Carrying out non-destructive flaw detection on components during overhauling activities

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This standard identifies the competences you need to carry out dye penetrant or magnetic particle flaw detection tests, on ferrous and non-ferrous engineering components to be re-used in overhaul activities, in accordance with approved procedures/techniques. You will be required to prepare the components for the non-destructive testing activities and to check that the equipment used complies with the testing instructions and requirements, and is safe to use and fit for purpose.

You must ensure that the ambient conditions are satisfactory for the tests to proceed, and you will carry out the specified tests, using the correct procedures/techniques, and will observe and record the test indications. You will conclude the tests by completing all relevant documentation/NDT test report, which will contain the required test information along with your interpretation of the test indications. You will be expected to mark up the components to show where there are indications of surface defects/flaws. The completed inspection report will be passed to the appropriate person, in accordance with organisational procedures.

Your responsibilities will require you to comply with organisational policy and procedures for the non-destructive testing activities undertaken, and to report any problems that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will show a good understanding of your work, and will provide an informed approach to the inspection of components using non-destructive flaw detection testing methods. You will have a working knowledge of the operating principles of the specific flaw detection equipment being used, and how any defects will be displayed. Your knowledge will include an appreciation of hazards and safe working practice, and you will understand the risks posed by material defects and the consequences of failure.

You will understand the safety precautions required when carrying out the dye penetrant or magnetic particle testing activities, and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

Glossary of Terms:

Discontinuity – Any imperfection in the material / component / structure

Flaw – A significant discontinuity to be recorded but within specified limits and tolerances

Defect – A flaw outside specified limits and tolerances causing the material / component / structure to be non-compliant and rejected

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. follow the correct specification/technique for the component, product or equipment being inspected
3. use the correct equipment to carry out the inspection
4. identify and confirm the inspection checks to be made and acceptance criteria to be used
5. carry out all required inspections as specified
6. identify any defects/flaws or variations from the specification
7. record the results of the inspection in the appropriate format
8. deal promptly and effectively with problems within your control and report those that cannot be solved

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1. how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. the hazards associated with carrying out the dye penetrant or magnetic particle inspection activities, and how to minimise them and reduce any risks
3. the personal protective equipment (PPE) to be used, and how to obtain it
4. the regulations relating to materials used during the inspection process
5. how to obtain the necessary job instructions and testing procedures/techniques, and how to interpret their information
6. the reasons why some components require non-destructive testing methods
7. why it is sometimes necessary to use a range of different non-destructive testing methods
8. the basic concepts of non-destructive testing using dye penetrant or magnetic particle testing
9. the preparations to be carried out on the components, materials or structure test area
10. how to check and set up the required equipment before the inspection takes place
11. how to carry out magnetic particle testing activities (including the application of the magnetic field and the application of the detecting media)
12. how to carry out the penetrant flaw detection activities (including the application of the penetrant, removal of excess penetrant, contact time, drying of products, application of developer)
13. conditions for viewing developed indications
14. the types of defect/flaws that are detectable using dye penetrant and magnetic particle detection methods
15. how to recognise defects/flaws in the components from the displayed indications, and how to identify false indication of effects, and their cause
16. the level of defects/flaws that are acceptable in the components; the influence of the defects/flaws on the service/performance of the components
17. the system of quality control within the company and who is responsible for it
18. the documentation to be completed on conclusion of the non-destructive testing activities
19. the extent of your own responsibility and to whom you should report if you have problems that you cannot solve

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1. Carry out all of the following during the non-destructive flaw detection activities:
   1. obtain the required defect/flaw detection testing equipment, and check that it is in a safe and usable condition
   2. adhere to procedures or systems in place for risk assessment, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
   3. provide and maintain safe access and working arrangements for the work area
   4. follow good practice/approved testing procedures/techniques at all times
   5. identify and record results of tests in the appropriate format
   6. leave the work area and tools in a safe and appropriate condition on completion of the activities
2. Carry out flaw detection activities using one of the following methods:
   1. dye penetrant
   2. magnetic particle
3. Check and confirm that all of the following ambient testing conditions are satisfactory:
   1. temperature
   2. humidity
   3. free from vibration (as applicable)
   4. free from pollutants
4. Prepare the components for testing, to include carrying out all of the following:
   1. identifying the test areas on the components
   2. removing any contaminants from the test area (such as by degreasing)
   3. where appropriate, preparing the test surface to the specified finish (such as by polishing or grinding)
5. Carry out one of the following, in accordance with instructions and procedures/technique:

Penetrant flaw detection: All of the following:


1. applying penetrant to the area under inspection
2. washing and drying the test area
3. applying a developer (where appropriate)
4. observing defect indications under correct lighting conditions (ambient light or ultra violet (UV))
5. recording conclusions of observations
6. restoring and cleaning the product on completion of the test


Magnetic particle testing:  All of the following:
7. checking condition and security of electrical cables, connections, mechanical functions and all safety devices
8. setting the equipment parameters to the appropriate levels
9. magnetising the components
10. applying the detecting medium (ink or powder) correctly
11. using magnetic flux indicators
12. observing defect indications under correct lighting conditions (ambient light or ultraviolet (UV))
13. recording conclusions of observations
14. demagnetising and cleaning the components on completion of the test

6. Identify all of the following:
   1. defect/flaw type
   2. dimensional size of the defect/flaw
   3. location of the defect/flaw
7. Follow the correct procedure to deal with components which fall into three of the following categories:
   1. components which meet the specification
   2. components with identified defects/flaws
   3. components requiring further investigation
   4. components requiring other inspection methods
8. Complete a NDT report, to include recording all of the following:
   1. component identification
   2. material of construction
   3. geometry, thickness and surface condition where defect indications were found
   4. ambient testing conditions
   5. defects identified
   6. comparison of flaw data with acceptance criteria
   7. conclusions and recommendations
   8. personal data
9. Complete the inspection activities, to include carrying out all of the following:
   1. marking up any defective components with all relevant information
   2. recording all the required details of the inspection, in the appropriate format
   3. handing over the inspection details to the appropriate people

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3

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31 Mar 2028

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Current

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Original

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Enginuity

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SEMMME3103

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Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

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3113

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Mechanical engineering; overhaul; test; non-destructive; flaw detection; dye penetrant; magnetic particle; ambient conditions; temperature; humidity; vibration; pollutants; defects; flaws; indications; NDT

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