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Checking engineering products using penetrant flaw detection methods

URN: SEMTS213
Business Sectors (Suites): Engineering Technical Support Suite 2
Developed by: Enginuity
Approved on: 2015

Overview

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This standard identifies the competences you need to carry out penetrant flaw detection tests on ferrous and non-ferrous engineering products, materials or structures, in accordance with approved procedures. You will be required to prepare the products, materials or structures for the penetrant flaw detection activities, and to obtain the appropriate penetrant and developer. You must ensure that the ambient conditions are satisfactory for the tests to proceed, and you will then carry out the specified tests using the correct procedures. You will be expected to mark up the products, materials or structures to show where there are indications of flaws.

Your responsibilities will require you to comply with organisational policy and procedures for the penetrant flaw detection activities undertaken, and to report any problems with the equipment in use, that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work to instructions, either alone or in conjunction with others, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.  You will be required to demonstrate your proficiency to carry out non-destructive testing (NDT) and this could be in accordance with the requirements of BS EN ISO 9712.

Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will provide an informed approach to the inspection of engineering products, materials or structures by using penetrant flaw detection testing techniques. You will have a basic understanding of the principles of penetrant flaw detection techniques, and the role of penetrant fluids, developers and ultraviolet light imaging. You will also have an understanding of the types of defects that can be detected using penetrant flaw detection techniques.

You will understand the safety precautions required when carrying out the penetrant flaw detection 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.

Performance criteria

You must be able to:

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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 for the 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 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

Knowledge and Understanding

You need to know and understand:

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  1. the specific safety precautions to be taken when carrying out penetrant flaw detection activities on engineering products, materials or structures (such as specific legislation or regulations governing the activities or work area, safe working practices and procedures to be adopted, general workshop safety practice)
  2. the hazards associated with carrying out the penetrant flaw detection activities (such as using inflammable materials, toxic and volatile material, use of aerosol containers and safety in the use of sprays and powders), and how they can be minimised
  3. the personal protective clothing and equipment (PPE) that should be worn during the penetrant flaw detection activities
  4. the COSHH regulations relating to materials used during the penetrant flaw detection process
  5. how and where to obtain the required job instructions, testing specifications and quality control/inspection documentation
  6. the reasons why some components, materials or structures require to be tested using non-destructive testing methods
  7. the various types of penetrant flaw detection equipment used (to include portable kits and fixed installations; containers and dispensers for penetrants, removers and developers)
  8. the basic concepts of penetrant flaw detection testing
  9. the different types of penetrant that are used (including colour and fluorescent intensity), methods of applying them and contact time required to be effective
  10. how to develop indications of the flaws so that they show up clearly
  11. the various types of developer that are used (such as dry powder, powder in aqueous and non-aqueous carriers, developers in solution); contact times required for effective development
  12. the various types of penetrant removers (such as solvents, water soluble and oil soluble emulsifiers)
  13. the type of lighting that is required for the defects to show up clearly
  14. the preparations to be carried out on the test area (such as degreasing); the effect of finish, contaminants and the testing temperature on the test results achieved
  15. how to carry out the testing activities (including the application of the penetrant, removal of excess penetrant, contact time, drying of products, application of developer), conditions for viewing developed indications (such as ambient light or ultra violet (UV) light), and cleaning of the products on completion of the testing activities
  16. the types of defect that are detectable using penetrant flaw detection methods
  17. how to recognise the defects from the developed indications, and how to identify false indication of effects, and their cause
  18. the level of defects that are acceptable in the products
  19. the importance of completing penetrant flaw detection documentation; what needs to be recorded, and where records are kept

the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

Scope/range

Scope Performance

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  1. Carry out all of the following during the penetrant flaw detection activities:

    1. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations
    2. obtain the required penetrant flaw detection equipment and materials, and check that they are in a safe and usable condition
    3. check that penetrant flaw detection dispensers are fully operational
    4. follow the defined testing procedures, and apply safe working practices and procedures at all times
    5. resolve any problems as they occur, within your level of responsibility
    6. leave the work area in a safe condition on completion of the activities

  2. Prepare the products, materials or structures for testing, to include carrying out all of the following:

    1. identifying and marking the test areas
    2. removing any contaminants from the test area (such as by degreasing)
    3. preparing the surface of the test area to the specified finish (such as by grinding or polishing)

  3. Use both of the following penetrant flaw detection dispensers:

    1. penetrant dispenser
    2. developer dispenser

  4. Carry out all of the following, in accordance with instructions and procedures:

    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 (such as ambient light or ultra violet (UV) light)
    5. recording the conclusions of observations
    6. restoring and cleaning the product on completion of the test

  5. Carry out penetrant flaw detection on one of the following:

    1. welded joints           
    2. castings              
    3. heat treated components       
    4. structures
    5. wrought products/materials (such as forged, rolled, extruded)
    6. cold formed products/materials (such as by bending, pressing, rolling)

  6. Identify all of the following:

    1. defect type                      
    2. location of the defect      
    3. dimensional size of the defect

  7. Follow the correct procedure to deal with products, materials or structures which fall into both of the following categories:

    1. components, materials or structures which meet the specification
    2. components, materials or structures with identified defects

  8. Complete the inspection activities, to include carrying out all of the following:

    1. marking up defective components, materials or structures 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

Scope Knowledge

Values

Behaviours

Skills

Glossary

Links To Other NOS

External Links

Version Number

2

Indicative Review Date

2018

Validity

Current

Status

Original

Originating Organisation

Semta

Original URN

SEMTS2-13

Relevant Occupations

Engineering, Engineering and Manufacturing Technologies

SOC Code

3113

Keywords

Engineering; technical support; engineering products; penetrant flaw detection; ferrous engineering products; non-ferrous engineering products; detection techniques; penetrant fluids; developers; ultraviolet light imaging