP Steam Generator CP Steam GeneratorExisting Syllabus Mandatory New Syllabus

additional Additional Theory1 Week 1 Week

Current training requirements for SAQCC CP PV and SGCurrent training requirements for SAQCC CP PV and SG

Each is a four day course examined by a two hour theory examination (Closed Book)

New scheme requirementsNew scheme requirements

Persons intending to apply for limited PV certification will need to attend only weeks 1 and 2 of the PV stream. Those intending to apply for Unlimited will need to attend all 6 weeks

Persons intending to apply for Steam Generator certification will need to attend all three weeks of the Steam Generator stream

Content of foundation weekContent of foundation week

Common to both the PV and SG streams:

Welding processes – characteristics and applications of SMAW, GTAW, GMAW, FCAW, SAW

Types of defects – associated with processes Visual inspection – aids and tools Introduction to NDT Welding procedures and welder qualifications –

purpose Introduction to materials technology – properties and

treatment

Exemptions from Foundation WeekExemptions from Foundation Week

SAIW Level 1 welding inspector or similar (IWP/IWS etc)

SAIW Engineers Appreciation course – direct access to exam

Content of CP PV core weekContent of CP PV core week

Regulations and codes: Competent person responsibilities Pre-inspection Safety and entry procedures External inspection Internal inspection Appurtenances NDT Toxic substances and medium specific failures e.g

ammonia Pressure testing Repairs

Content of week 1 Process plant for CP PVContent of week 1 Process plant for CP PV

Pressure vessel inspection (API 510 to be used as basis)

Drawing and design

ASME IX

ISO/EN Welding procedures and welders

Content of week 2 CP PV – Process plant contentContent of week 2 CP PV – Process plant content

Plant equipment knowledge

Risk based inspection

Failure mechanisms

Repair welding

Content of week 3 CP PV – Process plant contentContent of week 3 CP PV – Process plant content

Fitness for service

Advanced NDT

Tank inspection

Report writing

Content of week 4 CP PV – Process plant contentContent of week 4 CP PV – Process plant content

Inspection practices for piping

Inspection of pressure relief devices

Inspection, repair, alteration, re-rating of in-service piping systems

Pipe flanges and flanged fittings

Examination requirements for new schemesExamination requirements for new schemes

For both the PV and SG streams:

The part of an examination addressing general technical knowledge will be closed book

The part of an examination addressing codes, standards or regulations will be open book

Examination requirements for new schemesExamination requirements for new schemes

Pressure Vessel CoursesLimited Certification A two hour examination (1 hour multiple choice theory

and 1 hour practical) at the end of the Foundation week

A two hour examination at the end of week 2 (1 hour multiple choice general knowledge closed book and 1 hour regulations and codes open book)

Unlimited Certification As for Limited Certification A one hour general knowledge closed book exam and

a two hour open book exam at the end of each of the four additional weeks (closed and open book)

Revised Content of CP SG (core week 1)Revised Content of CP SG (core week 1)

Regulations, codes and standards – including competent person responsibilities

Types of generators Components, furnaces, superheaters, reheaters,

economisers, attemperators, air heaters, sootblowers

Ancillary equipment, fans, stokers, pulverisers Fabrication methods Refractories, lagging and cladding Knowledge of operation, heat transfer, steam and

water quality, maintenance Boiler metallurgy Corrosion and erosion

Revised Content of CP SG (core week 2)Revised Content of CP SG (core week 2)

Pre-inspection Safety and entry procedures Inspections, external inspection, internal inspection,

fireside inspection, waterside inspection Appurtenances, valves and fittings NDT Pressure testing Repairs Records

Examination requirements for new schemesExamination requirements for new schemes

Steam Generator Courses

A two hour examination (1 hour multiple choice theory and 1 hour practical) at the end of the Foundation week

A four hour examination at the end of week 3 (two hours multiple choice general knowledge, two hours regulations and codes open book)

When will the new courses be introduced?When will the new courses be introduced?

New course requirements come into effect from January 2011

Industry experts have worked with SAIW to develop new course material

SAIW lecturers are being trained by industry experts

Will the changes impact onexisting certified persons?

What will happen to existing certified persons?What will happen to existing certified persons?

All existing certifications will be retained

Renewals will be treated as they are currently

SUMMARYSUMMARY

Many AIAs have included in-service inspection in their scope of activities informally in the past. Now they are required to demonstrate their capabilities for these activities by assessment.

PER enhances the status of AIAs significantly and there is an expectation of professionalism by the regulatory authorities.

The changes made by SAQCC CP are intended to improve the professionalism of inspectors involved in periodic inspections, enhance their standing and support AIA-IS companies in meeting their responsibilities