IOSH 15 Mintues Presentation( Train The Trainer).pptx

Train the trainer

1. Introduction For The Trainer ENGR. AZHAR ABBAS KHAN ASNT NDT LEVEL III CONSULTANT& API, Welding Specialist. ZAMIL INSPECTION & CONT KSA ASNT Level – III UT,RT,PT,MT,VT, ECT USA API 510, API 570, CSWIP 3.1, Lead Auditor QMS 9001 &2015 USA LEEA Foundation Certified UK. IADC WELL SHARP Supervisor certified USA NCCER Certified Trainer USA 17 years Experience in oil & Gas Sector.

2. Health and Safety precautions when using NDT Techniques NDT methods like radiography, ultrasonic testing, magnetic particle testing, and others has risks if not handled properly. Here are some key points Radiation Safety (for Radiography) : You should Ensure all personnel wear proper radiation detection badges. Must Follow established zones to minimize exposure. Should used Shield equipment and personnel from radiation. Electrical Safety (for Ultrasonic Testing & Eddy Current Testing) : Must Use properly insulated cables and check for any wear. You should Avoid wet or damp conditions where electrical devices are used. Magnetic Field Safety (for Magnetic Particle Testing) : Must Avoid prolonged exposure to strong magnetic fields. Should Ensure that pacemakers or other sensitive medical devices are kept away from the testing area. Chemical Safety (for Dye Penetrant Testing) : Must Use of personal protective equipment (PPE) like gloves and goggles when handling chemicals. You should Ensure for proper ventilation when using volatile penetrants. General Safety Precautions : You must Conduct a risk assessment prior to beginning any NDT procedure. You should Ensure all personnel are trained in the specific NDT method used. By Keep all testing equipment properly maintained and calibrated. https://www.youtube.com/watch?v=yoo8k9afzzA

3. Learning Objectives Following are the learning Objectives Trainees will be able to know What is NDT? What are the types of NDT methods? Advantages of NDT Uses & Certifications.

4. NDT methods are used to detect flaws, ensure parts integrity , and maintain quality control in various fields such as aerospace, construction, automotive, and manufacturing. OR Non-Destructive Testing (NDT) is a way to check if something is strong, safe, or working properly without breaking or damaging it. Some common NDT techniques include: Ultrasonic Testing (UT) Radiographic Testing (RT) Magnetic Particle Testing (MT) Liquid Penetrant Testing (PT) Eddy Current Testing (ET) What is NDT?

5. General NDT Terms: Flaw/Defect/Discontinuity : A physical condition , such as a crack or void, that can affect the integrity of a material. Indication : A signal or evidence that a flaw may exist in the test material. Calibration : The process of adjusting and standardizing NDT equipment to ensure accurate measurements. Sensitivity : The ability of an NDT method to detect small defects . Resolution : The ability to distinguish between two closely spaced indications. Acceptance Criteria : The limits within which the material or component is deemed acceptable, despite the presence of flaws. False Positive/False Negative : A false positive indicates a defect where none exists, while a false negative misses a defect that is present. Probe : A device used to introduce signals into the material and detect responses (e.g., in ultrasonic testing). Transducer : A device that converts one form of energy into another , commonly used in ultrasonic testing. Reference Standards : Known specimens used for comparison during NDT inspection.

6. Overview for types of NDT methods Some examples of NDT methods are: Ultrasound : Using sound waves to look inside objects/ internal flaws/subsurface flaws X-rays : this method can look inside materials, subsurface flaws. Magnetic particle testing : Checking for cracks using magnets. i.e. dry & wet fluorescent particles. Liquid dye Penetrant Testing : used to see the surface flaws only. Eddy current testing : Used to see the flaws in ferromagnetic Materials only. Mostly used for Testing for Cracks in Airplane Wings. https://www.youtube.com/watch?v=SIu-66GaEf4.

7. The primary benefits include: 1. Preservation of Material Integrity Non-invasive : NDT methods allow for the inspection of materials, components, ensuring that the object remains functional. 2. Cost-Effectiveness Reduced wastage : it minimizes material loss and reduces the cost of scrap or rework. 3. Safety Enhancement Operational safety : Detecting potential defects or flaws in structures (like pipelines, pressure vessels, or aircraft parts) ensures that they are addressed before leading to failure, 4. Wide Range of Applications Versatility : NDT methods can be applied to a variety of materials 5. Real-Time or Quick Results Immediate feedback : Many NDT techniques provide fast results, allowing for real-time decision-making during production or inspection. 8. Comprehensive Evaluation Complete analysis : Many NDT methods can detect surface and subsurface flaws, providing a thorough inspection of the material without disassembly.

8. Here are the limitations of NDT methods: 1. Surface Accessibility Example : Detecting flaws in underground pipes or structures inside thick coatings can be difficult. i.e. visual testing 2. Depth of Detection Example : Flaws deep inside thick metal structures may be missed by surface-based NDT methods. i.e. ECT,PT 3. Operator Skill and Interpretation Example : An inexperienced operator might misinterpret noise in an ultrasonic test as a defect. 4. Material and Geometry Constraints Example : Non-ferromagnetic materials such as aluminum cannot be tested using magnetic particle testing. 5. Size of Defects Example : Microcracks that are not visible on the surface may remain undetected using dye penetrant testing. 6. Cost and Time Example : Performing radiographic testing on large pipelines requires significant preparation, including safety measures for radiation exposure. 7. Health and Safety Risks Example : X-ray and gamma-ray radiography can expose operators to ionizing radiation, requiring special protective measures.

9. NDT professionals need specific qualifications and certifications to ensure they can perform these tests accurately and safely. 1. Basic Education High School Diploma or Equivalent: Most NDT positions require at least a high school diploma . Technical or Vocational Training: While not always required, specialized training in fields like engineering, material science, or physics can be helpful. Associate's or Bachelor's Degree: Degrees in fields like Mechanical Engineering, Materials Science, or NDT-specific programs can enhance employment prospects. 2. NDT Training Programs Formal training in NDT methods is essential. Training is usually based on specific NDT methods and includes both classroom instruction and practical experience. Levels of Training: Level I: Basic understanding, limited to performing specific tests under supervision. Level II: Can independently conduct tests, analyze data, and interpret results. Level III: Advanced understanding, responsible for setting up testing procedures, training others, and managing NDT operations. Qualifications & Certifications

10. 3. Certifications NDT certifications are typically based on international standards and issued by recognized bodies. The most common standards for NDT certification include: ASNT (American Society for Nondestructive Testing) Certification: SNT-TC-1A: Recommended practice for the qualification and certification of NDT personnel. CP-189: ASNT’s standard for the qualification and certification of NDT personnel. ACCP (ASNT Central Certification Program): Certification for NDT professionals at Levels I, II, and III. ISO 9712 Certification: International standard for the qualification and certification of NDT personnel. Issued by accredited certification bodies like TWI (The Welding Institute) or BINDT (British Institute of Nondestructive Testing). NAS 410 (Aerospace): This is the aerospace industry's standard for NDT personnel certification. Required for working in aviation and space industries. PCN (Personnel Certification in Nondestructive Testing): Administered by the British Institute of Nondestructive Testing (BINDT), this program is widely recognized in Europe and beyond .

11. Here are some key reasons why certified NDT technicians are vital: Safety: NDT techniques help identify potential failures in materials and structures. This prevents accidents, injuries, and property damage. Quality Assurance: By detecting defects early on, NDT technicians contribute to the overall quality of products. Cost-Effectiveness: NDT can prevent costly repairs or replacements by identifying issues before they become major problems. Compliance: Many industries have stringent regulations regarding product safety and quality. Certified NDT technicians help organizations comply with these standards. Reliability: NDT techniques provide valuable data that can be used to assess the reliability and performance of materials and structures. Industries that rely on NDT technicians include: Aerospace Automotive Construction Energy Manufacturing Oil and gas Power generation Importance of Certified NDT Technicians.

12. NDT certifications generally have a validity period of five years. This means that after five years from the date of issuance, the certification needs to be renewed to remain valid. The renewal process typically involves: Re-examination: This is usually required for those who haven't been actively involved in NDT activities for a significant period. Point system: This allows individuals to maintain their certification by accumulating points through various NDT-related activities, such as attending conferences, workshops, or completing continuing education courses. The specific renewal requirements can vary depending on the certifying body. Some of the most common certifying bodies include: American Society for Nondestructive Testing (ASNT) British Institute of Non-Destructive Testing (BINDT) European Federation of Nondestructive Testing (EFNDT) Validity of NDT Certification

13. Summary Common NDT Methods: Visual Inspection (VI): The most basic method, using the human eye to detect defects. Magnetic Particle Testing (MT): Detects surface and subsurface discontinuities. Dye Penetrant Testing (PT): Detects surface-breaking discontinuities in materials. Ultrasonic Testing (UT): Uses sound waves to detect internal flaws. Radiographic Testing (RT): Uses X-rays or gamma rays to penetrate materials and flaws Eddy Current Testing (ECT): Detects changes in electrical conductivity. Advantages of NDT: Cost-effective: Prevents costly repairs or replacements. Efficient: Allows for continuous inspection. Safe: Prevents damage to materials or equipment. Accurate: Provides reliable results. Disadvantages of NDT: Limited to specific materials: Not all methods work for all materials. Requires specialized equipment: Can be expensive. Requires trained personnel: Proper interpretation is essential. Certifications: ASNT (American Society for Nondestructive Testing): Offers various certifications, including Level I, II, and III. ISO (International Organization for Standardization): Provides standards for NDT practices. EN (European Norm): Offers European standards for NDT.

14. NDT Methods: Quick Questions and Answers 1. Visual Inspection (VI) What is it? Looking at something with your eyes. When is it used? To find cracks, dents, or on surfaces. Advantages: Simple, cheap, and can be done quickly. Disadvantages: Needs good lighting and can miss small problems. 2. Dye Penetrant Inspection (DPI) What is it? Putting a colored liquid on a surface to find cracks. When is it used? To find tiny cracks in metals. Advantages: Can find very small cracks, and is relatively cheap. Disadvantages: Needs a clean surface and can be messy. 3. Magnetic Particle Inspection (MPI) What is it? Using magnets to find cracks in iron and steel. When is it used? To find cracks in metal parts that can be magnetized. Advantages: Can find cracks that are hard to see with other methods. Disadvantages: Only works on magnetic materials.

15. 4. Ultrasonic Testing (UT) What is it? Sending sound waves through a material to find flaws. When is it used? To find cracks or holes inside metal parts. Advantages: Can find problems deep inside materials Disadvantages: Requires special equipment and training. 5. Radiographic Testing (RT) What is it? Using X-rays or gamma rays to see inside things. When is it used? To find cracks or other problems inside thick metal parts. Advantages: Can see inside thick materials, and can find flaws. Disadvantages: Requires special equipment and training, 6. Eddy Current Testing (ECT) What is it? Using electricity to find problems in metals. When is it used? To find cracks or other problems in metal pipes or wires. Advantages: Can find problems in conductive materials, and can be used on moving parts. Disadvantages: Requires special equipment and training, and may not work on all metals.