SOUTHERN AFRICAN INSTITUTE OF WELDING. Non Destructive Testing (NDT) Course Syllabus & Programme

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SOUTHERN AFRICAN INSTITUTE OF WELDING Non Destructive Testing (NDT) Course Syllabus & Programme Certification Body Please refer to our Website (www.saiw.co.

Standard : ISO 9712 Industrial Sector : MT 1.0 Pre and In - Service MT 1.1 Wrought Products / Forgings Product Sector : MT 1.2 Castings Surface MT 1.

1 SOUTHERN AFRICAN INSTITUTE OF WELDING Non Destructive Testing (NDT) Course Syllabus & Programme Certification Body Please refer to our Website ( for any information relating to the Training, Qualification and Certification of SAQCC-NDT personnel Certification Scheme NDT Method : Magnetic Testing Qualification Level : Level 1 Reference Standard : ISO 9712 Industrial Sector : MT 1.0 Pre and In - Service MT 1.1 Wrought Products / Forgings Product Sector : MT 1.2 Castings Surface MT 1.3 Welds Surface Ferro-magnetic components Defect detection: Subsurface and Surface SAIW - CERTIFICATION: DOC/CS : MT/G 1.0 : General Applicable documents (Contained within this document) : SAIW - CERTIFICATION: DOC/CS : MT/S 1.1 : Specific - Forgings SAIW - CERTIFICATION: DOC/CS : MT/S 1.2 : Specific - Castings SAIW - CERTIFICATION: DOC/CS : MT/S 1.3 : Specific - Welds Compliant with ISO 25107, IAEA Tecdoc 628, ASNT CP 105 Compilation / Revision date : Date to be revised : 52 Western Boulevard, off Main Reef Road, City West, Johannesburg P.O. Box 527, Crown Mines, 2025, Telephone (011) , Fax (011) , info@saiw.co.za

2 INFORMATION Objective To provide the Level 1 candidate with adequate knowledge and skill to be able to inspect and report sector specific components in accordance with written instructions which are based on international codes and procedures. Target Group NDT Operators or Practitioners wanting to perform surface as well as subsurface inspections on castings, forgings, welds and tubes manufactured from ferromagnetic material. COURSE: 1. Grade 10 with Maths and Science Or Eligibility 2. Pass ( 70%) in applicable Proficiency test (No charge, available of contact jansenh@saiw.co.za for booking). EXAMINATION: 1. Training : 32 hrs (100% Attendance & formative assessments) 2. Vision Acuity Qualification Examination General : 40 Multiple Choice Questions : Pass 70% Specific : 40 Multiple Choice Questions : Pass 70% Practical : Weld, Casting, Forging samples INITIAL : INDUSTRIAL EXPERIENCE 1. 1 months / 176 hrs 2. Submit Industrial Experience and Training Matrix & Vision Acuity RENEWAL : After 5 years Certification 1. Full practical examination 2. Annual NDT Activity Report & Vision Acuity 3. Valid Certification 4. If lapsed < 1 year : Spec & Practical Exam 5. If lapsed > 1 year : Full examination RECERTIFICATION : After 10 years 1. Full examination : General, Specific & Practical 2. Annual NDT activity report & Vision Acuity 3. Valid Certification DOC / CS / MT 1.0 Page 2 of 16 TRAINING EXAMINATION CERTIFICATION

3 INDEX Description Duration MT1 - Sect 1. Foreword 1.1. Welcome to SAIW : Student Induction 1.2. Course objective 1.3. Course Format, Formative assessment and outcomes 1.4. Code of Ethics 1.5. South African NDT Industry 1.6. SAQCC NDT System : Qualification and Certification of NDT Personnel 1.7. Professional Designation 1.8. Career progress in NDT (ISO 9712) MT1 - Sect 2. Introduction : Non Destructive Testing 2.1. Task of NDT What is testing? Destructive vs. Non Destructive What is the purpose of NDT? When and why is NDT performed? NDT Methods and Techniques 2.2. Historical Timeline of NDT 2.3. Task of NDT Personnel 2.4. NDT Terminology: General: discontinuities, indications, defects, interpretation, evaluation, etc Quality: Code, Standard, Procedure, written instruction 2.5. General Safety Considerations (Occupational Health & Safety) MT1 - Sect 3. NDT Method in a Nutshell 3.1. Single sentence summation 3.2. Advantages 3.3. Disadvantages 3.4. Limitations 3.5. Applications DOC / CS / MT 1.0 Page 3 of 16 TRAINING EXAMINATION CERTIFICATION

4 INDEX (Continued) Description Duration MT1 - Sect 4. Physical Principals and associated knowledge 4.1. Magnetism Magnetism a Magnetic Poles b Permanent Magnets : Bar, horseshoe c Temporary Magnets d Magnetisation : Passing of flux from magnetic medium to nonmagnetic medium Magnetic fields & Lines of force Material Characteristics : Ferromagnetism, diamagnetism, paramagnetism, Hysteresis curve a Retentivity, residual magnetism, coercive force, reluctance b Permeability c Saturation Magnetic Flux, Magnetic Flux Density, Magnetization Force (Units & Typical values) Flux Leakage: formation, influence of depth and orientation on detection of discontinuities Curie point 4.2. Electromagnetism Electricity a Current i Direct Current ii Alternating Current b Voltage c Resistance Magnetic field around Conductor Magnetic Field around Coil / solenoid DOC / CS / MT 1.0 Page 4 of 16 TRAINING EXAMINATION CERTIFICATION

5 INDEX (Continued) Description Duration MT1 - Sect 5. Product knowledge, method capabilities and derivative techniques 5.1. Manufacturing process and related discontinuities in castings, forgings, rolled products and welds 5.2. Relevant, non-relevant and false indications 5.3. Testing parameters Magnetization a Methods of magnetization i Longitudinal ii Circular iii Vertical b Permanent Magnets c Magnetizing Current i Alternating Current (AC) ii Direct Current (DC) iii Half Wave Rectified Current (HWRC) iv Full wave rectified current (FWRC) Single or three phase d Electromagnetic Yokes i Current Flow Passage of current ii Induction methods Central conductor, Coils Magnetic Field a Distribution, strength, direction b Detection / measurement Detection medium a Magnetic Particle Characteristics b Dry Powders c Inks / Wet Particles i Characteristics and Control of Petroleum Suspensions ii Characteristics and Control of Water Suspensions d Pastes i Characteristics and Control of Rubber Suspensions e Concentrates f Health and Safety considerations Demagnetisation DOC / CS / MT 1.0 Page 5 of 16 TRAINING EXAMINATION CERTIFICATION

6 INDEX (Continued) Description Duration MT1 - Sect 6. Equipment & Consumables 6.1. Types of Current, Test Current Capacity 6.2. Portable equipment Permanent Magnet Yokes Electromagnetic yokes Prods Coils Other Devices 6.3. Stationary / Heavy Duty Equipment Power supplies Bench equipment a Multidirectional equipment Automatic units Special purpose units 6.4. Demagnetization equipment 6.5. Conditions of use Equipment operation Equipment Maintenance Safety Accessories: Contact points 6.6. Vessels for checking inspection baths 6.7. Magnetic field indicators Portable field strength meters (magnetometers/gauss meters) Shim/type/ foil strips (trade name Castrol Strips/Ely Strips) The ASME field indicator The berthold panameter Hall Effect Meters Performance checks / Calibration pieces Calibration Test Pieces (JIS) 6.8. Viewing conditions Non Fluorescent inks and powders Fluorescent inks and powders Safety Electromagnetic spectrum Light : Ultraviolet, Visible, Ambient, Extraneous DOC / CS / MT 1.0 Page 6 of 16 TRAINING EXAMINATION CERTIFICATION

7 DOC / CS / MT 1.0 Page 7 of 16 TRAINING EXAMINATION CERTIFICATION

8 INDEX (Continued) Description Duration MT1 - Sect 7. Information prior to test 7.1. Magnetic Particle Testing Practices Fundamentals Choice of equipment Effects of test object variables 7.2. Inspection techniques Remnant fields Continuous field Wet method Dry method Demagnetization techniques and verification of remnant fields 7.3. Written Instruction 7.4. Report Sheet MT1 - Sect 8. Testing according to Written instruction 8.1. Surface preparation Pre cleaning /machining Contrasting background 8.2. Magnetization Type, current, duration and sequence Grid / coverage of surface area 8.3. Application of detection medium Residual or Continuous 8.4. Verification of adequate magnetic field / control of magnetization conditions 8.5. Interpretation and recording of results 8.6. Treatment of components after test Residual field Demagnetization Post cleaning DOC / CS / MT 1.0 Page 8 of 16 TRAINING EXAMINATION CERTIFICATION

9 INDEX (Continued) Description Duration MT1 - Sect 9. Interpretation and reporting Evaluation (Level 2 only) 9.1. Welding : ISO Casting : ISO 4986 (EN 1369) 9.3. Forging : BS EN Rolled / wrought products 9.5. Viewing condition according to reference block 9.6. Verification of indication quality ISO Report of simple welding, forging, casting and rolled product indications 9.8. Discontinuities : Types, identification & parameters 9.9. Indications: Relevant, non-relevant and false Characteristics Preservation a transparent tape, coating transfers lacquer developers b photographic Factors affecting interpretation: surface prep, detecting medium, application MT1 - Sect 10. Assessment Depth, width, shape, position, orientation MT1 - Sect 11. Quality aspects Personnel Qualification & Certification Equipment verification Functionality checks a Consumable concentration and mobility b Colour contrast Operational calibration a Magnetic field strength & direction b Light Intensity Maintenance checks a Electrical current measurement and supply b UV / White light DOC / CS / MT 1.0 Page 9 of 16 TRAINING EXAMINATION CERTIFICATION

10 INDEX (Continued) Description Duration MT1 - Sect 12. Environmental and safety conditions Electrical risks hazards Magnetic field risks Risks related to consumables Risks related to UV radiation Disposal of effluents and environmental conditions Safety data sheets MT1 - Sect 13. Developments N / A MT1 - Sect 14. Appendices Appendix 1 : Method specific terminology / definitions ISO Appendix 2 : Core reference codes, standards & procedures Appendix 3 : Quality related terminology and examples Appendix 4 : Formulae & Reference Tables Appendix 5 : Answers to end of chapter and homework assignments Appendix 6 : Preparation for qualification examination Appendix 7 : Example questions and answers Appendix 8 : Additional reading material / internet sites for further study Level 1 certified personnel shall neither be responsible for the choice of test method or technique to be used, nor for the evaluation of test results. Total Training : General 32 Hrs DOC / CS / MT 1.0 Page 10 of 16 TRAINING EXAMINATION CERTIFICATION

11 Application In accordance with ISO 9712 & SAQA Unit Standard No DOC. REF. SAIW - CERTIFICATION: DOC/CS : MT/S 1.1 : Castings Specific Theory Section Description Page 1 Product Knowledge 2 Typical Discontinuities 3 Signal response & Detectability 4 Written Instruction & Report Sheets (Based on Codes, Standards or Specifications) OUTCOME 1 : Setup magnetic particle testing equipment 1.1 The principles of magnetic particle testing are described with reference to basic physical principles. 1.2 The principles of operation of testing equipment and accessories are applied in accordance with manufacturer specifications. 1.3 Type of equipment required is identified in terms of approved written instructions. Range: Written instruction includes equipment selection, operating modes, component/object, defect type and detection 1.4 Magnetic particle testing equipment for specific applications is set-up and calibrated in accordance with written instructions. Range: Field strength meters, lifting blocks, settling flasks, UV meters 1.5 Equipment checks and equipment performance are verified in accordance with written instructions. PRACTICAL : Product Sector OUTCOME 2 : Perform magnetic particle testing 2.1 The testing technique is implemented in accordance with the applicable work instruction. 2.2 The equipment is used in accordance with the work instructions. 2.3 The equipment and accessories are verified and checked in accordance with the work instructions. 2.4 Equipment problems are identified and communicated in accordance with works procedures. Range: Problems include out of range measurements, incorrect responses from meters and lifting blocks and UV light meters 2.5 Inspection progress and scope of coverage is monitored and documented in accordance with written instructions. OUTCOME 3 : Record and classify the results of test 3.1 Data recording sheets are completed in accordance with written instructions. 3.2 The quality of the data is in accordance with written instructions. Range: interfering parameters, data storage and accessibility 3.3 Discontinuities are interpreted and recorded according to parameters stipulated in working instructions. DOC / CS / MT 1.0 Page 11 of 16 TRAINING EXAMINATION CERTIFICATION

12 Application In accordance with ISO 9712 & SAQA Unit Standard No DOC. REF. SAIW - CERTIFICATION: DOC/CS : MT/S 1.3 : Welds Specific Theory OUTCOME 4 : Report the results 4.1 The relevant results are reported in accordance with the written instruction. 4.2 The language and terminology used is appropriate to the method and can be interpreted by the recipient. 4.3 The format is in accordance with the written instruction. DOC / CS / MT 1.0 Page 12 of 16 TRAINING EXAMINATION CERTIFICATION

13 Application In accordance with ISO 9712 & SAQA Unit Standard No DOC. REF. SAIW - CERTIFICATION: DOC/CS : MT/S 1.2 : Forgings / Wrought Products Specific Theory Section Description Page 1 Product Knowledge 2 Typical Discontinuities 3 Signal response & Detectability 4 Written Instruction & Report Sheets (Based on Codes, Standards or Specifications) OUTCOME 1 : Setup magnetic particle testing equipment 1.6 The principles of magnetic particle testing are described with reference to basic physical principles. 1.7 The principles of operation of testing equipment and accessories are applied in accordance with manufacturer specifications. 1.8 Type of equipment required is identified in terms of approved written instructions. Range: Written instruction includes equipment selection, operating modes, component/object, defect type and detection 1.9 Magnetic particle testing equipment for specific applications is set-up and calibrated in accordance with written instructions. Range: Field strength meters, lifting blocks, settling flasks, UV meters 1.10 Equipment checks and equipment performance are verified in accordance with written instructions. PRACTICAL : Product Sector OUTCOME 2 : Perform magnetic particle testing 2.1 The testing technique is implemented in accordance with the applicable work instruction. 2.2 The equipment is used in accordance with the work instructions. 2.3 The equipment and accessories are verified and checked in accordance with the work instructions. 2.4 Equipment problems are identified and communicated in accordance with works procedures. Range: Problems include out of range measurements, incorrect responses from meters and lifting blocks and UV light meters 2.5 Inspection progress and scope of coverage is monitored and documented in accordance with written instructions. OUTCOME 3 : Record and classify the results of test 3.3 Data recording sheets are completed in accordance with written instructions. 3.4 The quality of the data is in accordance with written instructions. Range: interfering parameters, data storage and accessibility 3.3 Discontinuities are interpreted and recorded according to parameters stipulated in working instructions. DOC / CS / MT 1.0 Page 13 of 16 TRAINING EXAMINATION CERTIFICATION

14 Application In accordance with ISO 9712 & SAQA Unit Standard No DOC. REF. SAIW - CERTIFICATION: DOC/CS : MT/S 1.3 : Welds Specific Theory OUTCOME 4 : Report the results 4.4 The relevant results are reported in accordance with the written instruction. 4.5 The language and terminology used is appropriate to the method and can be interpreted by the recipient. 4.6 The format is in accordance with the written instruction. DOC / CS / MT 1.0 Page 14 of 16 TRAINING EXAMINATION CERTIFICATION

15 Application In accordance with ISO 9712 & SAQA Unit Standard No DOC. REF. SAIW - CERTIFICATION: DOC/CS : MT/S 1.3 : Welds Specific Theory Section Description Page 1 Product Knowledge 2 Typical Discontinuities 3 Signal response & Detectability 4 Written Instruction & Report Sheets (Based on Codes, Standards or Specifications) OUTCOME 1 : Setup magnetic particle testing equipment 1.11 The principles of magnetic particle testing are described with reference to basic physical principles The principles of operation of testing equipment and accessories are applied in accordance with manufacturer specifications Type of equipment required is identified in terms of approved written instructions. Range: Written instruction includes equipment selection, operating modes, component/object, defect type and detection 1.14 Magnetic particle testing equipment for specific applications is set-up and calibrated in accordance with written instructions. Range: Field strength meters, lifting blocks, settling flasks, UV meters 1.15 Equipment checks and equipment performance are verified in accordance with written instructions. PRACTICAL : Product Sector OUTCOME 2 : Perform magnetic particle testing 2.1 The testing technique is implemented in accordance with the applicable work instruction. 2.2 The equipment is used in accordance with the work instructions. 2.3 The equipment and accessories are verified and checked in accordance with the work instructions. 2.4 Equipment problems are identified and communicated in accordance with works procedures. Range: Problems include out of range measurements, incorrect responses from meters and lifting blocks and UV light meters 2.5 Inspection progress and scope of coverage is monitored and documented in accordance with written instructions. OUTCOME 3 : Record and classify the results of test 3.5 Data recording sheets are completed in accordance with written instructions. 3.6 The quality of the data is in accordance with written instructions. Range: interfering parameters, data storage and accessibility 3.3 Discontinuities are interpreted and recorded according to parameters stipulated in working instructions. DOC / CS / MT 1.0 Page 15 of 16 TRAINING EXAMINATION CERTIFICATION

16 Application In accordance with ISO 9712 & SAQA Unit Standard No DOC. REF. SAIW - CERTIFICATION: DOC/CS : MT/S 1.3 : Welds Specific Theory OUTCOME 4 : Report the results 4.7 The relevant results are reported in accordance with the written instruction. 4.8 The language and terminology used is appropriate to the method and can be interpreted by the recipient. 4.9 The format is in accordance with the written instruction. DOC / CS / MT 1.0 Page 16 of 16 TRAINING EXAMINATION CERTIFICATION

SOUTHERN AFRICAN INSTITUTE OF WELDING. Non Destructive Testing (NDT) Course Syllabus & Programme

SOUTHERN AFRICAN INSTITUTE OF WELDING Non Destructive Testing (NDT) Course Syllabus & Programme Certification Body Please refer to our Website (www.saiw.co.za) for any information relating to the Training,