Certification Services Division 1 Spencer Parade, Northampton NN1 5AA, United Kingdom Tel: +44(0)1604-259-056. Fax: +44(0)1604-231-489.

E-mail: pcn@bindt.org

PCN/GEN APPENDIX G2.1 ISSUE 2 SPECIFIC REQUIREMENTS COVERING THE CERTIFICATION OF NDT PERSONNEL FOR LIQUID PENETRANT TESTING OF FERRITIC STEEL TUBES AND PIPES
ASSOCIATED DOCUMENTS: Appendix G2.2 to PCN/GEN Examination Syllabus for the certification of Personnel in Liquid Penetrant Testing of Ferritic Steel Tubes and Pipes. Appendix G2.3 to PCN/GEN Specimen Examination Questions for the Certification of Personnel engaged in Liquid Penetrant Testing of Ferritic Steel Tubes and Pipes.

CONTENTS:

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1. SCOPE .............................................................................................................................................2 2. EXAMINATION CONTENT...............................................................................................................2 3. CERTIFICATION ..............................................................................................................................3 4. RENEWAL AND RE-CERTIFICATION .............................................................................................3 5. SUPPLEMENTARY EXAMINATIONS ..............................................................................................4 6. GRADING.........................................................................................................................................4

REFERENCES ISO/IEC 17024 : 2003 General requirements for bodies operating certification systems of persons EN 473 : 2000 General principles for qualification and certification of NDT personnel. ISO 11484 : 1994 Steel tubes for pressure purposes - qualification and certification of non-destructive testing (NDT) personnel.

The British Institute of Non-Destructive Testing is an accredited certification body offering personnel and quality management systems assessment and certification against criteria set out in international and European standards through the PCN Certification Scheme.

1. SCOPE This document prescribes the specific requirements and procedures by which personnel may be examined and, if successful, certificated for the Liquid Penetrant Testing of Tubes and Pipes. Requirements contained in this document are supplementary to those contained in the current edition of PCN General Requirements for Certification of Personnel engaged in Non-Destructive Testing. Further information concerning the PCN Scheme is available from the Certification Services Division, BINDT, 1 Spencer Parade, Northampton NN1 5AA, United Kingdom. Tel: +44 (0)1604 259056. Fax: +44 (0)1604 231489. Email: pcn@bindt.org 2. EXAMINATION CONTENT The examination format is described in PCN General Requirements. This Appendix amplifies the provisions of that document only where necessary. 2.1 Level 1 Except where exemptions apply (refer to PCN General Requirements), all candidates will be required to attempt an examination comprised of the following parts: 2.1.1 General theory of the Liquid Penetrant NDT method. Thirty multiple choice questions to be answered in 45 minutes. Minimum pass mark 70%. 2.1.2 Sector Specific Theory of the application of the Liquid Penetrant NDT method to Ferritic Steel tubes and pipes. Twenty multiple choice questions, including questions covering application and written procedures. The time allowed is 30 minutes and the minimum pass mark is 70%. 2.1.3 Sector Specific Practical examination comprising: i) ii) iii) preparation of testing systems for use (this may involve system sensitivity and control checks). testing two tube/pipe samples (selected by the authorised PCN examiner) appropriate to the candidates work in accordance with NDT instructions provided. reporting test results in a prescribed manner on proforma report sheets.

The total time allowed for the sector specific practical examination is two hours, and the minimum pass mark is 70% (failure to detect and report a reportable discontinuity in any one sample will result in failure of this examination part). 2.2 Level 2 Except where exemptions apply (refer to PCN General Requirements), all candidates will be required to attempt an examination comprised of the following parts: 2.2.1 General Theory of the Liquid Penetrant NDT method. Thirty multiple choice questions to be answered in 45 minutes. The minimum pass mark is 70%. 2.2.2 Sector Specific Theory of the application of the Liquid Penetrant NDT method to the testing of tubes and pipes. A total of thirty multiple choice questions, including twenty questions covering application and written procedures, and ten questions on product technology, codes standards and specifications. The time allowed is 45 minutes and the minimum pass mark is 70%. 2.2.3 Sector Specific Practical examination comprising: i) ii) preparation of testing systems for use (this may involve system sensitivity and control checks). testing 2 samples (selected by the authorised PCN examiner from specimens appropriate to the candidates work), in accordance with NDT procedures or instructions (one to be provided by the examiner and one to be generated by the candidate see (iv) below) which will give, where appropriate, sensitivity levels and reporting thresholds. reporting the results on the forms provided. Each test report must indicate the location type and size of any flaws detected.

iii)

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iv)

preparation of a detailed NDT instruction (suitable for level 1 personnel to follow) for the testing of one of the above samples to a provided procedure, code, standard or specification, and proving the instruction by application.

The total time allowed for the sector specific practical examination is three hours. The minimum pass mark for the practical part is 70% per sample tested, 70% for the NDT instruction (failure to detect and report a reportable discontinuity in any one sample, or failure to produce an acceptable NDT instruction, will result in failure of this examination part) and 70% overall. 2.3 Level 3 Except where exemptions apply (refer to PCN General Requirements), all candidates will be required to attempt an examination comprised of the following parts: 2.3.1 A Basic Examination (information on the time allowed and pass mark is given in the current edition of PCN General Requirements), comprising: A1) A2) Thirty multiple choice questions covering materials technology and science, including typical defects in a range of products including castings, welds and wrought products. Ten multiple choice questions on the content of the current edition of PCN General Requirements for Certification of Personnel engaged in the application of nondestructive testing (a copy of which will be provided for use in the examination). Sixty level 2 multiple choice questions on the general theory of four NDT methods. The examination will include fifteen questions on the NDT method in which the candidate is presently seeking certification, and a further fifteen on each of three other methods selected by the candidate (N.B. at least one of the four methods examined must be a volumetric method).

B)

2.3.2 A Main Method examination comprising: C1) C2) C3) Thirty multiple choice questions covering the general theory of the Liquid Penetrant Testing NDT method. Twenty multiple choice questions covering the specific theory of Liquid Penetrant Testing applicable in the tubes and pipes sector. The candidate will be required to produce a comprehensive test procedure embodying an NDT instruction for a specific tube or pipe product, to a provided specification, standard or code.

2.3.3 Level 3 candidates who do not hold or have not held PCN level 2 certification for the Liquid Penetrant Testing of tubes and pipes are required to successfully complete the examination described in Clause 2.2.3. 2.3.4 The time allowed for the various Level 3 examination parts is detailed in PCN/GEN clause 7.4. 2.3.5 The grading of the level 3 examination shall be in accordance with PCN/GEN clause 10. 3. CERTIFICATION A PCN certificate of competence will be issued to the successful candidate and the employer must validate the certificate by signature in order to authorise the named certificate holder to carry out the testing covered by the scope of the certificate. These requirements address the certification criteria contained in ISO 11484 and EN 473 and cover the following certification: Level 1 Liquid Penetrant testing of tubes and pipes Level 2 Liquid Penetrant testing of tubes and pipes Level 3 Liquid Penetrant testing of tubes and pipes 4. RENEWAL AND RE-CERTIFICATION 4.1 The general rules for level 1 and level 2 renewal and recertification are fully described in PCN document CP16.

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4.2 Level 1 certificate holders seeking recertification will be required to undertake the practical examination detailed at Clause 2.1.3 above. The minimum pass mark for recertification is 80%. 4.3 Level 2 certificate holders seeking recertification will be required to undertake the practical examination detailed at Clause 2.2.3 above. The minimum pass mark for recertification is 80%. 4.4 The general rules for Level 3 renewal and recertification are fully described in PCN document CP17. 5. GRADING The method for composite grading of initial examinations, and the grading of supplementary and recertification examinations will be as specified in the current edition of PCN General Requirements.

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Certification Services Division 1 Spencer Parade, Northampton NN1 5AA, United Kingdom Tel: +44(0)1604-259-056. Fax: +44(0)1604-231-489. E-mail: pcn@bindt.org

PCN/GEN APPENDIX G2.2 ISSUE 1

EXAMINATION SYLLABUS FOR THE CERTIFICATION OF PERSONNEL IN LIQUID PENETRANT TESTING OF TUBES AND PIPES

ASSOCIATED DOCUMENTS: Appendix G2.1 to PCN/GEN Specific Requirements for the Certification of Personnel in Liquid Penetrant Testing of Tubes and Pipes. Appendix G2.3 to PCN/GEN Specimen Examination Questions for the Certification of Personnel in Liquid Penetrant Testing of Tubes and Pipes.

CONTENTS

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1. LEVEL 1 SYLLABUS -- GENERAL................................................................................................... 2 3. LEVEL 2 SYLLABUS -- GENERAL................................................................................................... 3 4. LEVEL 2 SYLLABUS -- SPECIFIC ................................................................................................... 3 5. LEVEL 2 SYLLABUS -- PRODUCT TECHNOLOGY ........................................................................ 3 6. LEVEL 3 SYLLABUS ........................................................................................................................ 3 7. REFERENCE LITERATURE ............................................................................................................ 4

The British Institute of Non-Destructive Testing is an accredited certification body offering personnel and quality management systems assessment and certification against criteria set out in international and European standards through the PCN Certification Scheme.

1. LEVEL 1 SYLLABUS -- GENERAL 1.1 Principles of Penetrant Inspection 1.1.1 Basic principles of liquid penetrant testing: surface tension, viscosity, volatility, capillary action and their relevance to penetrating fluids. 1.1.2 Properties and requirements of emulsifiers, spirit remover and of a developer. Terminology associated with penetrant flaw detection. 1.2 Equipment and Materials 1.2.1 Penetrant: colour contrast, fluorescent, combined colour contrast and fluorescent. 1.2.2 Penetrant removers: solvents in liquid form, water only, water soluble, oil soluble emulsifiers. 1.2.3 Developers: dry powders, aqueous suspensions, aqueous solutions, non-aqueous developers. 1.2.4 Fixed installations, portable inspection kits and auxiliary equipment. 1.3 Methods of Assessing Sensitivity and Control Testing Chromium plated and aluminium test blocks, defective components. Colour, fluorescent intensity and comparator checks of penetrants. Efficiency of penetrant removers. Fluorescence, coverage and concentration checks on developers. 2. LEVEL 1 SYLLABUS -- SPECIFIC 2.1 Preparation for Testing Surface preparation, cleaning methods, effect of surface finish and contaminants. Compatibility of materials. 2.2 Testing Technique 2.2.1 Selection of appropriate technique. 2.2.2 Method of application of penetrant, significance of temperature, drainage and self-drying, removal of excess penetrant, contact time. 2.2.3 Penetrant removal: liquid solvents, aqueous washes, post emulsifiers, contact times. 2.2.4 Drying of components. Application of developers; dry powders, liquid developers (aqueous and non-aqueous). 2.2.5 Viewing conditions: white light and UV(A) radiation and their assessment. 2.2.6 Types of discontinuity and their identification, false indications and their cause. 2.2.7 Preservation of indications: transparent tape transfer and other coating transfers, photographic (fluorescent and colour contrast). 2.3 Post Test Procedures Cleaning 2.4 Safety Precautions Fire hazards, electrical safety, ventilation, toxic materials and safe use of UV(A) radiation. 2.5 Standards, codes and specifications British Standards European and international standards Codes & Specifications (Industry Standards) Works practices (non-destructive testing of steel tube) BS571-1; BS EN ISO 3452 Parts 2 and 3; BS 4489; BS 3683 Part 1.

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3. LEVEL 2 SYLLABUS -- GENERAL The level 2 candidate will be examined on the syllabus for level 1 but the examination questions will be more complex. 4. LEVEL 2 SYLLABUS -- SPECIFIC As level 1, but in addition: 4.1 Testing Procedures Selection of the Penetrant and Developer for optimum sensitivity with due regard to inspection criteria, surface condition and ambient light levels. 4.2 Detectability of Defects Advantages and limitations of the test method with regard to defect detection. 4.3 Interpretation and Reporting Types of discontinuity and their identification. False indications and their cause. Preservation of indications: Lacquer developers, photographic (fluorescent and colour contrast). 4.4 Post Test Procedures Post test cleaning and the need for restoration of preservation coatings. 5. LEVEL 2 SYLLABUS -- PRODUCT TECHNOLOGY Basic production: crude and finished products. Forming processes; Stress relieving. Defect formation. 6. LEVEL 3 SYLLABUS Level 3 personnel are expected to be competent to assume the responsibilities of management of an industrial NDT facility. The PCN level 3 examination will therefore evaluate the candidate's knowledge of the following: Allocation of staff with appropriate certification according to customer's requirements. Supervision and maintenance of subordinate's certification and recertification documents and records. Compilation of records of equipment performance, repairs and maintenance; the work done and results achieved by supervised staff. The review of reports of work done by subordinates, its periodic validation, and the endorsement of routine reports. Review of current practices, equipment, techniques and instructions. Maintenance of standards and text book libraries. Safe working practices and current legislation. The examination syllabus is as follows: 6.1 General Theory Candidates will be required to be familiar with all the content of the general theory syllabus for level 2 but the examination questions will be more complex. 6.2 General Theory of NDT Methods at Level 2 General theory, including limitations to application, of four NDT methods. The examination syllabi are detailed in appendices to PCN General Requirements obtainable from www.bindt.org In detail, the level 3 candidate will be required to demonstrate a knowledge of the level 2 general theory syllabus covering the NDT method in which level 3 certification is sought and, in addition, three others selected by the candidate from RT, UT, MT, ET and VT.

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6.3 Knowledge of PCN Requirements A thorough understanding of the PCN criteria for certification of all levels of personnel as applied in the current edition of PCN general requirements for Certification of NDT Personnel. 6.4 Sector Specific Theory Candidates will be required to be familiar with all the content of the specific theory syllabus for level 2 but the examination questions will be more complex. The level 3 candidate will also be expected to demonstrate familiarity with the criteria in codes and standards covering the application of Liquid Penetrant Testing. 6.5 Materials Technology Theory This examination part will cover the syllabus given earlier for level 2 Product Technology, but the level 3 questions will require a greater understanding of the manufacturing processes and associated defects. 6.6 Sector Specific Practical Level 2 For level 3 candidates not holding or having held a PCN level 2 Liquid Penetrant Testing certificate, the level 2 sector specific practical examination must be passed. Refer to PCN/GEN Appendix G2.1. 6.7 NDT Instruction Writing For level 3 candidates not holding or having held a PCN level 2 Liquid Penetrant Testing certificate, the level 2 sector specific practical instruction writing examination must be passed. 6.8 NDT Procedure Writing The candidate will be required to produce a comprehensive test procedure, for a specific component to a provided standard. PCN publishes a document, CP25, for information and for use by candidates in this open book examination. The procedure must include acceptance levels to specified application standards, Liquid Penetrant Testing operator approvals, techniques, equipment and its calibration, reference documentation, the use of complementary NDT methods, the timing of inspection in relation to fabrication and testing procedures, surface condition of work, special contractual requirements, action to be taken in case of non-compliance and reporting instructions (implementation of the procedure). 7. REFERENCE LITERATURE Essential Reading For level 2 candidates, Product Technology Classroom Training Handbook. Obtainable from the Certification Services Division, The British Institute of Non-Destructive Testing, 1 Spencer Parade, Northampton NN1 5AA. Training Course Notes. PCN requires candidates to have attended an approved course of training. Training Establishments are required to provide trainees with an up-to-date set of training course notes. These are considered essential reading.

PCN/GEN Appendix G2.2

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Certification Services Division 1 Spencer Parade, Northampton NN1 5AA, United Kingdom Tel: +44(0)1604-259-056. Fax: +44(0)1604-231-489. E-mail: pcn@bindt.org

PCN/GEN APPENDIX G2.3 ISSUE 1

SPECIMEN EXAMINATION QUESTIONS FOR THE CERTIFICATION OF PERSONNEL IN LIQUID PENETRANT TESTING OF TUBES AND PIPES

ASSOCIATED DOCUMENTS: Appendix G2.1 to PCN/GEN Specific Requirements for the Certification of Personnel in Liquid Penetrant Testing of Tubes and Pipes. Appendix G2.2 to PCN/GEN Examination Syllabus for the Certification of Personnel in Liquid Penetrant Testing of Tubes and Pipes.

CONTENTS PAGE LEVEL 1 ............................................................................................................................................... 2 LEVEL 2 ............................................................................................................................................... 3 LEVEL 3 ............................................................................................................................................... 4

The British Institute of Non-Destructive Testing is an accredited certification body offering personnel and quality management systems assessment and certification against criteria set out in international and European standards through the PCN Certification Scheme.

LEVEL 1 The level 1 written examination is in two compulsory parts: General Theory and Sector Specific Theory. Except where exemptions apply (refer to PCN/GEN), all parts must be attempted. Level 1 General Theory of the Liquid Penetrant Method 1. a) b) c) d) 2. a) b) c) d) 3. a) b) c) d) 4. a) b) c) d) 5. a) b) c) d) A metal to be tested using the liquid penetrant flaw detection method: must be defective must be porous must be ferromagnetic can be any type Fluorescent penetrant indications should be inspected under: fluorescent light any light black light neon light Which of the following would assist the penetrant to enter sub-surface cracks in a component? the materials surface finish the penetrant viscosity the inherent surface tension none of the above The term used to define the period of time that a developer has been applied is: attraction time development time dwell time drain time Visible penetrant may be applied by: brushing spraying dipping all of the above

Level 1 Sector Specific Theory of the Application of the Liquid Penetrant Method 1. a) b) c) d) 2. a) b) c) d) Consumables of a toxic nature may: not be used at any time be used on site work only be used in accordance with the manufacturer's instructions be used in small amounts All surfaces to be examined using penetrant flaw detection should be initially: bead blasted painted clean sandblasted

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3. a) b) c) d)

The only discontinuities which penetrant testing can detect are: sub-surface surface breaking internal contaminant filled

LEVEL 2 The level 2 written examination is in two compulsory parts: General Theory and Sector Specific Theory. Except where exemptions apply (refer to PCN/GEN), all parts must be attempted. Level 2 General Theory of the Liquid Penetrant Method 1. a) b) c) d) 2. a) b) c) d) 3. a) b) c) d) The property of a liquid which affects the speed of flow is: surface tension viscosity contact angle a combination of all the above The corrosivity of a liquid penetrant is usually assessed by: actual component testing the manufacturer of the penetrant samples of material left in contact for 24 hours and examined samples of material left in contact for 16 hours and examined If fluorescent penetrant is applied after an acid pre-cleaning treatment: the penetrant should dwell for twice the time specified marking of the test piece may be evident a decrease in brilliance of the penetrant may occur an increase in brilliance of the penetrant may occur

Level 2 Sector Specific Theory of the Application of the Liquid Penetrant Method 1. a) b) c) d) 2. a) b) c) d) The British Standard to be referred to for penetrant flaw detection is: BS 6072 BS 4069 BS 4489 BS EN 571-1 To avoid the risk of fire, penetrants in cans should: be stored away from direct sunlight not be sprayed near or onto hot components kept away from incandescent surfaces be handled so as to avoid all of the above situations

3. Poor forging temperature or too great a reduction in section can give rise to rupturing of the material, this is called a: a) b) c) d) lap seam burst inclusion

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LEVEL 3 General Theory of the Liquid Penetrant Method 1. Colour contrast penetrants are best viewed in: a) a minimum of 500 lux white light b) a minimum of 800 lux white light c) a minimum of 10 lux white light d) a minimum 800 microwatts per square centimetre white light 2. If fluorescent penetrant is applied after an acid pre-cleaning treatment: a) the penetrant should dwell for twice the time specified b) marking of the test piece may be evident c) a decrease in brilliance of the penetrant may occur d) an increase in brilliance of the penetrant may occur 3. When using a post emulsifier penetrant, the emulsifier time should be: a) as long as the penetrant dwell time b) one half of the penetrant dwell time c) the same as the developer time d) minimised whilst ensuring all excess penetrant has been removed

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General Theory of NDT Methods at Level 2 The examination will test the candidate's understanding of the general theory at level 2 of four out of the radiographic, ultrasonic, eddy current, visual testing, magnetic particle and liquid penetrant NDT methods to enable him/her to recognise correct application but not necessarily to specify techniques. 1. Thin sheets of lead foil in intimate contact with radiographic film increase film density because they: a) fluoresce and emit visible light which helps expose the film b) absorb the scattered radiation c) prevent backscattered radiation from fogging the film d) emit electrons which helps darken the film 2. The fact that gases, when bombarded with radiation, ionise and become electrically conducting make them useful in: a) X-ray transformers b) X-ray tubes c) masks d) monitoring equipment 3. The most effective method of demagnetisation is: a) AC aperture coil b) reversing and decreasing DC c) stroking with AC yokes d) hammering along the length of the part 4. For fine, surface breaking cracks the best magnetic particle inspection medium is: a) dry powder, black b) dry powder, fluorescent c) magnetic ink, black d) magnetic ink, fluorescent 5. Water washable penetrants require longer dwell times than solvent removable versions because of the presence of: a) emulsifier b) stabiliser c) penetrant remover d) contaminants 6. The property of a liquid which affects the speed of flow is: a) surface tension b) viscosity c) contact angle d) a combination of all the above 7. In eddy current test systems where encircling coils are used, coupling efficiency is referred to as: a) lift off b) edge factor c) fill factor

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d) phase differentiation

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8. When the voltage applied to a circuit and the current through the circuit both reach their maximums at the same time the voltage and current are: a) additive b) in phase c) regenerate d) out of phase 9. The angle at which the shear component of an incident beam is refracted at 90 degrees to the normal is called the: a) normal angle of incidence b) first critical angle c) angle of maximum reflection d) second critical angle 10. As frequency increases in ultrasonic testing the angle of beam divergence of a given diameter crystal: a) decreases b) remains constant c) increases d) varies uniformly through each wavelength Knowledge of Requirements for PCN Certification 1. The minimum period of experience required to be eligible for the level 1 Liquid Penetrant examination is: a) 3 months b) 2 months c) 1 month d) 6 months 2. PCN candidates shall have near distance acuity, corrected or uncorrected, in at least one eye, such that the candidate is capable of reading: a) Jaeger number 1 letters at not less than 30 cm b) Jaeger number 1 letters at not more than 30 cm c) Jaeger number 1 letters at 300 cm d) Jaeger number 2 letters at 30 cm Sector Specific Theory of the Application of the Liquid Penetrant Method to General Engineering Products 1. The corrosivity of a liquid penetrant is usually assessed by: a) actual component testing b) the manufacturer c) the penetrant is left in contact with a test piece for 24 hours, followed by examination d) the penetrant is left in contact with a test piece for 16 hours, followed by examination

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2. To reduce the corrosive effect of a penetrant, which chemical group should be maintained at a low level? a) aqueous b) halogens c) thixotropics d) volatiles 3. Which of the following flaws is most likely to be missed due to improper rinse techniques? a) forging lap b) deep pitting c) shallow and broad flaws d) the rinse techniques will not affect the detection of flaws Materials Technology Theory 1. A common cause of solidification cracking in welds made with high deposition rate processes is: a) hydrogen entrapment b) contaminated flux or shielding gas c) weld preparation has an unsatisfactory depth to width ratio d) operator error 2. A casting discontinuity which is caused by gas release or the evaporation of moisture during solidification is: a) microshrinkage b) porosity c) porous segregation d) hydrogen induced porosity 3. The heat treatment process which is employed to give a soft ductile product, by recrystallisation of the material, is termed: a) tempering b) hardening c) stress relieving d) annealing 4. Poor through thickness ductility in rolled plate, often associated with non-metallic inclusions, gives rise to: a) lamellar tearing b) reheat cracking c) uniform porosity d) hydrogen cracking 5. The welding process which would be chosen for its rapid deposition rates, high welding speeds and deep penetration quality joints is: a) electroslag b) manual metal arc c) submerged arc d) TIG

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6. Hydrogen cracking, due to the break down of water molecules creating hydrogen which dissolves in the weld metal and HAZ, is most likely to occur in which of the following welding processes? a) TIG b) MIG c) sub-arc d) MMA

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