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 : PT 1.0 Pre and In - Service PT 1.1 Wrought Products / Forgings Product Sector : PT 1.2 Castings Surface PT 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 : Penetrant Testing Qualification Level : Level 1 Reference Standard : ISO 9712 Industrial Sector : PT 1.0 Pre and In - Service PT 1.1 Wrought Products / Forgings Product Sector : PT 1.2 Castings Surface PT 1.3 Welds Surface Non porous materials Defect detection: Surface SAIW - CERTIFICATION: DOC/CS : PT/G 1.0 : General Applicable documents (Contained within this document) : SAIW - CERTIFICATION: DOC/CS : PT/S 1.1 : Specific - Forgings SAIW - CERTIFICATION: DOC/CS : PT/S 1.2 : Specific - Castings SAIW - CERTIFICATION: DOC/CS : PT/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 inspections on castings, forgings, welds and tubes manufactured from non-porous 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 / PT 1.0 Page 2 of 16 TRAINING EXAMINATION CERTIFICATION

3 INDEX Description Duration PT1 - 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) PT1 - 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) PT1 - 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 / PT 1.0 Page 3 of 16 TRAINING EXAMINATION CERTIFICATION

4 INDEX (Continued) Description Duration PT1 - Sect 4. Physical Principals and associated knowledge 4.1. Liquid phase properties, adhesion and cohesion 4.2. Wetting Ability (expansion of drop), contact angle, surface tension, meniscus 4.3. Capillary action, penetration 4.4. Viscosity, 4.5. Volatility / Evaporation, flash point, 4.6. Development, Bleed out, blotting 4.7. Coloured and fluorescent penetrant 4.8. Mixtures, solutions & suspensions Solvents / solvent action Dispersive agents Emulsification a Lipophilic - Diffusion b Hydrophilic - Detergent PT1 - 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 Surface condition & cleanliness Surface temperature Penetrants a Properties i Corrosive Properties (Halogen, Sulphur, others) ii Colour : Visible, Fluorescent or dual sensitive dyes iii Evaporation, Flash point, Storage stability, Temperature stability iv Sensitivity & checks v Fluorescent brightness, ultraviolet stability vi Tank life, water tolerance, contamination vii Removability / washing ability viii Water / solvent based ix Application: Immersion, spraying, brushing, dipping x Penetrant dwell time : significance of temperature, drainage, contact time b Type I, II, III DOC / CS / PT 1.0 Page 4 of 16 TRAINING EXAMINATION CERTIFICATION

5 c Method A, B, C, D d Sensitivity Level1 ½, 1, 2, 3, 4, 5 : Selection Drying a Drying Requirements b self-drying / evaporation c cold hot air d temperature and time Excess penetrant removal a Properties of removers b Drain time (dipping) c Solvent in liquid form: water, solvent, emulsifiers d Removal process / method and action e Checks and verifications f Over washing / under washing, drying g Class 1, 2, Developer Application a Properties b Dry powders, c Powders in aqueous suspension d liquid carriers, e developers in solution, f powder in non-aqueous liquid carrier g Application, significance of temperature h Form a, b, c, d, e DOC / CS / PT 1.0 Page 5 of 16 TRAINING EXAMINATION CERTIFICATION

6 INDEX (Continued) Description Duration PT1 - Sect 6. Equipment & Consumables 6.1. Pre and post cleaning methods and equipment 6.2. Drying equipment 6.3. Portable aerosol spray cans 6.4. Dip / immersion installation 6.5. Brushing 6.6. Light sources Ultraviolet, White 6.7. Measuring units Light intensity Surface temperature 6.8. Reference blocks Chromium plated Al test blocks, Sherwin panels, TAM Panels 6.9. Viewing conditions Non Fluorescent inks and powders Fluorescent inks and powders Safety Electromagnetic spectrum Light : Ultraviolet, Visible, Ambient, Extraneous DOC / CS / PT 1.0 Page 6 of 16 TRAINING EXAMINATION CERTIFICATION

7 INDEX (Continued) Description Duration PT1 - Sect 7. Information prior to test 7.1. Penetrant Testing Practices Fundamentals Choice of equipment / process Effects of test object variables 7.2. Inspection techniques 7.3. Written Instruction 7.4. Report Sheet PT1 - Sect 8. Testing according to Written instruction 8.1. Surface preparation Surface preparation / pre cleaning Cleaning methods Effect of surface finish Effect of contaminants Compatibility of materials 8.2. Penetrant application 8.3. Excess penetrant removal 8.4. Application of developer 8.5. Verification of surface temperature and viewing condition 8.6. Interpretation and recording of results 8.7. Treatment of components after test Post cleaning Corrosion protection DOC / CS / PT 1.0 Page 7 of 16 TRAINING EXAMINATION CERTIFICATION

8 INDEX (Continued) Description Duration PT1 - Sect 9. Interpretation and reporting Evaluation (Level 2 only) 9.1. Welding : ISO Casting : EN Forging : BS EN Rolled / wrought products 9.5. Viewing condition ISO Reference block No 2 ISO Verification of indication quality 9.8. Report of simple welding, forging, casting and rolled product indications 9.9. Discontinuities : Types, identification & parameters 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 PT1 - Sect 10. Assessment Depth, width, shape, position, orientation PT1 - Sect 11. Quality aspects Personnel Qualification & Certification Equipment verification Functionality checks a Chromium plated Al test blocks, Sherwin panels, TAM Panels b Defective components c Comparator checks, Efficiency of removers, Fluorescence d Coverage and developer concentration checks Operational calibration a Surface temperature, Light Intensity b Water temperature, droplet size and nozzle pressure Maintenance checks a Electrical current measurement and supply to ovens / dryers b UV / White light DOC / CS / PT 1.0 Page 8 of 16 TRAINING EXAMINATION CERTIFICATION

9 DOC / CS / PT 1.0 Page 9 of 16 TRAINING EXAMINATION CERTIFICATION

10 INDEX (Continued) Description Duration PT1 - Sect 12. Environmental and safety conditions Electrical risks hazards Magnetic field risks Risks related to consumables Risks related to UV radiation Disposal of chemical and environmental conditions Penetrants Developer Emulsifier Material of process excess removal Safety data sheets PT1 - Sect 13. Developments N / A PT1 - 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 / PT 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 : PT/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) PRACTICAL : Product Sector OUTCOME 1 : OUTCOME 2 : Setup penetrant testing equipment 1.1 The principles of dye penetrant 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 Dye penetrant testing equipment for specific applications is set-up and calibrated in accordance with written instructions. Range: UV meters 1.5 Equipment checks and equipment performance are verified in accordance with written instructions. Perform penetrant testing 2.1 The testing technique is implemented in accordance with the applicable work instruction. Range: Penetrant application, Dwell time, Excess penetrant removal, Developer application 2.2 The equipment is used in accordance with the work instructions. 2.3 The equipment, accessories and consumable s 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 UV light meters 2.5 Inspection progress and scope of coverage is monitored and documented in accordance with written instructions. DOC / CS / PT 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 : PT/S 1.1 : Castings Specific Theory PRACTICAL : Product Sector OUTCOME 3 : OUTCOME 4 : 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. 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 / PT 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 : PT/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) PRACTICAL : Product Sector OUTCOME 1 : OUTCOME 2 : Setup penetrant testing equipment 1.6 The principles of dye penetrant 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 Dye penetrant testing equipment for specific applications is set-up and calibrated in accordance with written instructions. Range: UV meters 1.10 Equipment checks and equipment performance are verified in accordance with written instructions. Perform penetrant testing 2.2 The testing technique is implemented in accordance with the applicable work instruction. Range: Penetrant application, Dwell time, Excess penetrant removal, Developer application 2.2 The equipment is used in accordance with the work instructions. 2.3 The equipment, accessories and consumables 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 UV light meters 2.5 Inspection progress and scope of coverage is monitored and documented in accordance with written instructions. DOC / CS / PT 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 : PT/S 1.2 : Forgings / Wrought Products Specific Theory PRACTICAL : Product Sector OUTCOME 3 : OUTCOME 4 : 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. 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 / PT 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 : PT/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) PRACTICAL : Product Sector OUTCOME 1 : OUTCOME 2 : Setup penetrant testing equipment 1.11 The principles of dye penetrant 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 Dye penetrant testing equipment for specific applications is set-up and calibrated in accordance with written instructions. Range: UV meters 1.15 Equipment checks and equipment performance are verified in accordance with written instructions. Perform penetrant testing 2.3 The testing technique is implemented in accordance with the applicable work instruction. Range: Penetrant application, Dwell time, Excess penetrant removal, Developer application 2.2 The equipment is used in accordance with the work instructions. 2.3 The equipment, accessories and consumable s 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 UV light meters 2.5 Inspection progress and scope of coverage is monitored and documented in accordance with written instructions. DOC / CS / PT 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 : PT/S 1.3 : Welds Specific Theory PRACTICAL : Product Sector OUTCOME 3 : OUTCOME 4 : 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. 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 / PT 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,