CSWIP Plant Inspection Training and Certification Programme

In this competitive age, the resources of successful plant operators can be stretched when faced with unforeseen problems or when time-investment is required for long-term planning. The key is to identify the most cost-effective practical solution using state-of-the-art assessment tools and techniques.

Recognising the need to ensure that engineers involved in asset integrity management are suitably qualified to deliver optimised plant inspection and assessment, TWI is offering an internationally recognised CSWIP Plant Inspection Certification Scheme at three competency levels (Level 1, 2 and 3).

TWI has responded to industry’s need for plant inspection personnel to gain certification by offering the Plant Inspection training scheme in a modular format, giving prospective students the opportunity to follow a clearly defined, structured career path.

These courses are aimed at:

  • plant engineers
  • welding/NDT inspectors/practitioners
  • materials and corrosion engineers
  • plant inspectors


responsible for managing the safety and integrity of ageing process equipment, pipelines, boilers and storage tanks.

The scheme is designed to suit:

  • plant inspectors working for manufacturing works (Vendor)
  • inspection organisations
  • equipment owners and operator
  • classification societies
  • insurance companies
  • safety regulators


The courses have three goals:

  • To ensure inspectors and engineers responsible for assessing plant integrity have the essential tools and skills necessary
  • To recognise and certify plant inspector competence
  • To provide a structured career path for continuing professional development of plant integrity practitioners through formal training/certification


Course fees do not include copies of the associated API or ASME documents. API publications may be purchased from the API Standard Store: www.techstreet.com. For all courses, students must provide their own copies of the reference standards.

Plant Inspection Level 1



Plant Inspection Level 1 consists of two five-day modules and can be accessed from various routes: NDT/welding inspection route or mature candidate route.

An inspector certified to Plant Inspector Level 1 has a wide-ranging basic knowledge of technical issues relating to works (vendor) and in-service inspection of plant.

  • The inspector will be able to perform straightforward unsupervised inspections in accordance with an inspection and test plan (ITP) for new equipment or a written scheme of examination (WSE) for in-service equipment which is not subject to statutory requirements (PED, PSSRs, etc...)
  • The inspector will be able to choose the inspection method, liaise with technicians performing the test, and provide clear reports, with recommendations, for final assessment by others
  • The inspector will be capable of making basic subjective judgements on routine inspection results but will require assistance when dealing with more technically complex situations


MODULE 1 Part A: Rules/Regulations and Duties of a Plant Inspector



Course Content


Roles and duties of the Plant Inspector; QA/inspection; inspection safety; legislation, rules and regulations; basic inspection skills; inspection and test plans; inspection of materials; visual inspection skills; visual examination of welds; inspection and NDT; engineering materials; material degradation and failure.

MODULE 1 Part B: Inspection Methods



Course Content


The use of codes and standards; introduction to pressure equipment; pressure vessels inspection; inspection of pipelines; inspection of storage tanks; inspection of paint systems and linings; introduction to risk-based inspection; inspection reporting; corrosion processes.

Plant Inspection Level 2



To be awarded Plant Inspection Level 2, candidates must hold Plant Inspection Level 1 (Module 1: Parts A and B) and gain four of the seven available modules.

  • An inspector certified to Plant Inspector Level 2 would be capable of carrying out all duties for which a level 1 inspector is qualified but is able to add a deeper level of technical understanding and interpretation
  • The inspector also has a wider scope of knowledge relating to pressure equipment and their manufacturing and test procedure
  • A Level 2 inspector can make more detailed comparison of inspection results with code/defect acceptance criteria and justify conclusions using code calculations. In cases where corrosion and other in-service defects are found, the inspector is able to allocate severity levels and contribute input to a risk-based-inspection (RBI) scheme, if applicable


MODULE 2: Damage Mechanism Assessment for RBI and FFS, based on API RP 571



Three-day course covering the latest API recommended practice on in-service damage mechanisms in pressure systems, pipelines and storage tanks, in oil and gas production, refining and petrochemical industries. API RP 571 supports the API RP 580 risk-based inspection (RBI) and the new API RP 579-1/ASME FFS-1 2007 fitness-for-service (FFS) procedures.

Course Content


Common damage mechanisms in all major oil and gas production, refining and manufacturing processes and where they can be found; key process parameters, prevention and control and the most appropriate inspection and non-destructive testing methods for these damage mechanisms.

MODULE 3: Risk Based Inspection (RBI), based on API and ASME



Two-day course covering the latest recommended practice for RBI and maintenance planning on pressure systems, pipelines and storage tanks. This course covers Level 1 (qualitative) through to Level 3 (quantitative) RBI methods and will provide practical expertise on how to implement RBI.

Course Content


RBI in accordance with API RP 581, API RP 580; reasons for implementing RBI; benefits of using RBI; practical implementation of RBI; planning successful RBI implementation projects; practical likelihood and consequence analysis; preparing inspection plans and optimising maintenance and inspection intervals; implementing risk mitigation actions; overview of other procedures (e.g. RIMAP, ASME) and related API documents (API RP 510, API 570 and API 653).

MODULE 4: Fitness-For-Service (FFS) Assessment, based on API RP 579-1/ASME FFS-1 2007



This course has been developed, based around the API/ASME combined standard (API 579 Second Edition) which has been expanded to address material damage mechanisms other than just those commonly found in refining industry equipment.

Four-day course covering Levels 1 and 2 FFS assessments, in accordance with the latest edition of API RP 579-1/ASME FFS-1 2007.

Course Content


Introduction to FFS; material properties and the API RP 579 Annexes; stress analysis for FFS; NDT and flaw sizing for FFS; identification of damage mechanisms for FFS; brittle fracture; general metal loss; localised metal loss; pitting; laminations; weld misalignment and shell distortion; crack-like flaws; creep; fire damage; hydrogen blisters; hydrogen damage associated with HIC and SOHIC; dents and gouges; remaining life assessment and life extension examples; repair and remediation options; status of API RP 579 and future developments; interaction with other assessment procedures (e.g. FITNET, BS 7910, R5 and R6) and related API documents (API RP 510, API RP 570 and API RP 653).

MODULE 5: Weld Repair of Pressure Equipment and Piping



One-day course covering the requirements for weld repair in international codes and standards. The course will start with an introduction to main methods of repair (hot and cold). However the main focus of the day will be on welding processes and weld repair, production control and method statements for weld repair, qualifications and inspection - pre and post weld repair and the training will include interactive class exercises.

Course Content


Process to derive need for repair, selecting an appropriate repair method, a list of must do’s, life of weld repair, type of equipment and industry (time and consequence constraints), codes and standards to make weld repairs or alterations (temper bead repair, mock up vs PQT), proper weld procedure and welder qualifications and use of standard welding procedures (methods and requirements to qualify repair - typical qualification program - types of test - non-ideal conditions - what happens etc., what paperwork needs to be done, who should be notified), appropriate selection of NDE methods, examples and case studies including when weld repairs have gone wrong.

MODULE 6: Pressure Vessel Inspection, based on API RP 510



Five-day course covering a comprehensive introduction to the in-service inspection of pressure vessels based on the requirements of API/ASME standards.

Course Content


Extensive overview of API 510 “Body of Knowledge”, inspection intervals, corrosion allowances, joint efficiencies, static head and pressure calculations, impact testing, weld size determination, concepts of reinforcement, degradation mechanisms, remaining life calculations, ASME VIII welding and ASME V NDE requirements.

MODULE 7: Piping Inspection, based on API RP 570



Five-day course covering a comprehensive introduction to the in-service inspection of metallic piping systems based on the requirements of API/ASME standards.

Course Content


Extensive overview of API 570 “Body of Knowledge”, corrosion allowances, inspection intervals, joint efficiencies, pressure testing, impact testing, preheating and heat treatment requirements, remaining life calculations, degradation mechanisms, ASME welding and NDE requirements.

MODULE 8: Aboveground Tank Inspection, based on API RP 653



Five-day course covering a comprehensive introduction to the in-service inspection of above-ground storage tanks based on the requirements of API/ASME standards.

Course Content


Extensive overview of API 653 “Body of Knowledge”, corrosion allowances, inspection intervals, joint efficiencies, hydrostatic testing requirements, weld size determination, hot tapping, tank shell evaluation, degradation mechanisms, ASME welding and NDE requirements.

Plant Inspection Level 3



To be awarded Plant Inspection Level 3, candidates must hold Plant Inspection Level 2 and gain an additional two modules.
  • An inspector certified to Plant Inspector Level 3 would be capable of establishing techniques and procedures; interpreting codes, standards, specifications and procedures; recommending particular test methods, techniques and procedures to be used
  • The inspector shall be deemed to have the competence to interpret and evaluate results in accordance with existing codes, standards and specifications and have sufficient practical technical background to select methods and establish techniques and to assist in establishing acceptance criteria where none are otherwise available
  • The inspector will also be able to assume responsibility for a ‘user inspector’ operation and demonstrate a clear and justified view of the subject of risk


Entry Requirements


Direct Entry to Plant Inspection Level 1


Candidates shall hold a minimum of:

  • A valid CSWIP Welding Inspector certificate (Level 2)
AND
  • Current Level 2 ISO 9712 NDT certificates in two methods
OR
  • Candidates shall have obtained a minimum of five years verified work experience in plant inspection

NOTE:
  • If the candidate does not hold a valid CSWIP Welding Inspector certificate (Level 2) he/she must either gain the Level 2 approval or gain the Offshore Visual Inspection approval (Supplementary Module S1)
  • If the candidate does not hold a current ISO 9712 NDT certification in two methods he/she must either gain the required NDT approvals or attend an NDT appreciation training course (Supplementary Module S2)

Direct Entry to Plant Inspection Level 2


A mature candidate route is available for candidates who hold a minimum of a HNC in a relevant engineering subject or Incorporated Engineer with an appropriate Professional Body and have a minimum of five years’ verified experience in plant inspection.

Candidates with the appropriate academic qualification but without the required experience or welding Inspection and NDT certification must successfully complete supplementary modules S1/S2 as appropriate.

In addition to the above requirements, in order to be eligible to attend the Plant Inspector Level 2 training candidates shall successfully complete Level 1 Plant Inspection Module 1 (PART A).

To be awarded Plant Inspection Level 2

Candidates must hold Plant Inspection Level 1, those with the appropriate academic qualifications must hold Plant Inspection Level 1 (Module 1 Part A) and gain four Level 2 modules.

To be awarded Plant Inspection Level 3

Candidates must hold Plant Inspection Level 2 and gain 2 additional modules.