2gettingndtrightinmtandpt2015v3 151021083507 Lva1 App6892

ENGINEERING
TRAINING SOLUTIONS
GETTING NDT RIGHT
IN MT AND PT
Phil Raw
BSc (Hons) NDT
imeche.org
CAREER HISTORY
27 years experience in the NDT

industry
Holder of PCN, ASNT & EN 4179 Level
3 certification in multiple methods
also BSc Honours Degree in NDT
Employed by Argyll-Ruane Ltd since
2001 as a Level 3 Consultant, Trainer
and Examiner
Improving the world through engineering
imeche.org
GETTING NDT RIGHT

MAGNETIC PARTICLE AND PENETRANT
TESTING
As a trainer at Argyll-Ruane Ltd it is my job to teach NDT
personnel how to get NDT right
As a consultant I work for my clients as a Responsible Level 3
and then my job entails making sure NDT personnel are getting
NDT right.
Over the years I have witnessed many occasions when NDT has
not been done right and today I will discuss some of these
incidents.
Some of the consequences of these incidents have lead to
individuals being dismissed, or been very expensive to correct.
imeche.org
GETTING NDT RIGHT

TESTING
Why is getting NDT right so important?

The British Institute of NDT states: Non-destructive testing
and inspection are vital functions in achieving the
goals of efficiency and quality at an acceptable cost.
In many cases, these functions are highly critical; painstaking
procedures are adopted to provide the necessary degree of
quality assurance.
The consequences of failure of engineering materials,
components and structures are well known and can be
disastrous.
imeche.org
GETTING NDT RIGHT

MAGNETIC PARTICLE AND PENETRANT TESTING
It is an increasing requirement of quality assurance systems
that a company's technicians are able to demonstrate that they
have the required level of knowledge and skill.
This is particularly so since NDT and inspection activities are
very operator dependent and those in authority have to place
great reliance on the skill, experience, judgement and integrity
of the personnel involved.
Indeed, during fabrication, NDT and inspection provides the last
line of defence before the product enters service, whilst once a
product or structure enters service, in-service NDT is often the
only line of defence against failure.
imeche.org
GETTING NDT RIGHT

MAGNETIC PARTICLE AND PENETRANT TESTING
Basically the job you do is not an ordinary job the job you do
is critical and in many cases lives can depend on you doing
your job correctly.
Not getting NDT right is not an acceptable option, if we get
NDT wrong it can have tragic consequences.
The next few slides show what can happen if NDT has gone
wrong.
imeche.org
GETTING NDT RIGHT

TESTING
On 19th July, 1989, a United
Airlines DC-10-10, experienced a
catastrophic in flight failure of
the No. 2 engine.
This engine failure led to the
discharge of the stage 1 fan disk
assembly parts from the No. 2
engine which led to the loss of
all three hydraulic systems
powering the flight controls.
imeche.org
GETTING NDT RIGHT

TESTING
The crew experienced severe difficulties controlling the
airplane, which subsequently crashed during an attempted
landing at Sioux Gateway Airport.
There were 285 passengers and 11 crewmembers on-board, 1
flight attendant and 110 passengers were fatally injured, 47
suffered serious injuries, 125 suffered minor injuries and only
13 people on board were uninjured.
imeche.org
GETTING NDT RIGHT

TESTING
During its 17 year service life the engines in which the
accident disk was installed were overhauled, disassembled
and inspected using fluorescent penetrant inspection in
1972, 1973, 1976, 1978 1982 and finally in February 1988 17
months before the accident.
The NTSB concluded that the fatigue crack was likely to
have been between 12.0mm to 12.6mm surface length at the
time of the last fluorescent penetrant inspection, the
minimum detectable defect length in the critical disk bore
area is 2.54mm when using fluorescent penetrant inspection
therefore the fatigue crack should have been detected at the
last inspection.
imeche.org
GETTING NDT RIGHT

TESTING
The NTSB reviewed the technique used to inspect the disk
and one possibility for the failure of several inspections
carried out after the fatigue crack had exceeded the
minimum detectable defect size was the fact that the disk
was suspended by a cable through the bore.
To fully apply the penetrant and later the developer and to
fully inspect the bore including the area obscured by the
cable, the operator has to physically rotate the part.
imeche.org
GETTING NDT RIGHT

TESTING
It is possible that the inspectors may not have correctly
processed or viewed the bore area due to the cable, or that
during rotation the cable obliterated the indication or caused
loose developer to fall on to the crack and obscure the
indication.
The NTSB also consider that there is a strong chance the
inspectors were experiencing inattentional blindness. This
type of disk tends to produce indications near dove tail posts
and rarely in the bore, this could cause inspectors to inspect
the bore with less attention.
imeche.org
GETTING NDT RIGHT

TESTING
The NTSB considers the probable cause of the accident was
the inadequate consideration given to human factors
limitations in the inspection and quality control procedures
used by the engine overhaul facility.
Inspectors tend to work independently and have little or no
supervision and hence there is no redundancy to prevent
human error.
This resulted in several unsuccessful inspections which failed
to locate a detectable sized fatigue crack located in a critical
area of the fan disk.
imeche.org
GETTING NDT RIGHT

TESTING
imeche.org
GETTING NDT RIGHT

TESTING
In July 1996, a Delta Airlines flight suffered an uncontained
engine failure during routine take off from Pensacola airport.
The left hand side number 1 engine; a Pratt & Whitney JT8D219 on the McDonnell Douglas MD88 was destroyed during
the incident.
The front compressor front hub (fan hub) suffered a
catastrophic fatigue failure.
Uncontained engine debris penetrated the rear fuselage on
the left hand side and tragically two people were killed, one
person on the other side of the aisle suffered serious injuries
and one passenger sustained serious injuries during the
cabin evacuation.
imeche.org
GETTING NDT RIGHT

TESTING
The NTSB investigation revealed that the failed titanium fan
hub had fractured radially in two places; one of the radial
fractures contained a fatigue crack that originated at two
locations on the inboard side in a tie rod hole, at 7.79mm and
14.04mm from the aft edge of the tie rod hole respectively.
The fatigue fracture extended 38mm radially inboard towards
the centre of the engine, the rest of the fracture surface was
considered to be the catastrophic final overstress failure.
imeche.org
GETTING NDT RIGHT

TESTING
The last inspection that the accident hub received was a
fluorescent penetrant inspection carried out in October
1995 by a Delta airlines level 1 certified penetrant inspector
with 11 months experience.
The FAA inspected the Delta airlines testing facility and
determined that there was no assurance that parts received
by penetrant inspectors were clean enough for an adequate
penetrant test.
The hubs were not pre cleaned prior to penetrant testing by
qualified NDT inspectors; they were cleaned by shop floor
cleaning operatives with no NDT training and who were not
made aware of the criticality of the engine components and
the end purpose for which the components were being
cleaned.
imeche.org
GETTING NDT RIGHT

TESTING
The final cleaning operations involved immersing parts in a
hot water rinse and then flash drying.
For flash drying to work effectively and leave no water
trapped in any discontinuities that would prevent penetrant
entering the discontinuity, the part must reach the
temperature of the water which must be between 65C to
93C.
Cleaning operatives did not measure part temperature and
used only their sense of touch to feel if the part was hot
enough; the water temperature was only checked on a
weekly basis.
imeche.org
GETTING NDT RIGHT

TESTING
The report also looked at human factors as a potential cause
of the crack being missed; these hubs are very large and are
a very complicated shape and can take 40 minutes to two
hours to inspect fully.
Any distraction during this period could cause the inspector
to fail to resume the inspection where he left off, and with
penetrant inspection unless you physically mark an area you
do not know if it has been inspected or not.
imeche.org
GETTING NDT RIGHT

TESTING
Delta inspectors did not mark inspected areas or use a grid
pattern to assist inspection.
The NTSB also considered that there was a low expectation
amongst inspectors of finding a crack; the supervisor stated
that he was not aware that any cracks had ever been found
on this type of hub at Delta.
The conclusion was that in-attentional blindness could have
caused the inspector to overlook or minimise the
significance of an indication.
imeche.org
GETTING NDT RIGHT

TESTING
The NTSB concluded that the probable cause of the
accident was
the failure of the fluorescent penetrant
inspection process to detect a detectable fatigue
crack initiating from an area of altered microstructure
that was created during the drilling process and
lack of sufficient redundancy in the in-service
inspection program.
imeche.org
GETTING NDT RIGHT

TESTING
Next lets have a look at some examples of

how I have seen NDT not done correctly.
imeche.org
GETTING NDT RIGHT

TESTING
Ensure you are correctly certified for the work

you are being asked to do.
Case Study: An aerospace manufacturer supplying to an
engine manufacturer uses an EN 4179 certification
scheme (employer based certification) used NDT
contractors who held EN 4179 certification issued by their
employer. The written practice of the aerospace
manufacturer has not been complied with and the
contractors were not correctly certified to test parts.
imeche.org
GETTING NDT RIGHT

TESTING
The parts they had penetrant tested underwent further

manufacturing operations which meant the parts could
not be re-tested by correctly certified NDT personnel.
The engine manufacturer would not accept the 200k

of parts tested by the contractors and one individual
left the company over the issue.
imeche.org
GETTING NDT RIGHT

TESTING
Ensure your eye sight is tested annually.

Case Study: During a routine audit of an NDT facility
the vision test certificate of one individual had
expired some weeks previously and the operator had
tested many parts that were supplied to an
aerospace facility.
As his vision test was overdue his certification should
have been suspended and he should not have tested
any parts until he had passed an eye test.
imeche.org
GETTING NDT RIGHT

TESTING
When the customer was informed, they sent back all
the parts tested by the inspector from the date his
vision certificate had expired and demanded it was
re-tested at the suppliers expense.
imeche.org
GETTING NDT RIGHT

TESTING
Ensure you understand and comply with NDT

techniques and procedures.
Case Study: A client conducted an audit of a suppliers NDT
facility and watched an operator inspecting some of their
parts. The operator did not follow the approved NDT
technique and therefore did not correctly test the part.
The auditor twice asked the operator at the conclusion of

the inspection if he was happy that he had fully completed
the inspection and the operator said yes.
imeche.org
GETTING NDT RIGHT

TESTING
The client demanded the operators certification was
immediately suspended and that all material he had
tested for them had to be re-inspected. The inspector left
the company over the issue.
imeche.org
GETTING NDT RIGHT

TESTING
Case
Study:
Many
penetrant
testing
process
specifications specify using a solvent wipe technique to
evaluate indications. The process specifications usually
specify wiping once and only once across the indication
with a solvent damped cotton swab and then applying
developer.
On many occasions during NADCAP compliance audits

NDT inspectors have been seen to wipe across indications
more than once thus incurring a non-conformance.
imeche.org
GETTING NDT RIGHT

TESTING
Ensure you carry out shift checks correctly.

Case Study: During an audit of the NDT facility of a
company that produces motorsport racing engines, the
shift check log was reviewed and the result recorded for
UV-A inspection lamp irradiance was exactly the same
figure for every day for six months.
The operator was then asked to demonstrate the test and

the result was approximately half the value of the recorded
figure for the test carried out only an hour earlier.
imeche.org
GETTING NDT RIGHT

TESTING
Further investigation revealed other clear instances
where the operator was not carrying out the shift
checks just writing down numbers in the log sheet.
The operator was dismissed by his employer for
unethical behaviour.
imeche.org
GETTING NDT RIGHT

TESTING
Ensure you understand how to use NDT

equipment.
Case Study: A manufacturing company had numerous
customer complaints of defective material being delivered.
The company blamed the NDT inspectors and called me in
to carry out refresher training.
imeche.org
GETTING NDT RIGHT

TESTING
The inspection area on the shop floor was dimly lit from
high overhead lighting, when this was checked with a
photometer a reading of only 110 lux was observed, the
process specification required a minimum of 1000 lux.
The technician was misreading the photometer by a factor

of 10 and claimed how he was reading it was how he had
been instructed to do so by the previous quality manager.
The technician was then instructed how to use this
equipment correctly.
imeche.org
GETTING NDT RIGHT

TESTING
Once new lighting was installed the frequency of customer
complaints was reduced significantly.
imeche.org
GETTING NDT RIGHT

TESTING
Ensure you never forget NDT method basics.
Case Study 1: A magnetic particle testing technique using

bench equipment was raised by a Level 2 and submitted for
Level 3 approval.
The technique stated testing the part using magnetic flow
followed by a coil shot, this of course is basically testing the
part twice using longitudinal magnetisation and the part
would not be tested for defects in all possible orientations.
Had this technique been used defective parts could have
ended up on an aircraft.
imeche.org
GETTING NDT RIGHT

TESTING
Case Study 2: A Level 2 NDT inspector raised a technique
for magnetic particle testing and submitted it for approval.
Upon review it was noted that the part was made of
titanium! The data card was rejected.
imeche.org
GETTING NDT RIGHT

TESTING
Case Study 3: During an audit a magnetic particle testing
data card for bench equipment was reviewed, it was noted
that the parts tested with this data card were made of
austenitic stainless steel.
The data card had been used to test these parts for over
two years!
Operators were using correct test pieces to carry out shift
checks but were not using flux indicators on the parts under
test.
imeche.org
GETTING NDT RIGHT

TESTING
Case study 4: An audit was carried out on a facility
manufacturing car engine parts that was using an automatic
magnetic particle testing machine.
It was noted that the current flow shot stopped before the
automatic flow of ink stopped and was basically washing
any indications away as demonstrated when a flux indicator
was applied.
No defects had ever been found whilst this equipment had
been in operation.
The timing of ink application was amended and the
inspectors started finding defects for the first time.
imeche.org
GETTING NDT RIGHT

TESTING
Case study 5: During a performance review of an NDT
inspector using fluorescent penetrant it was noted that he
was wearing photochromatic spectacles in the UV-A
inspection area.
He had been using these spectacles for several months.
imeche.org
GETTING NDT RIGHT

TESTING
Keep an eye out for unethical behaviour
Case Study: During an audit of an NDT facility completed

follower cards were reviewed. The NDT penetrant testing
operation had been stamped off with the stamp of an NDT
inspector that had died several months previously.
The investigation found that a non NDT certified member of
staff had obtained the stamp and was using it to speed up
production.
Considerable quantities of parts had been despatched to
customers without any NDT inspection!
imeche.org
GETTING NDT RIGHT

TESTING
During NDT audits dont panic just do your job

normally
Case Study: As an observer during a NADCAP magnetic
particle testing compliance audit, it was observed that a young
inspector was very nervous.
He was testing some small parts in the heads of a bench unit
and made the mistake of handling the parts before he had
inspected them under the UV-A inspection lamp.
The auditor wrote this up as a non-conformance and the
inspector had to have a training session as part of the
corrective actions.
imeche.org
GETTING NDT RIGHT

TESTING
Ensure non NDT individuals do not abuse or use

NDT equipment.
Case Study: During a summer shutdown of a factory, the
factory floor received a shiny new coat of paint, certain
shop floor individuals who afterwards refused to identify
themselves used the fluorescent ink bath of the magnetic
particle testing machine to clean their brushes.
200 litres of fluorescent ink had to be replaced and a full
shift had to be spent cleaning the machine.
imeche.org
GETTING NDT RIGHT

TESTING
Case Study: A large forging was tested with penetrant and
a large crack was found.
A shop floor handyman was assigned to re-work the forging
by grinding with an NDT inspector retesting the ground area
to ensure it was cleared.
After several sessions of grinding and retesting without
clearing the defect the NDT inspector went for a lunch
break. When he returned from lunch the forging was on the
back of a lorry.
The handyman had tested the ground area and decided
the defect was clear.
He had in fact buried the defect under a thick layer of
developer and further grinding was required.
imeche.org
GETTING NDT RIGHT

TESTING
Keep an eye open for the unexpected.

Case Study: During an audit of a fluorescent penetrant
testing facility, a Level 2 inspector was demonstrating how
to carry out a test for fluorescent penetrant contamination
by taking a sample of penetrant in a glass beaker and
viewing this sample.
When I looked into the penetrant tank I saw something on
the tank bottom, the inspector put his hand in and retrieved
a broken tube from a fluorescent strip light.
imeche.org
GETTING NDT RIGHT

TESTING
As these lights have coatings on the inside of the tube the
penetrant had to be discarded, the tank cleaned and
replenished with fresh penetrant.
imeche.org
GETTING NDT RIGHT

TESTING
Ensure you review equipment calibration

certificates.
Case Study: It is fairly common that photometers and
radiometers have to be adjusted by calibration engineers to
bring them within tolerance of the relevant standards.
Review calibration certificates and see if they have an as
received condition which exceeds mandated tolerance
requirements i.e. 5% and then an after adjustment
figure which does comply with required tolerances. If this is
the case a risk assessment is to be carried out.
imeche.org
GETTING NDT RIGHT

TESTING
For example in the as received condition a radiometer has
an accuracy of + 10%, this means that it is reading the UVA output from inspection lamps 10% higher than the actual
lamp output; 1000W/cm as read is actually only
900W/cm.
A risk assessment would require reviewing the shift check
results for UV-A lamp output since the previous radiometer
calibration and find the lowest lamp output reading,
subtract 10% from this figure and if this is still above the
minimum required by the relevant standard there is no
impact on product.
imeche.org
GETTING NDT RIGHT

TESTING
Ensure you use equipment correctly.

Case Study 1: Electromagnetic yokes should be checked
with a test weight to determine if the lifting power of the
yoke is sufficient.
During audits it is common to see NDT inspectors using flux
indicator strips with electromagnetic yokes and neglecting
to use the test weight.
imeche.org
GETTING NDT RIGHT

TESTING
The problem is that if you put a flux indicator on any surface
even non ferromagnetic materials such as a piece of wood or
a slice of bread, spray ink and energise the electromagnet
the magnetic flux between the poles will form an indication
on the flux indicator clearly we cant test a plank of wood!
A flux indicator with an electromagnet can only show flux

direction, which we should know anyway but will not
determine if the flux density is adequate.
imeche.org
GETTING NDT RIGHT

TESTING
Case Study 2: During a performance review an operator
was asked to test a part in a magnetic particle testing
bench.
He set up a current flow shot and placed a flux indicator on
the part but in the wrong direction, when no indication
formed he stated the machine was not working.
He was then embarrassed when instructed to turn the strip
at 90 degrees to the first orientation and three strong
indications suddenly appeared.
imeche.org
GETTING NDT RIGHT

TESTING
Avoid distractions during testing

Case Study: An operator was distracted by an urgent
telephone call halfway through magnetic particle inspection
of a large forging.
When he returned to the job he thought he had completed
the inspection and released it to the next operation.
Another member of staff spotted a crack in the untested half
of the forging some time later.
Marking tested areas on large parts can help stop this type
of mistake.
imeche.org
GETTING NDT RIGHT

TESTING
Dont just look for small discontinuities

Case Study: An aero engine shaft was returned from a
customer that had been in-service in an engine for some
time.
During a routine engine strip down the shaft was tested
using magnetic particle techniques and a crack
approximately 100mm long was found.
Metallurgical analysis determined that this was not an inservice defect it was a manufacturing defect and fortunately
had not propagated during service.
imeche.org
GETTING NDT RIGHT

TESTING
The company that made the shaft concluded that NDT
inspectors seldom found defects on these components and
when they did they were only 2 3mm long maximum.
The crack was running circumferentially and may have
been mistaken for a machining line as the inspectors never
expected a crack that big to be found.
imeche.org
GETTING NDT RIGHT

TESTING
Ensure you are correctly trained to operate NDT

equipment
Case Study: A performance review was carried out on a NDT
inspector who was using a magnetic particle testing bench
unit.
The inspector put a part in the bench sprayed ink on it and
started inspecting it with a UV-A inspection lamp. He had not
pressed the button to energise the current!
When asked why he said he had never been told to press the
button and did not know what it was for.
Worryingly he had been testing work like this for over a
year!
imeche.org
GETTING NDT RIGHT

TESTING
Be aware of human factors in NDT

The reliability of NDT can be significantly influenced by the
environment in which parts are processed and inspected.
Consideration of human factors is an important element in
achieving process capability.
Human factors are typically dependent on a large number of
influences such as fatigue, environment, stress and
complexity of task.
imeche.org
GETTING NDT RIGHT

TESTING
How can these human factors be addressed?
Fatigue rotation of tasks, duration of inspection times
Environment working space, inspection booth

extraction, comfort level
Stress improved working practices, minimise

inspection interruption
Complexity of task appropriate equipment, fixtures

and training
imeche.org
GETTING NDT RIGHT

TESTING
Conclusions
MT and PT are in general easy methods to get right but as we
have seen in this presentation there are many pitfalls we need to
avoid, unfortunately it can be all too easy to get NDT wrong.
We must never be complacent,
We must never cut corners,
We must guard against making mistakes.
We must never forget how important NDT is;

ultimately peoples lives depend on us to get NDT
right.
imeche.org
THANK YOU
For more information please contact:
Phil Raw
p_raw@imeche.org
imeche.org/arl

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ENGINEERING

27 years experience in the NDT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Why is getting NDT right so important?

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Next lets have a look at some examples of

Improving the world through engineering

GETTING NDT RIGHT

Ensure you are correctly certified for the work

Improving the world through engineering

GETTING NDT RIGHT

The parts they had penetrant tested underwent further

The engine manufacturer would not accept the 200k

Improving the world through engineering

GETTING NDT RIGHT

Ensure your eye sight is tested annually.

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

Ensure you understand and comply with NDT

The auditor twice asked the operator at the conclusion of

Improving the world through engineering

GETTING NDT RIGHT

Improving the world through engineering

GETTING NDT RIGHT

On many occasions during NADCAP compliance audits

Improving the world through engineering