National Centre for Non Destructive Testing

(NCNDT)
of
Sri Lanka Atomic Energy Authorty

Quality Manual
in fulfillment of the requirements of
ISO/IEC17020:1998
Version 1
Date: December 2012
Table of Contents
1.0. General
1.1. History and background
1.2. Purpose of the manual
1.3. Quality policy
1.4. Revision status
1.5. Activites and scope
1.6. Distribution of Quality Manual

2.0. Definitions and abbreviations

2.1. Definitions and terminology
2.2. Abbreviations

3.0. Administrative requirements

3.1. Legal status
3.2. Organization chart
3.3. Functions and responsbilities of persons
3.4. Terms and conditions for work

4.0. Independence, impartiality and integrity

4.1. Independence of personnel
4.2. Type of organization
4.3. Confidentiality

5.0 Organization and management

5.1. Quality system
5.2. Document control
5.3. Review of requests, tenders and contracts
5.4. Subcontracting
5.5. Service to the client
5.6. Complaints
5.7. Control of non-conforming work
5.8. Corrective actions
5.9. Preventive actions
5.10. Control of quality records
5.11. Internal audits
5.12. Management review

6.0. Personnel
6.1 Recruitment of personnel
6.2. On-the-job- training of personnel
6.3. Formal training and certification of personnel
6.4. Technical Manager and Quality Assurance Manager (appointment, responsibilities or job
description)
6.4. Code of conduct for personnel
6.5. Personnel records
6.6. Salaries and other benefits for personnel

7.0. Facilities and equipment

7.1. Essential equipment for PT, MT, UT, RT, ET and VT
7.2. Purchase of equipment
7.3. Identification of equipment
7.4. Calibration of equipment
7.5. Storage and maintenance of equipment
7.6. Issue, transportation and receipt of equipment
7.7. Computerized equipment
7.8. Out of order equipment
7.9. Labelling of eqipment
7.10. Miscellaneous facilities

8.0. Inspection methods and procedures

8.1. General test procedures for PT, MT, UT, RT, ET and VT
8.2. Specific test procedures
8.3. Non-standard test procedures
8.4. Updating and circulation of procedures
8.5. Procedures for work order control
8.6. Safety procedures
8.7. Others???????????????

9.0. Handling inspection samples and items

9.1. Identification of items
9.2. Initial assessment of suitability of items for inspection
9.3. Handling and storage of the items

10.0. Inspection reports and inspection certificates

10.1. Preparation of inspection reports
10.2. Authorization for signing of reports and certificates
10.3. Corrections into the reports and certificates
10.4. Preservaton of reports and certificates

11.0 Records
11.1. Identification of essential records
11.2. Care and security of records

12.0. Complaints and appeals

12.1. Procedures for receipt of complaints
12.2 Redressal of complaints
12.3. Records of complaints and appeals

13.0. Cooperation
1.0. General
1.1. History and background
Non-destructive Testing (NDT) implies such checks and tests as are necessary to ascertain the soundness
and reliability of an industrial product (such as a turbine blade or rotor of an electric motor or simply a
crane hook etc.) or an assembly of individual members in the shape of machines or systems like
automobiles, railways, aircrafts, ships, power plants, chemical and other industrial set-ups etc. without
impairing the usefulness or altering any characteristic of the product under test.

In many industrial situations where the sudden failure of any component may prove to be life
threatening or where high risks of heavy losses are involved it is utmost necessary that the critical
components of an installation be monitored periodically (in-service inspection) using NDT techniques
to ascertain its safe operation for a reasonable period of time.

In today’s competitive world no manufacturer can afford to ruin its commercial standing by taking the
risk of failure of his products in the first few applications. To ensure reliability and gain the confidence of
the consumer it is essential that quality be built into the product right at the very onset. This concept
starts from the initial stage of selection of materials, their processing and quality control actions during
manufacturing, packing, transportation, usage and in-service performance.

Since the cost of producing a quality item is enhanced by doing re-working, repairs, replacements,
delays in production schedules and possible loss of customer, it is essential that every effort be made to
produce quality goods only. NDT techniques can be employed as a very reliable tool to assure consistent
materials, parts, processes and workmanship etc., that is, all the features that together form a quality
product.

The best strategy of maintenance seems to be to undertake in-service inspection of the critical
components at regular intervals without having to shut down. NDT methods are most suited to this
job.NDT is also an invaluable tool in plant life assessment and extension and other applications.

Starting from mid-sixtiesIAEA executed regional projects in the field of NDT in the regions of Latin
America and Caribean, Asia and Pacific, Africa and Middle East. As a result of this,thousands of
technicians have been trained.The standard used for such training has been ISO 9712 entitled ‘Non
Destructive Testing-Qualificationand Certification of Personnel’. For Asia and the Pacific seventeen
countries including SriLanka are members of the agreement. A large number of trainees have been
trained as a result of the project; many professional societies have been formed and become members
of ICNDT.
In the years ahead it is foreseen that NDT will continue to remain an essential part of the IAEA's
programs in view of its utmost importance for quality control of industrial as well as nuclear plants and
components. Efforts will be continued to consolidate the present NDT development in different Member
States. Member States will be encouraged to form the National NDT Societies and issue national
standards conforming to the minimum requirements of ISO 9712 standard for the qualification and
certification of NDT personnel. More regional projects will be initiated. Additional as well as advanced
NDT techniques will be addressed; training and certification of NDT personnel will be harmonized at the
regional and international levels and programs will be initiated for using the NDT for the Life Assessment
studies for industrial and nuclear plants and components. Modern developments in the field of NDT
involving the use of computer based digital techniques will be addressed in the program. Contacts will
be promoted with the other regional and international bodies such as ICNDT, EFNDT, Pan Pacific NDT,
ASNT etc. which have aims similar to those of IAEA for the promotion and international harmonization
of NDT practices, especially the training and certification of personnel.

In order to promote harmonization of NDT practices at the regional and international level it is
considered imperative that both the training and certification of personnel and the NDT services are
carried out following standard procedures. Both the processes need to be accredited according to
established standards and by the national or international bodies which themselves are members of
International Accreditation Forum (IAF).

The National Certifying Body of Sri Lanka is in the process of achievingaccreditation by Sri Lanka
Accreditation Board (SLAB). It is now intended to seek accreditation for the provision of NDT services by
the National Centre for Non Destructive Testing (NCNDT) of Atomic Energy Authority (AEA) of Sri Lanka.
This Quality Manual is produced and presented as fulfillment of one of the requirements for
accreditation.

1.2. Purpose of the manual

Purpose of this manual is to demonstrate the establishment of a system for the functioning of NCNDT in
a manner that fulfills the requirements of the international standard ISO/IEC 17020:1998 entitled
“General criteria for the operation of various types of bodies performing inspection.” The standard itself
has been drawn up with the objective of promoting confidence in those bodies performing inspection
which conform to it. In such cases the services provided by ISO/IEC 17020:1998 compliant bodies are
accepted by the clients and supervisory bodies. Once accredited under this standard the services offered
by NCNDT will be more reliable and thus will enjoy the confidence of clients within Sri Lanka as well as
abroad.

1.3. Quality policy and quality objectives

Quality policy

NCNDT is committed to develop competent professionals and reliable procedures to perform

nondestructive testing as per applicable codes and standards aimed at improving the quality and
reliability of Sri Lankan industrial products and processes, promotion of international harmonization and
enhancing exports.
The senior management and staff of the AEA and NCNDT also undertake to ensure that all activities are
conducted strictly in accordance with documented procedures and comply with the requirements of
ISO/IEC 17020: 1998 standard.
Quality Policy will be displayed at important locations within the NCNDT so that the policy is understood
and implemented by all concerned.

Quality objectives

Ensuring customer stratification through provision of efficient and reliable non-destructive testing
services for improving the quality and reliability of industrial products and processes.
Enhancing the reputation of NCNDT as well as the reputation of the client both within the country and
abroad.
Enhancement of exports from Sri Lanka both of manpower and industrial goods.
Continuous improvement of the services provided through interaction with the client and other relevant
bodies and personnel.
Promotion of better quality of life through enhancement in productivity, safety and protection of the
environment.

1.4. Revision status

Difficulties, experience during the process of inspection pointed out either by the client or his
representative or by the member of the inspection team will be reporting to quality assurance manager.
The quality Manager will then amend the relevant section of the quality manual which will be approved
by the Technical Manager / Director of the NCNDT.

All the changes made in this Quality Manual will be properly recorded in the Table below:

REVISION HISTORY
Version Description of Change Proposed by Approved by Effective Date
0 Initial release XYZ e.g. Sept. 2011
1 Corrections/changes ZXY e.g. Dec. 2012
made
2
3
4

1.5. Activites and scope

This Quality Manual is aimed at establishing compliance to ISO/IEC 17020:1998 for the provision of
services in the field of Non-destructive testing (NDT) to the AtomicEnergy Authority of Sri Lanka as well
to relevant and desirous national and international industrial organizations. Specifically it will provide
services for the following NDT methods and this will constitute the scope of the accreditation:
Visual Testing (VT)
Liquid penetrant testing (PT),
Magnetic particle testing (MT),
Eddy current testing (ET),
Ultrasonic testing (UT),
Radiographic testing (RT)

The services will be provided by properly trained and certified personnel using adequate and properly
calibrated equipment and authenticated test procedures.

1.6. Distribution of Quality Manual

All copies of the QM will be numbered. Copies will be distributed to Technical Manager, QA Manager,
Heads of Divisions. A record of this distribution will be kept with the office of QA Manager. Previous
versions will be withdrawn and replaced by revision copies as and when required. Withdrawn copies will
be destroyed except for one copy which will be retained in the archives in the office of QA Manager.

2.0. Definitions and Abbreviations

For the purpose of this Quality Manual the definitions and abbreviations as given in Annex I will apply.

3.0. Administrative requirements

3.1. Legal status

NCNDT is a part of Atomic Energy Authority of Sri Lanka which was established under the Act No. 19 of
1969. NCNDT has been authorized by the Chairman AEA to provide NDT services to various projects of
AEA as well as to national and international industrial organizations. Such authorization was issued vide
Letter No. (full reference) dated------
 General Administration HRM Branch Accounts Branch

Customer Care and Business Development

Following charts in figures 1 and 2 give the organization structure of NCNDT in relation to Atomic Energy

Administration Division

Staff Management
Audit

Transport
General Maintenance
Procurements & Supplies
Quality improvement activities, QA, QC & TQM
Ministry of Power and Energy

Atomic Energy Authority

Technical & Quality Management Div.

Development of new techniques

WQT Laboratory
NCNDT

Equipment repair, Maintenance and Calibration

CT Laboratory
IT and Networking
VT Laboratory
Coordination of Research activities
ET Laboratory

Inspection ServicesDivision
PT Laboratory
CBNDT
Organization chart

MT Laboratory
Promotional Seminars & Propaganda Programmes
RT Laboratory
Training & Qualification of common NDT
UTmethods
Laboratory
Authority

Training Division
3.2.
 Chairman, Atomic Energy Authority

Director of the AEA

SDD of NCNDT (01 Post)

DD –Training (01 Post)

DD – Inspection Services
DD – Technical & QM (01 Post) DD – Administration (01 Post)
(01 Post)

SSO / SO (02 Posts) SSO / SO (08 Posts) SSO / SO (02 Posts)

HRM & Customer Care Officer (01) Officer (01Accounta
Administrative Post)
(01 Post

STA / TA (02 Posts) STA / TA (08 Posts) STA / TA (02 Posts)

Management Assistants (06 Posts) Management Assistants (03 Posts)

MA (01), Cashier

Primary Level – Skilled (07 Posts)

Primary Level – Unskilled (04 Posts) Driver (03 Posts)

Primary Level – Unskilled (02 Posts)

As shown in figure 1 there are four divisions, namely Training, Inspection services, Technical and Quality
Management and Administration each headed by Deputy Director, under the Senior Deputy Director
who will be the Technical Manager/ Director.

Heads of Divisions will be scientists /engineers of Deputy Director Level and having Level 3 qualifications
in one of the NDT methods. If Level 3 persons are not available Level 2 should suffice during the interim
period until the availability of Level 3 person/s.

Technicians will invariably undertake practically the execution of the inspection jobs. They will be
adequately trained and certified to Levels 1 and 2. No uncertified person/s will be deployed to execute
inspection jobs except for the purposes of on-the-job training.
3.3. Functions and responsibilitiesof persons

Technical Manager/ Director (Senior Deputy Director)

 To be the administrative head/overall supervisor of NCNDT and take full responsibility for its
smooth and efficient functioning.
 To appoint a deputy to look after his functions and responsibilities in his absence.
 To implement all the requirements of the Quality Manual and have it revised/updated as and
when necessary.
 To recruit suitable personnel and arrange for their training and certification.
 To nominate teams for negotiating the contracts with the clients. As far as possible he should
himself lead such teams; otherwise suitable team leaders may be appointed.
 To adjust workloads and assign the inspection jobs to suitable teams and approve the test
procedures.
 To allot unique identification numbers to inspection jobs in consultation with the QAM.
 To countersign all the inspection reports; if situations demand he may designate this
responsibility to some other suitable person.
 To appoint teams to look into the complaints received from clients. As far as possible he should
himself lead such teams; otherwise suitable team leaders may be appointed.
 To arrange to procure adequate equipment and accessories for carrying out the inspection jobs
satisfactorily.
 To arrange for repair, maintenance and calibration of any equipment as well as its adequate
storage.
 To chair the management review committee meetings.
 He will have all the functional powers/authority (both administrative and financial) for efficient
and smooth functioning of NCNDT.

Quality Assurance Manager (Deputy Director)

 To assist the Technical Manager/Director in smooth and efficient functioning of NCNDT.

 To keep the Quality Manual and all the procedures revised and updated.
 To coordinate the development of additional procedures and instructions.
 To supervise the implementation of the Quality Manual.
 To coordinate the internal audits of NCNDT as required.
 To keep all the records related to the Quality System.
 To review the feedback or complaints received from the clients,coordinate sending replies and
corrective actions.

Head of Inspection Divison (Deputy Director)

 To supervise the inspections on site/s.

 To nominate team/s of suitable persons for executing the inspection job/s.
 To review the test procedures and instruction sheets before handing them over to the executing
team.
 To check for the suitability and calibration of test equipment before being dispatched to
inspection site/s.
 To prepare and review a check list of all the items to be taken along to the inspection
site/sbefore departure.
  To arrange for delivery of the executing team/s and equipment and accessories to and from the
inspection site/s.
 To review and countersign the inspection report/s.

Head of Training Divison (Deputy Director)

 To organize training courses of Level 1, Level 2 and Level 3 in all the common NDT methods
included in the scope of accreditation according to ISO 9712 standard.
 To organize non certification courses for the benefit of NDT community.
 To conduct with Certification Body for Non-Destructive Testing (CBNDT) to conduct examination
for certification.
 Maintain records of trained NDT Personnel.

Technicians

 To undertake inspection in accordance with the written procedures and instruction sheets.
 Organizing and reporting the results of inspection in the proper report format.
 Exercising a judgment on the results of inspection in consultation with the team leader.
 Remain vigilant about the safety of manpower and equipment during inspection.
 Prepare the equipment and accessories for return to NCNDT after completion of an inspection
job.

3.4. Terms and conditions for work

A. Jobs executed within the premises of NCNDT

 Transportation of specimens to be inspected to and from the NCNDT will be the responsibility of
client.
 Inspection will be carried out in accordance with written procedures which have been agreed to
in writing between the client and the NCNDT.
 Inspection charges as agreed to by the client will be payable. 50% of such charges will be
payable in advance while the remaining 50% will be payable at the time of collection of
inspection reports.
 Client will make his own arrangements for boarding and lodging in Colombo. However, help may
be provided by NCNDT for booking etc. of accommodation without any financial obligations.
 The inspected parts will be removed from the premises of NCNDT as soon as possible but no
later than a fortnight after the completion of inspection. In case this is not done within the
specified period, the NCNDT will have the discretion to dispose of these inspected parts.

B. Jobs executed at the premises of client

 Client will be responsible to vacate (where necessary) and prepare the site and the
parts/equipment to be inspected in accordance with the schedule and the manner agreed to by
him in the contract.
 Client will provide adequate accommodation including an office and place for storage of
equipment and accessories at the inspection site or nearest to it.
 Client will make arrangements for food etc. for the inspection team at cost to the latter.
 An employee of client at senior enough level will be attached with the inspection team for
purposes of coordination.
4.0. Independence, impartiality and integrity

4.1. Independence of personnel

(To ensure independence of personnel from any pressure that might affect the results
of inspection, )
 It wll be disallowed for any person from outside NCNDT to come in contact with the
members of an inspection team except at the level of team leader and Head of the
Division/Group.
 The inspection team members will not accept any financial and other benefits from the
client except for those agreed to in the contract.

4.2. Type of organization

NCNDT is part of the Atomic Energy Authority of Sri Lanka. As mentioned earlier it will provide
NDT services to departments within AEA as well as to other industrial organizations within and
outside Sri Lanka. In terms of ISO/IEC 17020:1998 it is, therefore, a Type C organization.

4.3. Confidentiality

Every person in NCNDT will be careful not to disclose or discuss the results of inspection before
the issuance of a proper inspection report.

The inspection report will be a confidential document and its distribution will be controlled, a
copy each going to the client, Technical Manager’s office, Quality Assurance Manager’s office
and the office of the Head of Division.

The contents of the inspection report will not be disclosed to non-relevant persons which include the
competitors of the client as well as the competitors of NCNDT.

5.0 Organization and management

5.1. Quality system

NCNDT will implement a Quality System as per requirements of ISO/IEC 17020:1998 standard. Most of
these requirements have been dealt with in this Quality Manual which itself meets the requirements of
Annex D of the said standard.

5.2. Document control

Document control procedure will be followed which is given in Annex 02 and Procedure No.02.
The Document Control Procedure which itself will have a unique numberwill lay down the following.
  Title of the document
 Unique number of the document
 Date of issue
 Revision number
 Revision history
 Signing and approving persons’ names and signatures both for original as well as revised
documents.
 List of documents covered by the Document Control Procedure.
 List of recipients of the documents

5.3. Review of requests, tenders and contracts

Review of requests, tenders and contacts will be undertaken according to Procedure No.
NCNDT/INS/P-06(TC)/00 (Annex 02)

5.4. Subcontracting

Sometimes there may be shortage of manpower and equipment such that it may difficult to meet the
inspection schedule of the client.

Also, sometimes part of the inspection work may not be within the capacity of NCNDT. In such cases
part of the work will be subcontracted.

The procedure for doing this has been given in Annex 2 (NCNDT/INS/P-26(SUB-CONT)/00)

5.5. Service to the client

The procedures for dealing with the client has been included in the procedures for review of requests,
tenders and contracts (Section 5.3)

5.6. Complaints

If the client expresses dissatisfaction with the inspection work he will send a written complaint to
NCNDT.

This will be dealt with in accordance with the ProcedureNCNDT/INS/P-19(COM)/00 (Annex 2) for dealing
with complaints.

5.7. Control of non-conforming work

Once non-conforming items have been noticed they are identified by location, associated documents, or
specific markings to prevent their inadvertent use. All non-conforming items and customer
complaintsare subject to review and rectification by nominated personnel. The type and extent of non-
conformity is documented in order to establish trends and identify possible areas for improvement.The
corrective action required to prevent recurrence is evaluated, documented, and its effective
implementation is monitored. All rectification is subsequently re-inspected to ensure complete
customer satisfaction. All employees are encouraged to suggest improvements in methods, materials,
suppliers, and sub-contractors. The NCNDT has established procedures for review of all activities in
order to identify and evaluate all possible improvements in methods/ materials and its procedures. This
is given the procedure No. NCNDT/INS/P-22(NON-CON)/00 (Annex 2).

5.8. Corrective actions

NCNDT will have appropriate procedure to take a corrective action to eliminate the causes of actual or
potential non-conformities to a degree appropriate to the magnitude of problems and commensurate
with the risks encountered. The procedure followed will be as given in Annex 2 (NCNDT/INS/P-
29(CA)/00).

If a corrective action for any given finding identifies a lack of employee awareness of procedures then
the organizations update-training programmewill be updated to include training in this area.

5.9. Preventive actions

NCNDT will have appropriate procedure to take a preventive action to avoid the causes of potential non-
conformitiesto a degree appropriate to the magnitude of problems and commensurate with the risks
encountered. The procedure followed will be as given in Annex 2 (NCNDT/INS/P-30(PA)/00).

5.10. Control of quality records

Documented procedures for identification, collection, indexing, access, filing, storage, maintenance and
disposition of quality records are established and maintained.

Quality records are maintained to demonstrate conformance to specified requirements and the
effective operation of the quality system. Pertinent quality records from the sub-contractor are an
element of these data.

All quality records are legible and are stored and retained in such a way that they are readily retrievable
in facilities that provide a suitable environment to prevent damage or deterioration and obligation to
verify the records by the customer does not arise.

The procedure followed will be as given in Annex 2 (NCNDT/INS/P-25(RC)/00).

5.11. Internal quality audits

The purpose of internal audits is not to search for the guilty, or to find fault with individuals'
performance. The system is being audited, not the individuals. The auditors must be suitably qualified,
and must approach this important task with the seriousness it deserves. Auditors may be inspection
body employees or external consultants. Internal audits are the most effective way of continually
assessing the effectiveness of the Quality System. It is aimed at ensuring that the NCNDT management is
being operated correctly and effectively, by performing planned and documented checks, designed to
ensure that:
 the quality system documentation adequately defines the needs of the business
 the documented procedures and instructions are practical, understood and implemented
 the training of employees is adequate to allow them to do their tasks

This procedure defines the way in which NCNDT will perform internal auditing of the quality
management system.It applies to all internal quality audits, which will generally be performed against
the requirements of ISO 17020, the inspection body's quality manual, procedures, process plans and
work instructions. The procedure followed will be as given in Annex 2 (NCNDT/INS/P-23(IAUD)/00).

5.12. Management review

The objective of Management review is to assess how efficiently and faithfully the Quality System is
being implemented in the NCNDT, to point out deficiencies and shortcomings if any and to identify
whatcorrective actions need to be taken. Such corrective actions may be necessitated either by the
complaints/suggestions of clients or other outside agencies or the members of NCNDT themselves.The
procedure followed will be as given in Annex 2 (NCNDT/INS/P-28(MR)/00).

6.0. Personnel

6.1 Recruitment of personnel

Scientific Officer
a. Qualification
A special degree of four years duration with a first class or second class upper in
Physics/Chemistry/Computer Science/Mathematics/Engineering (Metallurgy ,Mechanical
,Electrical, Civil etc.) from the recognized University.
OR
A special degree of four years duration with a second class lower in
Physics/Chemistry/Computer Science/Mathematics/Engineering (Metallurgy ,Mechanical
,Electrical, Civil etc.) from the recognized University with appropriate subject
combination and post graduate degree in nuclear Science or as related to the first degree.
b. Age
Should not be less than 22 years and not more than 45 years. The upper age limit will not
apply to internal candidates.
c. Recruitment Procedure
Recruitment will be done after calling applications through a public advertisement and on
the results of a written competitive examination and structured interview conducted by
the appointing authority.
d. Aptitude Test
Written examination will be held to test the aptitude of the candidate.
e. Medical Examination.
Every candidate will be given thorough medical examination including visual acuity test.
f. Interview

Technical Assistant
a. Qualification
G.C.E.(A/L) in science with 03 passes in one sitting
And
Having completed a two years diploma or Certificate course not below the N.V.Q. level 5
conducted by a recognized institution of technological training.
b. Age
Should not be less than 22years and not more than 45 years. The upper age limit will not
apply to internal candidate.
c. Recruitment Procedure
Recruitment will be done after calling applications through a public advertisement and on
the results of a written competitive examination and structured interview conducted by
the appointing authority.
d. Aptitude Test
Written examination will be held to test the aptitude of the candidate.
e. Medical Examination.
Every candidate will be given thorough medical examination including visual acuity test.
f. Interview

6.2. On-the-job- training of personnel

Newly appointed persons are attached with qualified and experienced personnel for at
least sis months to get real experience.

6.3. Formal training and certification of personnel

After the completion on the job training all the persons will be nominated to participate
in National Training courses for all methods. Such courses are organized by NCNDT
itself. After completing these courses and the experience requirements of ISO 9712: 2005
they will be eligible to take certification examinations conducted by the National
Certifying Body (NCB) of Sri Lanka. Only those persons who pass such examinations
and obtain certificates will be deployed on the inspection jobs.

6.4. Technical Manager and Quality Assurance Manager

Technical Manager/Director NCNDT

Technical Manager/Director NCNDT is the overall incharge and responsible person of
NCNDT. He ia appointed by and reports directly to Chairman AEA of Sri Lanka and his
responsibilities include:
(a) Management of activities pertaining to NDT services.
(b) Provision of adequate resources that include trained personnel,
appropriate calibrated equipment / accessories, consumables and workable
environment.
(c) Promoting research and development and liaison with national and
international institutions/industries for the promotion of NDT methods.
(d) Ensuring the effective implementation of the established quality
management system.
(e) Identifying training needs of personnel under his control and ensuring
that all personnel are adequately trained.
(f) Establishing and maintaining procedures to control processes involved
in NDT services and training of personnel.

Quality Assurance Manager

Quality Assurance Manager is the incharge and responsible person for the Quality
Assurance Division of NCNDT. He ia appointed by and reports directly to Technical
Manager/Director of NCNDT and his responsibilities include:
(a) Acting as Technical Manager/Director NCNDT in the absence ofTechnical
Manager/Director
(b) Updating the Quality Manual and Procedures as and when necesary.
(c) Arranging QA indoctrination and training to meet the applicable requirements of Quality
Manual, associated procedures, portions of the related Codes and Standards for all
personnel who perform activities which affect quality.

Heads of Technical Divisions

Head of each Tehnical Division is appointed by and reports directly to Technical
Manager/Director NCNDT. His responsibilities include:
(a) Implementing quality management strategy and plans according to defined scope of
work.
(b) Ensuring availability of appropriate resources that include calibrated equipment,
instruments and necessary consumables, trained and qualified personnel and
workable environment.
(c) Developing and implementing technical procedures and instruction sheets as per
applicable codes and standards relevant to the scope of work assigned.
(d) Management of NDT activities performed.
(e) Ensuring that all technical personnel have proper and valid academic and practical
training including certificatio.
(f) Coordinating and providing guidelines to the Divisional personnel for performing
requisite NDT activities.
(g) To assign to the engineers and scientists in the Division activities such as:
 Preparation of relevant technical procedures.
 Calibration of relevant equipment & accessories.
 Managing/ performing of applicable NDT methods/techniques against
assigned work scope.
 Reporting and maintaining record of NDT inspections performed.
 Head of Procurement Division
Head of Procurement Division is the incharge and responsible person for the purchase of
all equipment and accessories for NCNDT. He is appointed by and reports directly to
Technical Manager/Director of NCNDT and his responsibilities include:

(a) To complete the process for qualification of approved equipment suppliers /

manufacturers.
(b) To obtain the demand for equipment and accessories with complete specifications
from the Heads of the technical divisions.
(c) To prepare advertisments for inviting quotations from reliable, reputable and
approved equipment suppliers /manufaturers of equipment and accessories.
(d) To open the tenders and quotations and get them evaluated from the technical
divisions.
(e) To obtain the neccessary approval from the competent authority.
(f) To place order to the selected equipment suppliers/manufacturers.
(g) To receive the ordered equipment and send it to the stores.
(h) To inform all the concerned persons about the receipt of the equipment.

Head of Stores Division

Head of Stores Division is the incharge and responsible person for the Stores of NCNDT.
He is appointed by and reports directly to Technical Manager/Director of NCNDT and
his responsibilities include:
(a) To receive the equipment and accessories from the procument division.
(b) To allot a unique identification numbers to the received equipment and accessories in
consultation with the odering division.
(c) To keep the equipment securely in a proper place in the stores.
(d) To send intimation to the ordering division to give equipment and accessories issued.
(e) To issue the equipment and accessories to the ordering divisions and keep a proper

6.4. Code of conduct for personnel

Integrity has always been a Sasol value. It is fundamental to and underlies Sasol’s values
of “customer focus”, “winning with
people”, “safety”, “excellence in all we do” and “continuous improvement”.
Integrity means to act consistently on a set of ethical principles. Ethics are rules of
conduct aimed at ensuring morally
justifiable behaviour.
Research proves a direct correlation between sustainable business success and consistent
ethical behaviour. Acting
consistently on a set of ethical values makes long-term business sense. We also believe
ethical conduct is inherently the right
thing to do.
Since its inception, Sasol has taken steps to ensure that employees act consistently on a
set of ethical principles. These ethical
principles have been expressed in various ways through Sasol policies and codes over the
years. Each phase in the
development of the Sasol group has required a new expression of the group’s ethical
principles to make it relevant to
contemporary challenges and circumstances. However, the tried and tested ethical
principles on which Sasol has historically
based its reputation and success have remained fundamentally consistent.
Sasol’s Code of Ethics (“the code”) is based on principles rather than detailed rules. The
complexities of global business
make it impractical to formulate a code of ethics that provides detailed rules for every
conceivable situation where ethical
considerations may be relevant. A detailed rules-based code of ethics removes all
individual discretion and results in
mechanistic decision-making where wisdom and good counsel would have been more
appropriate. We trust our employees
to apply the four fundamental ethical principles (responsibility, honesty, fairness and
respect) and the 15 ethical standards
of the code in a way that consistently results in defensible business conduct.
This guide to the Implementation of the Sasol Code of Ethics (“the guide”) is intended to
assist employees to make ethical
decisions by:
exposing them to the thinking behind the ethical principles and standards of the Code;
suggesting some processes and tools to guide ethical decision-making; and
communicating Sasol’s policy on some specific ethical dilemmas.

Compliance with the code of ethics

The code applies uniformly to all wholly owned Sasol businesses, employees and
directors globally without exception.
Each Sasol employee and director is required to know and understand the code’s
relevance to their areas of responsibility.
In most instances it is clear what constitutes ethical business conduct. In such instances
Sasol has a policy of zero tolerance
of unethical conduct irrespective of whether the consequences for Sasol resulting from
the unethical conduct are big or small.
Matters dealt with specifically in the code, the guide and in official Sasol policies are
regarded as matters in respect of which
there is ethical clarity.
 “Zero tolerance” in this context means that managers may not simply ignore clear
deviations from Sasol’s Code of Ethics
in their areas of responsibility and should take such formal developmental, corrective or
disciplinary action as may be
appropriate in view of the seriousness of the deviation. Failure to take such action is in
itself unethical.
Employees’ ethical performance will be evaluated in their annual performance
discussions, under the Integrity value and will
be measured on conduct relating to inter alia interpersonal relationships, responsibility
and work cadence.
Compliance with the code in instances where it is not clear how to apply the code
requires a discussion of the matter with
your line manager. If uncertainty persists, the matter should be referred to a member of
group management and if the
consequences of a decision may be material from a reputational or value point of view,
the group management member
has a duty to refer the issue via the Sasol Limited company secretary to the appropriate
tier one or two board of directors,
and the group executive committee (“GEC”).

Code of Ethics
 To service client companies and candidates in a professional and ethical manner.
 To exercise professional judgment in screening and referring candidates for identified
positions with clients.
 To refuse job listings that violate equal employment laws regarding race, sex, sexual
orientation, marital status, color, age, religion, national origin or disability.
 To comply with all state and federal laws dealing with employment issues.
 To insist upon thorough job specifications in order to understand and meet the exact
needs of the client.
 To describe the specifics and requirements of the job to the candidate in accordance with
the consultant's best understanding of the opportunity at hand.
 To thoroughly assess all candidates as to their ability to perform the specific job
functions, and to refer only those candidates whose credentials appear to be a reasonable match
to the client's job description.
 To divulge all pertinent information, within legal boundaries, to the employer regarding
anything that may affect the candidate's ability to do the job.
 To accurately transmit to the client all relevant information obtained from a candidate
about his or her background, expertise, motives, objectives and earnings history—but only with
prior permission from the candidate.
 To be an effective and objective liaison between employer and candidate in assisting each
party to evaluate the other's strengths and weaknesses.
 To always keep in mind the candidate's career needs. He or she deserves an honest,
ethical approach concerning career opportunities, including confidential and discreet handling of
credentials and privileged information.
 To be sensitive to the goals and needs of candidates. If unable to help them, to do the best
to recommend them to an appropriate source. 
 To avoid making representations or promises that cannot be supported by facts.
 To help candidates, to the best of our ability, avoid employers with documented histories
of unstable financial, unethical, or illegal, employment or business practices.
 To never withhold information that is detrimental to the candidate.
 To refer candidates only to bona fide positions that have been discussed with all parties.
 To avoid actions or advice that might jeopardize a candidate's position with his or her
current employer.
 To advise all candidates to avoid giving notice or leaving their current employment until
all stages of the hiring process are complete.
To view all FPC offices as partners in the employment process.

Show responsibility for the welfare, health and safety of the community at all times, and for the
laws and statutory regulations, and this responsibility shall come before there responsibility to
their profession, to sectional or private interests or to other non-destructive testing (NDT)
personnel.
ii) Act at all times to uphold the integrity and dignity of the NDT industry.
iii) Accept professional obligations only for those areas of work for which they are competent.
iv) Accept responsibility for all work carried out by them and others under their supervision.
v) Apply their skill and knowledge in the interests of their employer or client for whom they act
as faithful agents or trustees.
vi) Provide professional advice, express opinions, or make statements in an objective and
truthful manner to the best of their ability, and on the basis of adequate knowledge.
vii) Continue their professional development throughout their career and should actively assist and
encourage other NDT personnel to advance their knowledge and experience.

6.5. Personnel records

Important personnel records will be listed

The quality manager maintains a separate file on all company maintenance personnel. These
personnel files will include the following:
 Tombstone data applicable to each individual
 Experience
 Qualifications
 Training History
 AME license
 Aircraft Certification Authority and/or Shop Certification Authority issued

All personnel are to advise the quality manager whenever there has been a change affecting
their personal records.

A current list of all approved company personnel and scope of certification authority is
located in the documents incorporated by reference section.

All personnel records will be retained for at least 2 years after the company no longer employs the employee.
6.6. Salaries and other benefits for personnel

The procedure will be given as Annex 2

7.0. Facilities and equipment

7.1. Essential equipment for VT, PT, MT, ET, UT and RT

NCNDT will have the following equipment as a minimum. Multiple numbers of equipment may,
however, be needed depending upon the workload and the sites being simultaneously served.

Liquid Penetrant Testing (PT)

 An effective component cleaning,degreasing facility for thorough cleaning of specimens.

 A penetrant line comprising water washable penetrant tank, post emulsifiable penetrant
tank, emulsifier tank, water rinsing station with spray nozzle, drying station, dust storm
cabinet.
 Aerosol liquid penetrant inspection kits comprising penetrant remover/degrease,
fluorescent penetrant, colour contrast dye penetrant, developer.
 Inspection area or booth equipped with black out facilities for visible and UV (A)
viewing of samples.
 Portable black light (UV) lamp.
 Independent or combined photometer & radiometer for measuring the intensity of visible
and black light.
 Artificial flaws (TAM panels) or other means of process control of penetrant line.
 PT indication catalogue.
 NDT test specimens with known defects.

Magnetic Particle Testing (MT)

 A 1500 Amp bench or free standing transformer with AC or DC output (and half wave
rectified AC) with a current flow adapter and prods, magnetic flux flow and an ink
reservoir with feed.
 Portable magnetizing unit with wth flexible cables and prods.
 AC/DC electromagnetic yokes with articulated legs and pole pieces.
 Permanent magnets with pole pieces adapters suitable for all applications.
 Various rigid and flexible coils.
 Threading bars.
 Inspection area or booth equipped with black out facilities for visible and UV(A) viewing
of samples.
 Portable black light (UV) lamp.
 Independent or combined photometer and radiometer for measuring the intensity of
visible and black light.
 Demagnetizing equipment.
  Flux measuring and comparison gauges to BS or other relevant standards’
recommendations.
 Sutherland Flask or Crowe Receiver for measuring solid content of magnetic ink.
 Powder dispensers.
 Supplies of detection media including non-fluorescent (visible), fluorescent and dry
powders.
 Artificially or naturally cracked blocks/specimens for performance checking.
 Standard weights for determining lifting power of magnets.

Eddy Current Testing(ET)

A. Wrought and Welds

 At least one standard single frequency impedance plane instrument.
 At least one single frequency analogue meter display instrument, frequency range 1 kHz
to 3 MHz.
 Where inspections incorporate bolt hole testing, one dynamic rotating probe assembly
and compatible instrument.
 Where inspections are offered for multi frequency boiler tube inspection, one dual
frequency impedance plane instrument suitable for testing.
 Absolute and dfferentally wound standard and shielded pencil an spade probes suitable
for testing ferritic and austenitic steels and aluminium alloys.
 A selection of encircling, internal, bolthole and comparative coil types.
 Calibration blocks, appropriate to all probe and material types.

Note: Where inspection of specific components i.e. automated/semi-automated testing of steel

tubes/condenser tubes, coils/probes and test equipment together with reference test pieces
containing relevant holes/notches.

B. Tube Testing
 One impedance plane, dual frequency, two-channel flaw detector with the ability to mix
channels manually. The flaw detectro to carry a valid annual certificate of calibration.
Frequency range 1 kHz to 1 MHz.
 One two-channel chart recorder having a minimum chart width of 50 mm with a speed of
between 25-50 mm/sec and a nominal 500 Hz frequency response.
 Calibration tube type A, B and D from draft iinspection ESI 98-15 and produced in test
sample material. Tubes to be 25 mm external diameter and 18 g thickness.
 Eddy current probes of the air cored bobbin type. A minimum of one of each of diameter
20 mm minimum 24 kHz nominal frequency and differential mode; and diameter
appropriate to be a sliding fit through a plastic inlet insert and having a flexible (brush
type) centring device; 24 kHz nominal frequency and absolute.
 Appropriate cabling.

C. Others
 Crack detector based on ET principle.
 Conductivity meter 15% to 100% IACS.
  Coating thckness gauge with FC and NFC probes.
 Test specimens for conductivty measurements.
 Test specimens wth surface and sub-surface cracks.

Ultrasonic testing (UT)

 At least one analogue ultrasonic flaw detector.

 Range of normal beam probes of 01, 02. 04. 05 MHz frequency.
 Range of angle beam probes of 01, 02, 04, 05 MHz frequency and for each frequency
angles of 45, 60 and 70 degrees.
 Any special purpose probes where required.
 Calibration blocks, one each, oftype V 1 and V 2.
 Set of IOW type test block.
 Connecting cables for all parts of the equipment.
 Various couplants such as grease, oils and water based couplant.
 Collection of NDT test specimens with known defects, may be locally fabricated or
imported.
 Equipment for Time of Flight Diffraction (TOFD) along with accessories such as
compatible computer and related software, TOFD scanner including probe ig and line
encoder, pair of 05 MHz transducers with matching wedges producing centre beam
refracted angles of 45, 60 and 70 degrees, BS 2704 type A2 or BS EN 12223 calibration
block No. 1, connecting cables for all parts of the equipment.

Radiographic Testing (RT)

 Properly designed exposure rooms for X-ray machine and radioisotope sources.
 At least one X-ray tube wiith a kV range appropriate to thetype and thickness of materials
tio be inspected.
 For gamma radiography (where appropriate) an Iridium-192 source, with suitable
container and projection mechanism.
 For gamma radiography (for thicknesses greater than the range of Ir-192), a Cobalt-60
source, with suitable container and projection mechanism.
 An X-ray beam centring device.
 A range of image quality indicators (IQIs).
 Lead letters and numbers.
 Blocking off compounds and liquida
 Copper and lead filters.
 Standard ASTM and IIW reference radiographs for welds and castings.
 Densitometers, for normal viewing of 2.5 D and special viewing upto 4.5 D.
 Film viewers including at least one high intensity viewer.
 Radiation monitor.
 Stepped blocks of relevant materials for making exposure charts.
 NDT test specimens with known defects.
 Caliper and other devices for measuring material thicknesses.
 Separate dark room for film processing and film preparation/viewing
  Viewing aids such as magnifiers.
 A manual or automatic film processing unit incorporating thermostatically controlled
developing tank, stop bath, rinsing, fixing and washing tanks.
 Thermostatically controlled drying cabinet
 Viewer with wet film attachment.
 Channel and clip type film hangers in the common sizes
 Lead and calcium tungstate screens in the common sizes.
 Flexible and rigid type cassettes.
 Darkroom timer.
 Safelights.
 Trimmer to accommodate larger size of films.
 Labels and barriers
 Tongs, lead bricks, lead shots in bag.
 Gamma alarm system.
 Pocket dosimeters with charger, film badges or TLD system for personnel.

7.2. Purchase of equipment(to make it compatible with existing system at NCNDT)

The procedure followed for purchase of the equipment and accessores will be as follows:

 The concerned Head of the Division will constitute a team to prepare the specifications of
the needed equipment along with the quantities required, the price estimates and possible
manufacturers/suppliers.
 Head of the Division will recommend such equipment and acessories and send to the
Finance Department for their concurrence and availabilty of funds. The proposal will be
sent to the Procurement Department.
 Procurement department will advertise and invite tenders from the recommended
manfacturers/suuppliers. An invitation letter may also be sent to the individual
manufacturers/suppliers. From its own knowledge of reputed and reliable
manufacturers/suppliers, the Procurement Department may add additional names to the
recommended list.
 A cut off date will be specified for the receipt of tenders.
 Tenders will be opened a day after the cut off date as above All the offers will be filed
and sent to the concerned Division where the team that proposed the equipment will
review all offers and select the appropriate one. The appropriateness will be decided on
the basis of cost and suitability of the required equipment and accessories.
 The decision will be forwarded, through Head of the Division to the Procurement
Division.
 Order of the selected equipment and accessories will be placed after approval of the
Technical Manager/Director of NCNDT. The purchase order will include all the
necessary details such as specifications, warrantees required, terms of payment, insurance
against damage during shipment/transportation and the tentative date for receipt of items.

Purchasing (Merge with above)

Suppliers of products, materials and services, where unspecified by a customer contract, are
selected on their ability to meet the company's requirements given due consideration to the
quality, statutory obligations, timescale and cost. A list of approved suppliers and sub-
contractors is maintained which is compiled on the following criteria:-
a) Previous performance in supplying to similar specifications and requirements.
b) Stocking of high volume standard items conforming to a relevant British Standard, or supplied
with a statement of conformity.
c) Compliance with an approved third party product/ quality registration scheme.
d) Recommendation by other similar purchasers or manufacturers of equipment.
e) A trial order and evaluation of performance.
All supplies and sub-contracts are subject to an authorized Purchase Order providing full
clarification of the type and extent of supply.
Should a supplier, not appearing on the Approved Suppliers List be proposed, they will be
analysed by capability and subject to acceptance on the authority of a Director.

7.3. Receipt and Identification of equipment

 Receipt of ordered equipment and accessories from the port or airport will be the
responsbiliity of Procurement Department.
 Representative of Procurement Department will receive the equipment along with
shipping documents, quality inspection reports of the manufacturer, warranty cards. He
will inspect the container or packaging etc. for any physical damage. Such physical
damage, if noticed, will be pointed out in writing to the handling agents.
 The container/packaging along with relevant papers will be properly entered in the
records of Stores Department.
 The container/packaging will be opened by the Stores Deprtment personnel in the
presence of one or more representatives of Procurement Department and the team of
Technical Department that originally requested for the equipment and accessories.
 The items will be checked against the list in the purchase order and defciencies if any
noted.
 The items will be taken into temporary custody by the Technical Divison where the team
that orignally proposed the equipment will give it a more thorough check up. Such check
up will include the verification of specifcations, warantee period, presence of all the
items as per purchase order and the equipment along with accessories being functional.
An acceptance report will be signed by the representative/s of the Technical Division. In
case any deficiencies are found or the equipment cannot be operated following the
procedure given in the Operation Manual this will be written down and signed.
 The fit equipment will then be given a unique identification number. The accessories will
each carry the identification number of main equipment plus their own identification
number. For example an X-ray machine of 150 kV may be given a number as RTX-150-
01. The second X-ray machine of the same rating will have the number RTX-150-02.
Power cable for the first X-ray machine will have the number as RTX-150-01-PCBL. A
centring device for this X-ray machine may be numbered as RTX-150-01 CD. Similarly
all the equipment for the other NDT methods may be numbered using the abbreviations
of those methods.
  A complete master list of all the equipment and accessories available at the NCNDT may
be prepared showing the abbreviated numbers and what the abbreviations stand for. Such
lists be present with all the Divisions of NCNDT and will form a part of records.
 Identification numbers will be permanently written on the body of the equipment and
accessories as well as on detachable cards hung with the identified items at appropriate
places. The detachable cards, besides identification number, will also indicate the date of
purchase and date of calibration of the equipment.
 Taken on permanent charge of the Technical Division by raising a proper Stores Issue
Demand.
 The Stores Department will issue and send the equipment and accessories to the
Technical Division and make entries into the Stores Issue Demand as well as in the
register maintained for this purpose.
 One copy each of Stores Issue Demand will be sent to the Procurement Department, the
Technical Department, the Finance Department and the Technical Divisons.

7.4. Calibration of equipment

(will look for calibration procedure otherwise cast this one into numbered/dotted steps)
All equipment for measurements and tests, where the results of such measurements and tests
have a significant influence on the results of the inspection i.e. the conclusion about conformance
with requirements shall be properly calibrated or controlled by the authorised technical staff
according to the calibration/ calibration control instructions. The instruments used in the
laboratories will be provided with calibration control cards indicating the dates of the last and the
next check. Details of calibration and calibration control will also be available in the equipment
files in the respective laboratories of each Division as well as with the QAM. For the calibration
and calibration control of the equipment the following Calibration Procedure is applied. This will
include details such as equipment type, unique identification number, location, frequency of
checks, check method, calibration status and the date when next calibration is due.

Calibration to traceable standards.

The validity of previous inspections and test results will be ascertained when the test equipment
is found to be out of calibration.

It will be ensured that the environmental conditions are suitable for the calibrations, inspection,
measurements and tests being carried out.

7.5. Storage and maintenance of equipment

(Storage and maintenance of equipment according to documented procedure)

This procedure will appear here.

7.6. Issue, transportation and receipt of equipment

7.7. Computerized equipment
7.8. Out of order equipment
7.9. Labelling of eqipment
7.10. Miscellaneous facilities

8.0. Inspection methods and procedures

8.1. General test procedures for PT, MT, ET, UT and RT

The Report Forms for each mathod may be taken from IAEA books, existing Forms of
NCNDT (Sri Lanka) or designed from abinitio keeping in view the pattern of available
Forms

8.1.1. Lquid Penetrant Testing (PT)

Title: Procedure for Liquid Penetrant Testing (this will appear on each page)
Procedure No: P-?? PT (P number will be same as in Section 5.2 and will appear on each page)
Date of issue: e.g. December 2012 (this will appear on each page)
Version: 1 (future revisions will have version nos. 2, 3, 4 etc. and will appear on each page)
Procedure written by: name and designation(this will appear on each page)
Procedure checked by: name and designation(this will appear on each page)
Procedure approved by: name and designation(this will appear on each page)

Purposeand Scope

This procedure will provide the guidelines for performing liquid penetrant testing (PT). In
particular this procedure is to performliquid penetrant inspection for detection of open to the
surface discontinuities in non porous metals and other materials as per applicable referencing
documents.

Responsibilities

A team from the Technical Division is responsible to prepare the procedure which will be
checked by the Head of the Division and approved by the Technical Manager/Director of
NCNDT.

Distribution

Each copy of the procedure will be numbered. Two copies will be present with the Head of
Division, QAM, Technical Manager. Person performing the tests may be issued one copy by
Head of the Division which will be returnable after completion of the test. Copies will be
withdrawn and replaced by the revised procedure as and when necessary.

Applicable Documents

 Relevant standards from ASME, ASTM and others

 Quality Assurance Manual
 Contract with the client
Equipment

 Black light
 Light intensity meter
 UV light Intensity Meter
 Thermometer
 Hot air dryer
 Brush

Penetrants

 Water washable visible dye penetrant.

 Solvent removable visible dye penetrant.
 Post-emulsifiable visible dye penetrant.
 Water-washable fluorescent dye penetrant.
 Solvent removable fluorescent dye penetrant.
 Post-emulsifiable fluorescent dye penetrant.

Developers

 Dry powder developers.

 Aqueous developers.
 Non-aqueous developers.

Solvent Removers; Emulsifiers

 Oil-base or lipophilic emulsifiers.

 Water-base or hydrophilic emulsifiers.

Quality Control of Consumables

 Expiry date will be written on all penetrant materials, out dated penetrant materials will not be
used.
 All penetrant materials will meet the requirements of applicable code for contaminant control
when examining nickel based alloys and austenitic stainless steel or titanium.

Surface Preparation

 In general, satisfactory results may be obtained when the surface of the part is in the as-
welded, as-rolled, as-cast or as-forged condition. Surface preparation by grinding,
machining, buffing or other methods may be necessary where surface irregularities could
mask indications.
 Surface preparation by grinding, machining, buffing or other methods may be necessary where
surface irregularities could mask indications of unacceptable discontinuities.
  Prior to each liquid penetrant inspection, the surface to be inspected and all adjacent areas
within at least 25 mm will be dry and free of all dirt, grease, lint, scale, welding flux, weld
spatter, paint, oil and other extraneous matter that could obscure surface opening or otherwise
interfere with the examination.
 The surface to be inspected and all adjacent areas within at least 25 mm will be cleaned by
solvent and lint free cloth.
 After cleaning, drying of the surfaces to be inspected will be accomplished by normal
evaporation or with forced hot or cold air. A minimum period of time will be established to
ensure that the cleaning solution has evaporated prior to the application of penetrant.

Personnel Qualification

All personnel carrying out the inspection will have valid certifications from the National
Certifying Body (NCB) of Sri Lanka.

Precautions

 The penetrant materials can be flammable and toxic. Observe all the instructions and
precautions of the manufacturer.
 Check that the filter of UV light is not damaged or cracked.
 After prolonged running the housing of UV light becomes hot, so never touch it with
unprotected flesh.
 Proper ventilation is necessary for inspection.
 Do not, under any circumstances, shine the UV light onto the eyes; it may cause blindness.

Limitations

 Test surfaces must be free of all contaminants (dirt, oil, grease, paint, rust etc.)
 Detects surface discontnuities only.
 Cannot be used on porous specimens and is difficult to use on very rough surfaces.
 Removal of all penetrant materials, following the test, is often required.
 There is no easy method to prodce permanent record.

Procedure for Inspection

a). Visual inspection; Visual inspection will be carried out to note the surface irregularities such as
spatters, undercut, cavities, non-uniform ripples or misalignment etc. which may interfere the
inspection results. The irregularities will be removed by wire brushing or grinding prior to the
commencement of penetrant testing.

b). Marking plan

b-1). Reference point: A point “O” would be marked on the surface to be tested as a reference
point.
b-2). Marking and location of indications: The indications would be marked on the surface
and their location would be measured from “O” reference.
c). Technique
c-1). Process: Either a colour contrast (visible) penetrant or a fluorescent penetrant will be
used with one of the three penetrant processes, namely, i) Water Washable, ii)Post
Emulsifiable, Solvent Removable

c-2). Penetrant application : The penetrant may be applied by any suitable means, such as
dipping, brushing or spraying.

c-3). Penetration time: Penetration time is critical. The minimum penetration time
recommended will be as per table-1.

Table 1: Recommended Dwell Times

Material Form Type of Discontinuity *Dwell Times (in minutes)
Penetrant Developer
Aluminium, casting and welds Cold shuts, porosity,
magnesium, lack of fusion, cracks
steelm, brass (all forms) 10
and bronze, 5
titanium and
high Wrought materials Laps, cracks (all forms)
temperature 10
– extrusions. 10
alloys Forgings, plate
*For temperature range from 50º F to 125º F (10ºC to 52ºC). For temperatures from 40ºF (5ºC)
up to 50ºF (10ºC), minimum penetrant dwell time shall be 2 time the value listed.

d). Excess Penetrant Removal

After the specified penetration time has elapsed, any penetrant remaining on the surface will be
removed, taking care to minimize removal of penetrant from discontinuities.

d-1). Water Washable Penetrants

Excess water washable penetrant will be removed with a coarse water spray. The water pressure will
not exceed 50 psi, and the water temperature will not exceed 110ºF (43ºC) or the excess water
washable penetrant will be removed by swabbing action. Excess Fluorescent penetrants will be
removed under black light.

d-2). Post-Emulsifiable Penetrants

a. Lipophilic Emulsification
After the required penetrant dwell time, the excess surface penetrant will be emulsified by
immersing or flooding the part with the emulsifier. Emulsification time is dependent on the
type of emulsifier and surface condition. The actual emulsification time shall be determined
experimentally. After emulsification, the mixture shall be removed by immersing in or rinsing
with water. The temperature and pressure of the water shall be as recommended by the
manufacturer. Excess Fluorescent penetrants will be removed under black light.
b. Hydrophilic Emulsification
 After the required penetrant dwell time and prior to emulsification, the parts shall be pre-rinsed
with water spray using same process as for water washable penetrants. Pre-rinsing
time will not exceed 1min. After pre-rinsing, the excess surface penetrant shall be emulsified
by immersing in or spraying with hydrophilic emulsifier. Bath concentration will be as
recommended by the manufacturer. After emulsification the mixture will be removed by
immersing or rinsing with water. Emulsification time is dependent on the type of emulsifier
and surface condition. The actual emulsification time shall be determined experimentally. After
emulsification, the mixture shall be removed by immersing in or rinsing with water.

d-3). Solvent Removable Penetrants

Excess solvent removable penetrants will be removed by wiping with a cloth or absorbent
paper, repeating the operation until most traces of penetrant have been removed. The remaining
traces will be removed by lightly wiping the surface with cloth or absorbent paper moistened
with solvent. To minimize removal of penetrant from discontinuities, care will be taken to
avoid the use of excess solvent. Flushing the surface with solvent following the application of
penetrant and prior to developing, is prohibited. Excess fluorescent penetrants will be removed
under black light.

e). Drying after Excess Penetrant Removal

e-1). For the water washable or post-emulsifying technique, the surfaces may be dried by
blotting with clean materials or by using circulating air, provided the temperature of the surface
is not raised above 125F (52C).

e-2). For the solvent removable technique, the surfaces may be dried by normal evaporation,
blotting, wiping, or forced air.

f). Developing
The developer will be applied as soon as possible after penetrant removal. With colour contrast
penetrants, only a wet developer (aqueous & non-aqueous) will be used. With fluorescent penetrants, a
wet or dry developer may be used.

f-1). Dry Developer Application: Dry developer will be applied only to a dry surface by a
hand powder bulb, powder gun, or other means, provided the powder is dusted evenly over the
entire surface being examined.
f-2). WetDeveloper Application: Prior to applying suspension type wet developer to the
surface, the developer must be thoroughly agitated to ensure adequate dispersion of suspended
particles.
f-3). Aqueous Developer Application: Aqueous developer may be applied to either a wet or
dry surface. It will be applied by dipping, brushing, spraying, or other means, providing a thin
coating is obtained over the entire surface being examined.
f-4). Non-Aqueous Developer Application: Non-aqueous developer will be applied only to a
dry surface. It will be applied by spraying. Drying will be by normal evaporation.
f-5). Developing Time:Developing time for final interpretation begins immediately after the
application of a dry developer or as soon as a wet developer coating is dried.

g) Inspection Conditions
 g-1). Final interpretation will be made within 10 to 60 min after the application of
developer. If bleed-out does not alter the examination results, longer periods are
permitted. If the surface to be examined is largeenough to preclude complete examination
within the prescribed or established time, the examination will be performed in
increments.
g-2). Visible penetrant indications will be inspected under natural or artificial white light. A
minimum of 100 foot-candles (1000 lx) illumination will be required.
g-3). With fluorescent penetrants, the process is essentially the same as colour contrast
penetrants with the exception that the examination is performed using an ultraviolet light,
called black light. The examination will be performed as follows:
a) It will be performed in a darkened area.
b) The examiners will be in the darkened area for at least 5min prior to performing the
examination to enable their eyes to adapt to dark viewing. If the examiner wears
glasses or lenses, they will not be photosensitive.
c) The black light will be allowed to warm up for a minimum of 5 min prior to use or
measurement of the intensity of the ultraviolet light emitted.
d) The black light intensity will be measured with a black light meter. A minimum of
1000 µw/cm2 on the surface of the part being examined will be required. The black
light intensity will be measured prior to use whenever the work station is changed or
the light’s power source is interrupted.

h). Interpretation

h-1). RelevantIndications: Only indications with major dimension greater than 1/16 in (1.6
mm) will be considered relevant.
h-2). Linear Indication: Indication having the length greater than three times the width is
called linear indication.
h-3). Rounded Indication: Indication that is circular or elliptical shape with the length equal
to or less than three times the width.
h-4). False Indication: Indications, which are due to poor processing. Any questionable or
doubtful indication will be re-examined to determine whether or not they are relevant.

i). Post Cleaning

After inspection post cleaning shall be carried out first by dry cloth and then by slightly moistened cloth
with remover. Post cleaning shall be carried out as quickly as possible.

j). Evaluation
All indications shall be evaluated in terms of the acceptance standards of the referencing Code or
Standard Section. Repairs will be re-inspected by the same procedure used for the original
inspection
.
k). Report/Record
Results of the PT inspection are reported in a proper format. A typical Report Form may include
the following as a minimum:
 Unique report number
  Test specimen characteristics such as material, dimensions, thickness, sketch.
 PT equipment type and specifications.
 PT process (penetrants, developers, removers) employed.
 Results obtained.
 Signing personnel.
 Report distribution

Requirements for a revised procedure

 The temperature of the penetrant and the part surface would not be below 05º C or above 52º C
throughout the inspection period. Local heating or cooling is permitted provided the part
temperature remains in the range of 05ºC to 52ºC during the penetrant testing. Where it is not
practical to comply with these temperature limitations, other temperatures and times may be
used, provided the procedure has to be qualified for that temperatures by using comparator
block. If it is desired to qualify a liquid penetrant examination procedure then use the
comparator blocks as described in this procedure.
 Whenever a change or substitution is made in the type or family group of penetrant
materials or in the processing technique.
 Whenever a change or substitution is made in the type of pre-cleaning materials or
processes.
 For any change in part processing that can close surface openings of discontinuities or
leave interfering deposits, such as the use of grit blast cleaning or acid treatments.
 Fluorescent penetrant examination shall not follow a color contrast Penetrant examination.
 Intermixing of penetrant materials from different families or different manufacturers is not
permitted.

Use of Comparator Blocks

One half of the comparator block shall be designated block “A” and the other half as block “B”.
a) If it is desired to qualify a liquid penetrant inspection procedure at a temperature of less than 40°F
(05°C), the proposed procedure shall be applied to block “B”. The block and all materials have
been cooled and held at the proposed inspection temperature until the comparison is completed. A
standard procedure which has previously been demonstrated as suitable for use shall be applied to
block “A” in the 40°F to 125°F (05°C to 52°C) temperature range. The indications of cracks shall
be compared between blocks “A” and “B”. If the indications obtained under the proposed
conditions on block “B” are essentially the same as obtained on block “A” during inspectionat 40°F
to 125°F (05°C to 52°C), the proposed procedure shall be considered qualified for use.
b) If the proposed temperature for the inspectionis above 125°F (52°C).
Block “B” shall be held at this temperature throughout the inspection. The indications of cracks
shall be compared as described while block “B” is at the proposed temperature and block “A” is at
the 40°F to 125°F (05°C to 52°C) temperature range.
c) A procedure qualified at a temperature lower than 40°F (05°C) shall be qualified from that
temperature to 40°F (05°C). To qualify a procedure for temperatures above 125°F (52°C), the
 upper and lower temperature limits shall be established and the procedure qualified at these
temperatures
d) As an alternate when using colour contrast penetrants, it is permissible to use a single comparator
block for the standard and non-standard temperatures and to make the comparison by photography.
The identical photographic techniques shall be used to make the comparison photographs.

8.1.2. Magnetic Particle Testing (MT)

Title: Procedure for Magnetic Particle Testing (this will appear on each page)
Procedure No: P-?? MT (P number will be same as in Section 5.2 and will appear on each page)
Date of issue: e.g. December 2012 (this will appear on each page)
Version: 1 (future revisions will have version nos. 2, 3, 4 etc. and will appear on each page)
Procedure written by: name and designation(this will appear on each page)
Procedure checked by: name and designation(this will appear on each page)
Procedure approved by: name and designation(this will appear on each page)

Purposeand Scope

This procedure will provide the guidelines for performing magnetic particle testing (MT) of
welds. In particular this procedure is to perform MT by using yoke magnetization technique to
detect open to the surface discontinuities on circumferential and longitudinal welded joints of
ferromagnetic material equipment of various thicknesses and sizes.

Responsibilities

A team from the Technical Division is responsible to prepare the procedure which will be
checked by the Head of the Division and approved by the Technical Manager/Director of
NCNDT.

Distribution

Each copy of the procedure will be numbered. Two copies will be present with the Head of
Division, QAM, Technical Manager. Person performing the tests may be issued one copy by
Head of the Division which will be returnable after completion of the test. Copies will be
withdrawn and replaced by the revised procedure as and when necessary.

Applicable Documents

 Relevant standards from ASME, ASTM and others

 Quality Assurance Manual
 Contract with the client

Equipment

 Electromagnetic AC yoke
 Ultraviolet Light
  ASME Field Indicator
 Light Intensity Meter
 UV Light Intensity Meter

Calibration of Electromagnetic AC Yoke

 Calibration will be performed once a year.

 Each alternating current yoke will have a lifting power of at least 10 lbs. at the maximum
pole spacing that will be used.
 Each weight will be weighed with a scale from a reputable manufacturer and marked with
the applicable nominal weight prior to first use. A weight needs verification if damage
that have caused a loss of material.

Consumables

 Black magnetic ink,

 Fluorescent magnetic ink,
 White contrast paint and
 Cleaning solvent (Aerosol cans).

Surface Preparation

 Surface preparation by grinding, machining or other methods may be necessary where

surface irregularities and other extraneous matter such as paint could mask indications
due to discontinuities.
 Prior to magnetic particle examination, the surface to be examined and all adjacent areas
within at least 25 mm shall be dry and free of all dirt, grease, lint, scale, welding flux,
weld spatter, oil and other extraneous matter that could interfere with the inspection.

Personnel Qualification

All personnel carrying out the inspection will have valid certifications from the National
Certifying Body (NCB) of Sri Lanka.

Procedure for Inspecton

a). Marking Plan

Reference Point: For circumferential weld, the point of intersection of longitudinal and
circumferential weld will be taken as reference point ‘0’ and for longitudinal weld, the top edge of the
circumferential weld which lies at the center line of longitudinal weld will be taken as reference point
‘0’.
Identification of Surfaces: For circumferential welds, the examination surfaces will be identified as
‘A’ & ‘B’ of the weld and marked on the surface.
Marking and Location of Indication: The indications should be marked on the surface and their
location should be measured in clockwise direction from ‘0’ reference.
b). Yoke Technique
The yoke technique will be applied to detect discontinuities that are open to the surface of the part.

c). Extent of Examination: 100% examination of weld and heat affected zone.

d). Area of Interest: Weld and adjacent area within at least 1 inch of the weld. This area will be
properly cleaned. Cleaning solvent will be used to remove organic materials e.g. oil grease etc. from the
surface.

e). Sequence of Operation: Continuous, the examination will be carried out by continuous methods
i.e. the magnetizing current remains on while the examination medium is being applied.

f). Application of White Contrast Paint: Weld and adjacent area within at least 1 inch of the weld
will be sprayed with white contrast paint to make adequate contrast with the inspection medium (If
needed).

g). Application of Magnetic Particle Material: Wet magnetic particle will be applied by spraying
over the area to be inspected during the application of magnetizing cur rent. Care must be taken to
prevent high velocity flow over the surfaces and to cut off the bath application before removing the
magnetic field.

h). Overlap: All examinations will be conducted with 50% overlap.

i). Repeated Tests: At least two separate tests will be performed on each area, during the 2nd test
the line of magnetic flux will be approximately perpendicular to those used during the first test.

J). Checking Magnetic Field: During the examination the adequacy or the field direction will be
verified with the help of ASME field indicator. The field indicator will be positioned on the
surface to be examined. Suitable flux or field strength is indicated when a clearly defined lines of
magnetic. Particles are formed across the copper face of indicator when the particles are applied
simultaneously with the magnetizing force.

k). Marking of Suspected Area: During the examination if the indications are observed, mark
that area with a marker.

l). Light Level Control: Interpretation for visible ink will be performed under white light. Light
intensity at the surface of the part to be examined will be at least 100fc (1000 lux).
Fluorescent magnetic particle examination will be performed under black light. Minimum black
light intensity at the test surface will be 1000 µW/cm2.

m). Demagnetization: When residual magnetism in the part could interfere with subsequent
processing or usage, the part shall be demagnetized any time after completion of the
examination.
n). Post Examination Cleaning: After examination post cleaning will be carried out either by
cloth or any other suitable cleaning agent.
o). Evaluation: All indications shall be evaluated in terms of the acceptance standards of the
referencing Code or Standard Section.

p). Recording of Indications

Non-rejectable Indications: Non-rejectable indications shall be recorded as specified by

referencing Code Section.

Rejectable Indications: Reject able indications shall be recorded. As a minimum, the type of
indications (linear or rounded), location and extent (length or diameter or aligned) shall be
recorded.

q). Report/Record
Results of the MT inspection are reported in a proper format. A typical Report Form may include
the following as a minimum:
 Unique report number
 Test specimen characteristics such as material, dimensions, thickness, sketch.
 MT equipment type and specifications.
 Calibration procedure followed.
 Results obtained.
 Signing personnel.
 Report distribution

General Precautions for MT Inspection

 The colour of the magnetic ink will provide adequate contrast with the surface being
examined; white contrast paint can be used to meet this requirement.
 Magnetic particle inspection will not be performed near flames, welding or burning.
 Magnetic particle inspectionwill be performed in well-ventilated areas.
 Fluorescent magnetic particl inspection will be performed under black light.
 The temperature of the wet particle suspension and the surface of the part shall not
exceed. The limits set by the manufacturer of the particles.

Limitations of MT

 Applicable only to ferromagnetic materials.

 Orientation and strength of magnetic field is critical.
 Detects surface and near surface defects only.
 Large currents sometimes required.
 Possibility of ‘burning’ of test specimens.
 Parts must be demagnetized after inspection which may be difficult.

8.1.3. Eddy CurrentTesting

Title: Procedure for Eddy Current Testing (this will appear on each page)
 Procedure No: P-?? ET (P number will be same as in Section 5.2 and will appear on each page)
Date of issue: e.g. December 2012 (this will appear on each page)
Version: 1 (future revisions will have version nos. 2, 3, 4 etc. and will appear on each page)
Procedure written by: name and designation(this will appear on each page)
Procedure checked by: name and designation(this will appear on each page)
Procedure approved by: name and designation(this will appear on each page)

Purpose and Scope

This Procedure is applicable for inspection of conducting non-ferromagnetic materials tubes,

conducting materials, material sorting and thickness measurements in non-conductive and non-
magnetic coatings.

Responsibilities

A team from the Technical Division is responsible to prepare the procedure which will be
checked by the Head of the Division and approved by the Technical Manager/Director of
NCNDT.

Distribution

Each copy of the procedure will be numbered. Two copies will be present with the Head of
Division, QAM, Technical Manager. Person performing the tests may be issued one copy by
Head of the Division which will be returnable after completion of the test. Copies will be
withdrawn and replaced by the revised procedure as and when necessary.

Applicable Documents

 Relevant standards from ASME, ASTM and others

 Quality Assurance Manual
 Contract with the client

Personnel Qualification

All personnel carrying out the inspection will have valid certifications from the National
Certifying Body (NCB) of Sri Lanka.

Equipment and Accessories

Eddy Current Equipment

Model of main equipment from Hocking, UK.GE Inspections, ECT USA, Olympus Canada as
available with NCNDT having frequency range appropriate for the desired inspection.

Data Acquisition / Analysis Equipment

 The outputs from the main eddy current instrument shall provide phase and amplitude
information.The eddy current instrument shall be capable of operating with bobbin coil probes in
the differential mode or the absolute mode, or both. The eddy current system shall be capable of
real time recording and playing back of inspection data and finally the eddy current equipment
shall be capable of detecting and recording dimensional changes, metallurgical changes and
foreign material deposits, and responses from imperfections originating on either tube wall
surface.

Reference Standard

A piece of same material, dimensions and heat treatment conditions with artificial discontinuities
used for establishing the test sensitivity setting, periodically checking and adjusting sensitivity
setting for testing is required essentially.

Reference standards for tubes shall contain the following artificial discontinuities which will
comprise of through wall holes of different diameters, some flat bottom holes of different depths
and some notches on the internal as well as outer surfaces. The suppliers of main equipment
usually can supply these calibration tubes as well.

Probes

Absolute/differential bobbin or surface probe shall be required of inducing current in the test
material and sensing changes in the electromagnetic characteristics of material/structure. The
sizing of the eddy current probes should range from with maximum fill factor/ min lift-off.

Inspection Procedure

Tube Inspection

a). Differential Bobbin Coil Technique

 Adjust sensitivity to produce a minimum peak-to-peak signal of 4 volts from the four 20% flat-
bottom holes or 6 volts from the four through wall drilled holes.
 Adjust the phase or rotation control so the signal response due to the through-wall hole forms
down and to the right first as the probe is withdrawn from the calibration reference standard
holding the signal response from the probe motion horizontal as in Fig. 1.
 Withdraw the probe through the calibration reference standard at the nominal examination speed.
 Record the responses of the applicable calibration reference standard discontinuities.

b). Digital System Off-Line Calibration

The eddy current examination data is digitized and recorded during scanning for off-line analysis
and interpretation. The system set-up of phase and amplitude settings shall be performed off-line
by the data analyst. Phase and amplitude settings shall be such that the personnel acquiring the
data can clearly discern that the eddy current instrument is working properly.
 c). Auxiliary Frequency(s) Calibration Procedure

 Auxiliary frequency(s) may be used to examine the tube wall. Reference standards other than
that specified in 6.1 may be used to establish examination specific sensitivity settings and an
impedance plan phase reference. Auxiliary frequency(s) may be combined (mixed) with the basis
frequency or with each other for extraneous variable suppression.
 Reference standards simulating the extraneous variables shall be used to establish mixing
parameters. Auxiliary frequency response to the extraneous variable reference standard, or basis
frequency response to the extraneous variable reference standard, or both, should be a part of the
calibration record.
 Repeat withdrawing the probe through the calibration standard at the probe speed selected for
examination. Record the auxiliary frequency response of the applicable reference discontinuities.

Fig. 1: Differential technique response from calibration reference standard

Surface and Subsurface Flaw Detection in Conducting Material

 Select the probe frequency and gain settings to provide a suitable depth of penetration within the
material so that the depth of the deepest notch is distinguishable from the next smaller notch.
 Set the gain settings on the vertical and horizontal axis so that there is a dB difference with the
discontinuity depth gain being higher.
 Move the probe away from the notches to reach a null position on the bare metal.
 Place the X-Y position of the null point on one corner of the screen.
 Adjust the phase or rotation control so that when the probe is lifted off the metal surface, the
display point travels at 90 degrees to the discontinuity depth.
 Increase the vertical or horizontal gain, as applicable, if the smallest indication or the largest
indication from the notches do not make 10% or 50% full screen height (FSH), respectively.
 Maximum response from the notches is achieved when the probe is scanned perpendicular to the
notch and centred on the notch. Differences in the vertical and horizontal gain may have to be
adjusted.
 Record the screen indication lengths from the baseline (lift-offline) for each of the notch depths
as in Fig. 2.

Fig. 2: Impedance Plane presentations of indications

Material Sorting by Conductivity Measurement

a) Analog Equipment

 Adjust suitable frequency according to equipment and probe range

 Set the lift off signal vertical with phase control knob on ferrite material
 Adjust the appropriate gain of the system which forms the lift of signal within screen
 Select the calibration samples having known conductivity
 Put the probe on each sample and note down the corresponding X and Y value of lift off from
reference point
 Calculate the phase angle through corresponding X and Y values and draw a calibration curve as
shown in Fig. 3.
 Calculate the unknown conductivity value by correlating the calibration curve
 Figure 3: Conductivity Curve
b). Digital Equipment

 Select the probe for conductivity measurement.

 Select the conductivity value of higher and lower range and enter it in data folder
of the equipment
 Put the probe on calibration and unknown samples and record the conductivity digital numeric
value shown on LCD display of the equipment

Conductive, Non Conductive and Non Magnetic Coating Thickness Measurement

The probe frequency and gain settings shall be selected to provide a suitable and repeatable
examination. The probe shall be nulled on the bare metal.

a). Impedance Plane Displays

For instruments with impedance plane displays, gains on the vertical and horizontal axes shall be
the same value. The phase or rotation control and the gain settings shall be adjusted so that the
bare metal (null) and the air point are located at diagonally opposite corners of the display.

b). Meter Displays

For instruments with analog meter displays, the phase and gain controls shall be used to provide
near full scale deflection between the bare metal and maximum coating thickness.

c). All Instruments

 For all instruments, the difference in meter readings or thickness positions on the screen shall be
adequate to resolve a 10% change in the maximum thickness.

d) Calibration Data

 Record the screen positions or meter readings and the shim thicknesses along with the bare metal
position or meter reading.
 The readings obtained depend on the pressure applied to the probe and the ratio of applying a
circuit balancing as it varies from one individual to another. Therefore the instrument will be
calibrated by the same operator who will make the measurement or by using constant pressure
probe.
 Place the probe perpendicular to the specimen surface at the point of measurement. However, it
is desirable to tilt the probe slightly and set the angle of inclination giving the maximum reading.
 Observe the change in impedance by placing the probe on other calibration standards.
 Note the amplitude and phase shift of the different thickness samples.
 Record the eddy current signals while placing the probe on the plate and note the plate
number/grid number.
 Establish a means of correlating the coating thickness with the signal amplitude by using the
basic calibration standards. This will be accomplished by using calibration curve as shown in
Figure 4.
 Verify the calibration readings every two hours. If during recalibration, a reading representing a
coating thickness change greater than ±10% from the prior calibration is observed, examinations
made after the prior calibration shall be repeated.

Fig. 4: Typical calibration curve for coating thickness showing thickness calibration
points along the curve.
Scanning Direction

The data shall be recorded while pulling the probe through the tube. For surface scanning the
probe should be placed at right angle to the test plate and moved in X and Y direction.
Scanning Speed
The scanning speed should be such that the response indicated by the ET instrument shall be
distinguishable from each other as well as from probe motion signals. For tube inspection the
pulling speed of the probe shall not exceed the limit of 35 cm/sec.

Marking

The tube number shall be marked on the tube sheet as Rows and Columns for tube inspection
while the indication detected with surface probe shall be marked on the test sample.

Support Plates

The location of support plates shall be used as reference points to locate the indication.

Examination Technique

Manual push/pull technique shall be utilized for inspection.

Recording of Signals

The recording of eddy current signals shall be done while pulling the probe through the tube. The
tube number will be noted. The signals on storage device like hard disk should be saved.

Recording Criteria

Indication reported in accordance with the requirements of the reference code shall be described
in terms of the following information as a minimum. Location along the length of the tube with
respect to support plates, depth of the indication through the tube wall signal amplitude and the
frequency from which the indication was evaluated shall be reported.

Analysis Criteria

The maximum evaluation depth of flaw shall be analyzed in terms of percentage of wall loss.
When the loss of tube wall is less than 20% the exact percentage of tube wall loss need not be
recorded. The defect under support plates need to be estimated on the basis of approximation of
the signal.

Interpretation of Signals

A means of correlating the indications depth with the signal amplitude or phase will be
established. It shall base on the basic calibration standard or other representative standards. This
should be accomplished by using calibration curve at Figure 5.
Fig. 5: Calibration Curve between thickness loss and phase angle

Limitations of ET
 Applicable to conducting materials only.
 Extremely sensitive to surface variations therefore, requires smooth surface and stringent
cleaning requirements.
 A reference standard is required for system calibration else the examination cannot be
performed.
 Ability to detect deep lying defects is limited
 Indication near tube sheet or edges of surface may not be classified due to end/edge
effect.
 Combination of defects on circumference has to be approximated due to net change in
impedance of the test circuit.

Acceptance Criteria
Acceptane criteria s to be exercised according to the applicable code and procedure as agreed to
with the client. Generally tube wall loss equal to or more than 60% is rejected.

Report/Record
Results of the ET inspection are reported in a proper format. A typical Report Form may include
the following as a minimum:
 Unique report number
 Test specimen characteristics such as material, diameter, wall thickness.
 Eddy current equipment type and settings.
 Calibration procedure followed.
 Results obtained.
 Signing personnel.
 Report distribution

8.1.4. Ultrasonic Testing (UT)

Title: Procedure for Ultrasonic Testing (this will appear on each page)
Procedure No: P-?? UT (P number will be same as in Section 5.2 and will appear on each page)
Date of issue: e.g. December 2012 (this will appear on each page)
Version: 1 (future revisions will have version nos. 2, 3, 4 etc. and will appear on each page)
Procedure written by: name and designation(this will appear on each page)
Procedure checked by: name and designation(this will appear on each page)
Procedure approved by: name and designation(this will appear on each page)

Purposeand Scope

This procedure will provide the guidelines for performing ultrasonc testing (PT). In particular
the procedure is applicable for the ultrasonic examination of weldments, cladding, forged, rolled,
cast products/components, bolts/studs and ultrasonic thickness measurement of metals and their
alloys such as carbon steel, stainless steel, aluminium etc.

Responsibilities

A team from the Technical Division is responsible to prepare the procedure which will be
checked by the Head of the Division and approved by the Technical Manager/Director of
NCNDT.

Distribution

Each copy of the procedure will be numbered. Two copies will be present with the Head of
Division, QAM, Technical Manager. Person performing the tests may be issued one copy by
Head of the Division which will be returnable after completion of the test. Copies will be
withdrawn and replaced by the revised procedure as and when necessary.

Applicable Documents

 Relevant standards from ASME, ASTM and others

 Operating manuals of equipment
 Quality Assurance Manual
 Contract with the client

Personnel Qualification

All personnel carrying out the inspection will have valid certifications from the National
Certifying Body (NCB) of Sri Lanka.

Equipment and Accessories

Ultrasonic Flaw Detectors

A pulse echo type of ultrasonic instrument shall be used. The instrument shall be capable of
operation at frequencies over the range of at least 1 MHz to 5 MHz and shall be equipped with a
stepped gain control in units of 2.0 dB or less.

Ultrasonic Thickness Meters

Any ultrasonic thickness meter which is designed for measurement and direct numerical readout
of specific ranges of thickness and materials shall be used.

Search Units

The nominal frequency shall be from 1 MHz to 5 MHz for ultrasonic flaw detection and 0.8MHz
to 10MHz for thickness measurement unless variables, such as production material grain
structure, require the use of other frequencies to assure adequate penetration or better resolution.
Search units with contoured contact wedges may be used to aid ultrasonic coupling. The same
contact wedges to be used during the examination shall be used for calibration.

Couplants

The couplant, including additives, shall not be detrimental to the material being examined.
Couplants used on nickel based alloys shall not contain more than 250 ppm of sulphur.
Couplants used on austenitic stainless steel or titanium shall not contain more than 250 ppm of
halides (chlorides plus fluorides).

Checking Of Equipment Characterictics

Screen height linearity and amplitude control linearity of the ultrasonic instrument shall be
checked according to ASME Sec.V, Article 4. This check shall be met at intervals not to exceed
one year for digital type instrument and three months for analog type instrument or prior to first
use thereafter.

General Calibration Requirements

 Ultrasonic System: Calibrations shall include the complete ultrasonic system and shall
be performed prior to use of the system in the thickness range under examination.
 Calibration Surface: Calibrations shall be performed from the surface (clad or unclad,
convex or concave) corresponding to the surface of the component from which the
examination will be performed.
 Instrument Controls: Any control which affects instrument linearity (e.g. filters, reject,
or clipping) shall be in the same position for calibration, calibration checks, instrument
linearity checks, and examination.
 Temperature: For contact examination, the temperature differential between the
calibration block and examination surfaces shall be within 25 Fº (14 Cº).

Calibration of Ultrasonic Instrument for Straight Beam and Angle Beam Probes
  Sweep Range Calibration: Sweep range calibration of ultrasonic instrument for
straight beam and angle beam probes by using IIW V1 block or side drilled holes
shall be made according to ASME Sec. V, Article 4.
 Calibration Checks: A calibration check on at least one of the basic reflectors in the
basic calibration block or a check using a simulator shall be made at the completion
of each examination or series of similar examinations, and when examination
personnel (except for automated equipment) are changed.

Visual Inspection

Visual inspection will be carried out to note surface irregularities such as spatters, undercut,
cavities, loose paints, non-uniform ripples or misalignment etc. The irregularities will be
removed by wire brushing or grinding prior to the commencement of UT.

Limitations
 The procedure is limited to UT of metals and their alloys. This procedure is not
applicable for thickness below 10 mm.
 The procedure is limited to the ultrasonic thickness measurement of materials
thickness range of (1-300 mm).

ULTARSONIC EXAMINATION METHODES FOR WELDS

General requirements for the ultrasonic examination of welds

 The volume to be scanned shall be examined by moving the search unit over the
scanning surface so as to scan the entire examination volume for each required search
unit.
 Each pass of the search unit shall overlap a minimum 10% of the transducer
dimension parallel to the direction of scan indexing.
 The rate of scanning shall not exceed 6 in./s (150mm/s).
 The scanning sensitivity level shall be set a minimum of 6dB higher than the
reference level gain setting.

Miscellaneous Requirements

Identification of Weld Examination Areas

i). Weld locations: Weld locations and the identification shall be recorded on a weld map or in an
identification plan.
ii). Marking: Starting from the reference point, the scanning surfaces on either side of the weld
will be marked at every 50mm or 100mm or 300mm according to length of the longitudinal
weld of the plate or diameter of circumferential weld of the pipe by using a permanent marker.
iii). Reference System: Each weld shall be located and identified by a system of reference points.
The system shall permit identification of each weld centreline and designation of regular
intervals along the length of the weld.

Calibration blocks and Reference blocks

Appropriates calibration blocks and reference blocks shall be used according to ASME Sec. V,
Article-4.

Distance Amplitude Correction for Straight beam or angle beam probes.

i). Position the search unit for maximum response from the SDH, which gives the highest
amplitude.
ii). Adjust the sensitivity control to provide an indication of 80% (±5%) of full screen height.
Mark the peak of the indication on the screen.
iv). Position the search unit for maximum response from other SDHs.
v). Mark the peak of the indication on the screen.
vi). Connect the screen marks to provide the 100% DAC.
vii). Mark the maximized echo tips of the holes when the gain control setting is 14dB lower than
the PRE level.
viii). Connect the screen marks to provide the 20% DAC.

Examination Techniques

i). Straight Beam Technique: Before performing the angle beam examination, a straight beam
examination shall be performed on the volume of base material through which the angle beams
will travel to locate any reflectors that can limit the ability of the angle beam to examine the weld
volume.
ii). Angle Beam Technique: When the referencing code section specifies a distance amplitude
technique, weld joints shall be scanned with an angle beam search unit in both parallel and
transverse direction (4 Scans) to the weld axis. The search unit selected shall be 45 deg or an
angle appropriate for the configuration being examined and shall be capable of detecting the
calibration reflectors, over the required angle beam path.

ULTRASONIC EXAMINATION OF CLADDING

General requirements for the ultrasonic examination of cladding

i). When the component material is clad, the block shall be clad by the same welding procedure
as the production part.
ii). It is desirable to have component materials which have been clad before the drop outs or
prolongations are removed.
iii). When the cladding is deposited using an automatic welding process, and, if due to block
size, the automatic welding process is impractical, deposition of clad may be done by the manual
method.

Calibration Blocks for Cladding

i). Calibration Block for Technique One: The basic calibration block shall be section of pipe
of the same nominal size and schedule. The block size and reflector locations shall be adequate
to perform calibration for beam angles used.
ii). Alternate Calibration Blocks for Technique One: Either flat bottom hole or a side drilled
hole may be used. The thickness of the weld overlay shall be at least as thick as that to be
examined. The thickness of the base material shall be at least twice the thickness of the cladding.
Calibration Block for Technique Two
A flat bottom hole drilled to the weld metal overlay interface shall be used. The hole can be
drilled from either side i.e. from base material or weld overlay side. The thickness of the weld
overlay shall be at least as thick as that to be examined. The thickness of the base material shall
be within 25 mm of the calibration block thickness when the examination is performed from the
base material surface. The thickness of the base material on the calibration block shall be at least
twice the thickness of the cladding when examined from the clad surface.

Calibration for Cladding

i). Calibration for Technique One: The search unit shall be positioned for maximum response
from the calibration reflector. The gain control shall be set so that this response is 80% (±5%) of
full screen height.
ii). Calibration for Technique Two: The search unit shall be positioned for the maximum
response of the first resolvable indication from the bottom of the calibration reflector. The gain
shall be set so that the response is 80% (±5%) of FSH.

Examination Procedure
i). Technique One: The examination shall be performed from the clad surface with the plane
separating the element of the dual element search unit positioned parallel to the axis of the weld
bead. The search unit shall be moved perpendicular to the weld direction.
ii). Technique Two: The examination may be performed from either the clad or unclad surface
and the search unit may be moved either perpendicular or parallel to the weld direction.
Technique one is used when examination of lack of bond and clad flaw indication is required.
Technique two is used when examination for lack of bond is required.

Evaluation of Indications
i). Distance Amplitude Techniques: All indications greater than 20% of the reference level
shall be investigated to the extent that they can be evaluated in terms of the acceptance criteria of
the referencing code section.
ii). Evaluation of Laminar Reflectors: Reflectors evaluated as laminar reflector in base
material which interferes with the scanning of examination volumes shall require the angle beam
examination technique to be modified such that the maximum feasible volume is examined, and
shall be noted in the record of the examination.

ULTRASONIC EXAMINATION OF HEAVY STEEL FORGINGS

General requirements for the ultrasonic examination of heavy steel forgings

 To ensure complete coverage of the forging volume, index the search unit with at
least 15% overlap with each pass.
 For manual scanning, do not exceed a scanning rate of 6 in./s (150mm/s).
 If possible, scan all sections of forgings in two perpendicular directions.
 Scan disk forgings using a straight beam technique from at least one flat face and
radially from the circumference, whenever practicable.
 Scan cylindrical sections and hollow forgings radially using a straight beam
technique. When practicable, also examine the forging in axial direction. In addition,
examine hollow forgings by angle beam technique from the outside diameter surface.
Straight Beam Examination by Back Reflection Technique
Establish the instrument sensitivity with the attenuator set at an appropriate level, for example 5
to 1 or 14 dB, adjust the instrument controls to obtain a back reflection approximately 75% of the
full screen height from the opposite side of the forging. Scan the forging at the maximum
amplification setting of the attenuator. Carry out the evaluation of discontinuities with the gain
control set at the reference level. Recalibration is required for significant changes in section
thickness or diameter.

During examination of the forging, monitor the back reflection for any significant reduction in
amplitude. Reduction in back reflection amplitude may indicate not only the presence of a
discontinuity but also poor coupling of the search unit with surface of the forging, nonparallel
back reflection surface, or local variations of attenuation in the forging. Recheck any areas
causing loss of back reflection.

Angle Beam Examination

Perform the examination from the circumference of rings and hollow forgings that have an axial
length greater than 2 in. (50mm) and an outside to inside diameter ratio of less than 2.0 to 1.
Calibrate the instrument for the angle beam examination to obtain an indication amplitude of
approximately 75% full screen height from a rectangular or a 60 deg V-notch on inside diameter
(ID) in the axial direction and parallel to the axis of the forging. Perform the examination by
scanning over the entire surface area circumferentially in both clockwise and counter clockwise
directions from the OD surface. Examine forgings, which cannot be examined axially using a
straight beam, in both axial directions with an angle beam search unit.

Recording of Indications

Straight Beam Examination

i). For Individual Indications: Individual indications equal to or exceeding 10% of a nominal
back reflection from an adjacent area free from indications shall be recorded.
ii). For Planar, Traveling or Clustered Indications: Determine the location of the edges and
the major and minor axes using the half amplitude (6 dB drop) method and report the following;
 The variation in depth or planar area, or both, of traveling indications.
 The length of major or minor axes of planar indications.
 The volume occupied by indication levels and the amplitude range.

Angle Beam Examination

Record discontinuity indications equal to or exceeding 50% of the indication from the reference
line.

ULTRASONIC EXAMINATION OF ROLLED STEEL PLATES

General requirements for the ultrasonic examination of rolled steel plates

 Perform the inspection in an area free of operations that interfere with proper
performance of the test.
 Unless otherwise specified, make the ultrasonic examination on either major surface
of the plate.
  The plate surface shall be sufficiently clean and smooth to maintain a first reflection
from the opposite side of the plate at least 50% of full scale during scanning.
 A nominal test frequency of 2MHz is recommended. When testing plates less than ¾
in. (20mm) thick, a frequency of 5 MHz may be necessary. Thickness, grain size or
microstructure of the material and nature of the equipment or method may require a
higher or lower test frequency.

Examination Procedure
 Scanning shall be along continuous perpendicular grid lines on nominal 225mm
centers, or at the option of the manufacturer, shall be along continuous parallel paths,
transverse to the major plate axis, on nominal 100mm centers, or shall be along
continuous parallel paths parallel to the major axis, on 75mm or smaller centers.
Measure the lines from the center or one corner of the plate with an additional path
within 50mm of all edges of the plate on the searching surface.
 Conduct the general scanning with an instrument adjustment that will produce a first
reflection from the opposite side of a sound area of the plate from 50% to 90% of
full scale. Minor sensitivity adjustment may be made to accommodate for surface
roughness.
 When a discontinuity condition is observed during general scanning, adjust the
instrument to produce a first reflection from the opposite side of a sound area of the
plate of 75 ± 5% of full scale. Maintain this instrument setting during evaluation of
the discontinuity condition.

Recording of Indications
 Record all discontinuities causing complete loss of back reflection.
 For plate 20mm thick and over, record all indications with amplitude equal to or
greater than50% of the initial back reflection and accompanied by a 50% loss of back
reflection.
 Where grid scanning is performed and recordable conditions as above are detected
along a given grid line, the entire surface area of the squares adjacent to thisindication
shall be scanned.
 Where parallel path scanning is performed and recordable conditions as aboveare
detected, the entire surface area of a 225 x 225mm square centered on this indication
shall be scanned. The true boundaries where these conditions exist shall be
established in either method by the following technique:
 Move the transducer away from the center of the discontinuity until the height of the
back reflection and discontinuity indications are equal. Mark the plate at a point
equivalent to the center of the transducer. Repeat the operation to establish the
boundary.

ULTRASONIC EXAMINATION OF CASTINGS

General requirements for the ultrasonic examination of casting

 Test surface of casting shall be free of material that will interfere with the ultrasonic
examination. They may be as cast, blasted, ground or machined.
  The ultrasonic examination shall be conducted prior to machining that prevents an
effective examination of the casting.
 To assure complete coverage of the specified casting section, each pass of the search
unit shall overlap by at least 10% of the width of the transducer.
 The rate of scanning shall not exceed 6 in./s (150mm/s).
 The ultrasonic beam shall be introduced perpendicular to the examination surface.

Calibration blocks and Reference blocks

Appropriates calibration blocks and reference blocks shall be used according to ASME Sec. V,
Article-23(SA 609).

Distance Amplitude Correction Curve

Calibrate the time base for a suitable range. Using the set of reference blocks spanning the
thickness of the casting being inspected, mark the flat bottom hole indication height for each of
the applicable blocks on the cathode ray tube shield. Draw a curve through these marks on the
screen. The maximum signal amplitude for the test blocks used shall peak at approximately
three-fourths of the screen height above the sweep by use of the attenuator. This curve shall be
referred to as the 100% DAC curve.

Examination Procedure
The casting examination surface will normally be rougher than that of the test blocks;
consequently, employ a transfer mechanism to provide approximate compensation. In order to
accomplish this, first select a region of the casting that has parallel walls and a surface condition
representative of the rest of the casting as a transfer point.

Select the test block whose overall length, most closely matches the reflection amplitude through
the block length.

Place the search unit on the casting at the transfer point and adjust the instrument gain until the
back reflection amplitude through the casting matches that through the test block. Using this
transfer technique, the examination sensitivity in the casting may be expected to be within ± 30%
or less of that given by the test blocks.

Do not change those instrument controls and the test frequency set during calibration, except the
attenuator or calibrated gain control, during acceptance examination of a given thickness of the
casting. Make a periodic calibration during the inspection by checking the amplitude of the
response from the ¼ in. (6.4mm) diameter flat bottom hole in the test block utilized for the
transfer.

During examination of areas of the casting having parallel walls, recheck areas showing 75% or
greater loss of back reflection to determine whether loss of back reflection is due to poor contact,
insufficient couplant, misoriented discontinuity, etc. If the reason for loss of back reflection is
not evident, consider the area questionable and further investigate.

Recording of Indications
Record the total number, location, amplitude, and area when possible to delineate boundaries by
monitoring the movement of the centre of the search unit of all indications equal to or greater
than 100% of the DAC.

ULTRASONIC EXAMINATION OF BOLTS / STUDS

Calibration Blocks
Calibration blocks shall be full scale or partial section bolts, which are sufficient to contain the
maximum sound beam path and area of interest, and to demonstrate the scanning technique.

Material
The calibration block shall be of the same material specification, product form, and surface finish
as the bolts to be examined.

Reflectors
Calibration reflectors shall be straight cut notches. A minimum of two notches shall be machined
in the calibration standard, located at the minimum and maximum metal paths, except that
notches need not be located closer than one bolt diameter from either end. Notch depths shall be
as follows;

Bolt Size Notch Depth

Less than 2 in. (50mm) 1 thread depth
2 in. (50mm) and greater, 5/64 in. (2mm)
but less than 3 in. (75mm)
3 in. (75mm) and greater 3/32 in. (2.5mm)

Distance Amplitude Correction Curve

A DAC curve shall be established using the calibration reflectors. The sound beam shall be
directed towards the calibration reflector that yields the maximum response, and the instrument
shall be set to obtain an 80% of full screen height indication. This shall be the primary reference
level. The search unit shall then be manipulated, without changing instrument setting, to obtain
the maximum response from the other calibration reflectors to generate a DAC curve. The
calibration shall establish both the sweep range calibration and the distance amplitude correction.

General requirements for the ultrasonic examination of bolts/studs

 The volume to be scanned shall be examined by moving the search unit over the
scanning surface so as to scan the entire examination volume for each required search
unit.
 Each pass of the search unit shall overlap a minimum 10% of the transducer
dimension parallel to the direction of scan indexing.
 The rate of scanning shall not exceed 6 in./s (150mm/s).
 The scanning sensitivity level shall be set a minimum of 6dB higher than the
reference level gain setting.

Examination Procedure
  Scanning of Threaded Area: A normal beam probe single crystal or twin crystal (1
MHz to 5 MHz & Ø=08mm to 24mm), calibrated for appropriate range will be used
for the scanning of threaded area for the detection of cracks in the thread roots.
 Scanning of Un-Threaded Area with Normal Beam Probe: A normal beam probe
single crystal or twin crystal (1 MHz to 5 MHz & Ø=08mm to 24mm), calibrated for
apporiate range will be used for the detection of lamination.
 Scanning of Un-Threaded Area with Angle Beam Probe: Apporiates angle beam
probes 35°, 45° or 60° (2 MHz to 4 MHZ), calibrated for appropriate range will be
used for the detection of cracks.

THICKNESS MEASUREMENTS

Calibration Blocks
The following blocks of carbon steel, stainless steel, aluminum etc. will be used for calibration.
 IIW V1 (K1-Zert)
 DIN V2 (K2-Zert)
 VW

Calibration
Calibration of the thickness meter will be carried out for one point or two points as per
requirement according to the operating manual.

Wall Thickness Measurement

 Calibrate the instrument
 Apply a thin layer of couplant onto the surface of the material.
 Place the probe carefully but firmly onto the surface of the material. Apply a constant
pressure in order to obtain a suitable measurement value.
 The coupling symbol appears when there is sufficient coupling. At the same time the
thickness reading is displayed.
 When the measurement reading become stable, store it in a already created file.

Accept/Reject Criteria
Accept/Reject shall be made according to the applicable codes & standards or any document
provided by the client.

Examination Of Repairs
Repair shall be re-examined by the same procedure used for the original examination.

Report/Record
Results of the UT inspection are reported in a proper format. A typical Report Form may include
the following as a minimum:
 Unique report number
 Test specimen characteristics such as material, dimensions, wall thickness.
 UT equipment type and settings.
 Calibration procedure followed.
  UT technique/s followed.
 Results obtained.
 Signing personnel.
 Report distribution

Limitations of Ultrasonic Testing Method

 Unfavourable geometry of the test specimen causes problems during inspection.

 Inspection of materials having undesirable internal structure is difficult.
 It requires the use of a couplant.
 The probe must be properly coupled during scanning.
 Defect orientation affects the defect detectability.
 Equipment is relatively quite expensive.
 Highly skilled manpower is required.
 Reference standards and calibration required.
 Rough surfaces can be a problem and surface preparation is necessary.

8.1.5. Radographic Testing

Title: Procedure for Radiographic Testing (this will appear on each page)
Procedure No: P-?? RT (P number will be same as in Section 5.2 and will appear on each page)
Date of issue: e.g. December 2012 (this will appear on each page)
Version: 1 (future revisions will have version nos. 2, 3, 4 etc. and will appear on each page)
Procedure written by: name and designation(this will appear on each page)
Procedure checked by: name and designation(this will appear on each page)
Procedure approved by: name and designation(this will appear on each page)

Purposeand Scope

This procedure will provide the guidelines for performing radiographic testing (RT). In
particular this procedure is to perform radiographic inspection of butt welds of metals and their
alloys such as carbon steel, stainless steel, aluminium etc. up to 230 mm thick steel or equivalent.

Responsibilities

A team from the Technical Division is responsible to prepare the procedure which will be
checked by the Head of the Division and approved by the Technical Manager/Director of
NCNDT.

Level-1 or higher certified personnel will carry out radiographic testing, marking and sizing of
indications.

A level-2 or higher certified personnel will carry out the evaluation of indications.
Physical identification, marking of welds and surface preparation will be the responsibility of the
representative of the client.

The client will provide suitable facilities for examiner(s)/inspector(s) in case the inspecton is
performed at the premises of the client.

Distribution

Each copy of the procedure will be numbered. Two copies will be present with the Head of
Division, QAM, Technical Manager. Person performing the tests may be issued one copy by
Head of the Division which will be returnable after completion of the test. Copies will be
withdrawn and replaced by the revised procedure as and when necessary.

Applicable Documents

 Relevant standards from ASME, ASTM and others.

 Quality Assurance Manual.
 Operating manual/s of equipment.
 Contract with the client.

Personnel Qualification

All personnel carrying out the inspection will have valid certifications from the National
Certifying Body (NCB) of Sri Lanka.

Radiation Safety Considerations for Radiographic Testing

Radiographic Testing involves the use of ionizing radiation (X and γ) which are harmful for
living beings. Therefore mandatory special precautions need to be taken. These are enumerated
below:

The area will be cordoned off when the radiographic exposure is in progress to warn the people
about the presence of radiation. For this purpose barrier tape, warning lamps, radiation danger
signs and audio alarms may be used.

The occupational exposure of any radiation worker shall be so controlled that the following
limits are not exceeded.
 An effective dose of 20 mSv per year averaged over five consecutive years
 An effective dose of 50 mSv in any single year.

The estimated average doses for general public shall not exceed.
 An effective dose of 1 mSv in a year.
 In special circumstances, an effective dose of up to 5 mSv in a single year provided that
the average dose over five consecutive years does not exceed 1 mSv per year.
There must be two separate barriers for radiation workers and general public such that their
doses shall not exceed 1.67 mSv per month & 0.083 mSv per month respectively.

During the exposure of test job the following precautions against the effects of gamma-rays/ X
rays will be observed.
 Each radiographer will wear film badge/dosimeter issued to him. Care will be taken not
to change the film badge/dosimeter with others. In case of pocket dosimeter, reading will
be noted and recorded before and after each inspection shift.
 Properly calibrated survey meters will be used to mark and if possible cordon off the area
to warn the people about the presence of radiation.

Keeping in view over exposure to radiographers which have been reported by numerous
regularity authorities, following shall be strictly observed.
 Gamma alarm shall be kept “ON” during each operation of radiographic examination.
 Survey meter shall be available and in “ON” position during each operation of
radiographic examination.
 At least one pocket dosimeter shall be kept and checked after each operation of
radiographic inspection.
 A regular film badge of TLD detector will be used by all radiographers.
 During any abnormality the workers shall stay in safe area.
 Any abnormality shall be iimmediately reported to relevant officials.

Storage of Radioactive Source will be given due consideration by taking the following measures.
 The radioactive source will be stored in proper and controlled storage area.
 Storage area will be a covered, cool and dry place and safe from natural disasters.
 Storage will be kept locked to avoid access of un-authorised persons or general public.

General Safety Precautions

 Before undertaking testing in industrial area, always wear safety helmet and safety shoes.
 Observe the necessary precautions against electrical shock.
 Always ensure that there are no “live wires” (exposed or without insulation)present in the
area where the testing is being conducted.
 Electrical hazards by ignition of combustible materials may be kept in view.
 Be careful in pulling long electrical cords used for electrical extensions especially in
cutting corners. The cord might accidentally come in contact with sharp objects that
might uncover the cord and thus expose the wires.
 Avoid working on wet grounds or floors. If such areas cannot be avoided, place pieces of
plywood over the wet surfaces before doing the testing.

EXAMINATION PROCEDURE

Surface Condition of the Weld and Heat Affected Zone

The surface of the area to be inspected comprises of weld bead plus heat affected zone (HAZ) on
each side.
The surface of the area to be examined will be clean and free from rust and foreign
material/spatters on both inside (where accessible) and outside.

Blending of the weld edges with base metal and the weld ripples or weld surface irregularities on
both inside (where accessible) and outside will be removed by any suitable process to such a
degree that the resulting radiographic image due to any irregularities cannot mask or be confused
with the image of any discontinuity.

The identification of welds to be examined will be marked clearly for each weld by the
representative of the client.

Films Viewing Facilities

Films viewing facilities will provide subdued background lighting of an intensity that will not
cause troublesome reflections, shadows, or glare on the radiograph. Equipment used to view
radiographs for interpretation will provide variable light source sufficient for the essential IQI
wire to be visible for the specified density range. The films viewing conditions will be such that
light from around the outer edge of the radiograph or coming through low-density portions of the
radiograph does not interfere with interpretation.

Calibration of Equipments
The equipments used (survey meter, dosimeter, transmission densitometer, thermometer and
illuminator) for radiographic inspection, examination and testing will have valid calibration
stickers.

Equipment and Accessories

Sources of Radiation
 X-ray machine: make, kV, focal spot size, beam angle, tube current.
 Gamma ray source (Ir-192 or Co-60): activity (on the date of inspection), effective
source size, beam angle, typical steel thickness.

Transmission Densitometer
Densitometer will be properly calibrated to measure optical densities up to 4.0.

Illuminator/Film Viewer
Properly calibrated illuminator/ viewer will be capable to read optical densities up to 3.0 or
higher.

Radiation Monitoring Equipment

Properly calibrated radiation dose rate meter will be used to monitor the radiation area. For
personnel monitoring film badges/TLDS or pocket dosimeters will be used.

Industrial Radiographic Films& Screens

Following industrial radiographic films or their equivalent will be used for radiographic testing:
Agfa Gevaert D7+Pb, D5+Pb, D4+Pb
Fuji Ix-100+Pb, Ix-80+Pb, Ix-50+Pb
Note: The film will be considered useful as long as the fog density of the film is not greater
than 0.3.

Image Quality Indicator (IQI)

ASTM/DIN/EN or equivalent wire type IQI will be used. Selection of IQI as per Annexure-I and
the material of IQI used will be of the same group as that of the test specimen.
Note: The thickness on which the selection of exposure conditions and image Quality Indicator
(IQI) is based on the base metal thickness plus the estimated weld reinforcement.

Film Processing Unit

Manual/Automatic processing unit will be used for processing of exposed industrial radiographic
films.

Radiographic Exposure Techniques

Depending on the shape and conditions of the welds, the following techniques will be followed:

For Longitudinal Welds

Single Wall Single Image (SWSI) Technique: In single wall single image (SWSI) technique
the radiation passes through single wall and single wall is viewed for interpretation (Fig. 1).
Placement of IQI: The IQI will be placed on source side.
Placement of Location Markers: Location markers will be placed on source side.

Fig. 1: Single Wall Single Image Technique (SWSI)

Double Wall Double Image (DWDI) Technique (For Pipes Less Than or Equal to 89 mm
Diameter)
In the double-wall double image viewing technique (Fig. 02) the radiation passes through both
walls of weld and the both walls are viewed for interpretation.
Number of Exposures
The radiation beam may be off-set from the plane of the weld at an angle sufficient (1/5 to 1/3 of
the sfd) to separate the images of the source side and film side walls of the pipe. A minimum of
two exposures taken 90 degree to each other will be made for each weld.
As an alternative, the weld may be given exposure with the radiation beam positioned so that the
images of both walls are superimposed. A minimum of three exposures taken at either 60 degree
or 120 degree to each other will be made for each weld.
Placement of IQI: IQI will be placed on source side.
Location Markers: Location markers, which appear on the film, will be placed on source side.
Coverage: 100% weld and Heat Affected Zone (HAZ) on each side.

(a) (b)
Fig.2: Double Wall Double Image Technique (DWDI)

Double Wall Single Image (DWSI) Technique (For Pipes More than 89 mm Diameter)
If geometric arrangement is not possible for double wall double image then double wall single
image will be used but the sensitivity and density shall be achieved as per procedure.

In the double-wall single image viewing technique (Fig. 3) the radiation passes through both
walls of weld and only the weld on the film side is viewed for interpretation.
Numbers of exposure
In general, at least three exposures will be taken 120 degree to each weld depending on the
dimension of the piping. The actual number of exposures and hence radiographs to cover
complete weld may increase depending on the dimensions of pipe.
Placement of IQI: IQI will be placed on the film side of the weld to be examined.
Location Markers: Location markers, which appears on the film to indicate the effective
interpretation area, will be placed on the film side.
Coverage: 100% weld and Heat Affected Zone (HAZ) on each side.

Fig. 3: Double Wall Single Image Technique (DWSI)

Single Wall Single Image (SWSI) Technique (Directional)

The technique is mostly applied for Circumferential welds of larger diameter shells / pipes where
inside approach is possible.
 (a) (b)
Fig. 4: Single Wall Single Image (Directional)

Placement of IQI: The IQI will be placed on the source side of the weld to be examined.
Location Markers: The location markers will be placed on source side in case of Fig. 4(a) and
the location markers will be placed on the film side in case of Fig. 4(b).

Single Wall Single Image (SWSI) Technique (Panoramic)

For larger diameter shells / pipes, where inside approach is possible, one panoramic exposure
will cover the whole of the circumferential weld.

Fig. 5: Single Wall Single Image (Panoramic)

Placement of IQI: IQI shall be placed on the source side of the weld to be examined. At least
three IQIs, shall be placed, spaced approximately 120 degree apart.
Location Markers: The location markers will be placed on either the source side or film side.
Exposure
The determination of exposure time will take into account the following factors:
 Film type.
 Wall thickness to be penetrated by radiation.
 Source activity.
 Distance from source to film.
 Film density required.

The exposure to be given for a particular test specimen will be determined from the exposure
charts of the radiation source or logbook or trial shot method.
Calculation of Minimum Source-to-Film Distance (SFDmin)
Calculate Sfdmin using the following formula:
Sfdmin = (F/Ug+1) x ofd
Where F = effective focal spot size of the radiation source
ofd = object to film distance
Ug = Geometric unsharpness of the radiograph
Geometric unsharpness of the radiograph will not exceed the following:
Material Thickness, Ug Maximum, inch
inch (mm) (mm)
Under 2 (50) 0.020 (0.51)
2 through 3 (50 to 75) 0.030(0.76)
Over 3 through 4 (75 to 100) 0.040(1.02)
Greater than 4 (100) 0.070(1.78)

Selection of Appropriate SFD

Select an appropriate Sfd ≥ Sfdmin taking into consideration the ease in handling during exposure
set up.
Total Number of Radiographs for the Coverage of the Total Weld Length
The density of a radiograph measured on the area of interest at both extremities, will at least be
1.8 forX-rays and 2.0 for gamma rays. The interpretable length of radiographs between these
minimum required density points is the coverage. If total weld is to be covered in two or more
than two radiographs then an overlap of 10% will be given.
Identification of Radiographs (Marking System)
The following information will appear permanently on the radiographs as radiographic images
along side the weld.
 Client name
 Weld No./ System code
 Radiograph No.
 Date on which the radiograph is taken
 Markers showing marking the length of the weld to be interpreted i.e. lead tape, arrow
and lead numbers.
 The letter R will be used to designate a repair and will include 1, 2, etc. for number of
repairs.
 Radiographer and his department.
Note: If somehow such informations cannot appear on radiographs as an image, this will be
written by permanent marker on the radiograph as well as on the test specimen.
Minimizing the Effects of Scattered Radiation
Following steps will be taken to minimize the effect of scattered radiation;
 Films with lead screens (VACUPAC) will be used.
 A lead sheet will be placed behind the film, where back scattering can affect the
radiographic sensitivity.
Check for Back Scattered Radiation
A lead letter ‘B’ with minimum dimension of 1/2 in. (13mm) in height and 1/16 in. (1.5mm)
thickness will be attached to the back of each film holder during each exposure to determine, if
back scatter radiation is exposing the film. The letter will be placed in such a way that it will not
mask the image of the area of interest i.e. an area between limits of 5-13 mm depending upon the
thickness of the job on each side of the weldment. Radiograph will be checked for the presence
of the image of letter B. If a light image of the letter “B” appears on a darker background of the
radiograph, protection from backscatter is insufficient and the radiograph will be considered
unacceptable. A dark image of the letter “B” on a lighter background is not a cause for rejection.
Placement of Reference Markers
Lead tape will be used as reference markers. It will be placed on one side of the pipe from the
edge of the weldment at distance of at least 5-13 mm depending upon the wall thickness of the
job. The position of the lead tape will be correctly marked on the surface of the job with a
permanent marker.
Placement of Identification Markers
Those identification markers, which have to appear as radiographic images, will be placed on the
test specimen at a distance of at least 5-13 mm depending upon the thickness of the test specimen
on any side from the edge of the weldment.

Selection of IQI
The IQI shall be selected as per following Tables
Placement of IQI
 Wire type IQI will be placed across the weld and near the end of the length of the
weld to be radiographed in such a way that the thinnest wire in the IQI is farthest
from the beam axis and the identification markers of the IQI do not mask any
portion of the image of the weld to be interpreted. The IQI will always be placed
on the source side (except in “double wall single image” technique in pipes /
shells provided no access is possible to the inside of the pipes / shells). Whenever
IQI is placed on film side, place a lead letter “F” on the film to appear as
radiographic image.
 Plate type (Hole type) IQI should be placed alongside the weld at about 3 mm
from the edge of the weld. For hole type penetrameter, it is usual to place the
penetrameter on a shim to equalize with the thickness of the weld.

Processing of Exposed Films

Exposed films will be processed according to the procedure described below, using developer G-
230 and fixer G-305 of Agfa Gevaert or other equivalent standard developer and fixer.

Following steps are carried out in the dark room.

 Stir thoroughly all the processing tanks.
 Check the temperature of the developer tank. It will be between 18C and 30C, and
preferably close to 20C. The temperature can be brought within this range by either
cooling or heating.
 After measuring the temperature, find the developing time from the following table:
 Temperature (C) Developing Time(Min)
18 6.0
20 5.0
22 4.0
24 3.5
26 3.0
28 2.5
30 2.0

 In general, development will be avoided above 30C and below 18C.

 Switch off ordinary lights
 Switch on safe light
 Take out the exposed film from the cassette/wrapper and intensifying screens
carefully.
 Put the film into a hanger.
 Set the timer
 Immerse the film gently into the developing tank.
 Tap the film hanger vigorously for 15 to 30 seconds to dislodge any air bubbles
clinging to the film.
 Agitate film for approximately 10 seconds at each minute of development.
 At the end of developing time, remove the film from developing tank, and drain
excess developer back into the tank for approximately 5 second.
 Immerse the film into the stop bath for about 30 seconds. Agitate the film moderately
when it remains in the stop bath. If stop bath solution is not available wash the film in
washing tank for 30 to 60 seconds.
 After proper rinsing transfer the film into the fixing bath and agitate it vigorously for
about 15 to 30 seconds and then let it remain in the fixer bath for about 6 minutes.
 After proper fixing, drain out the film and transfer it to washing tank. Depending
upon the temperature, wash the film in the washing tank for the time as given below:
 From 10C - 12C Wash for 30 minutes
 From 13C - 25C Wash for 20 minutes
 After washing, dip the film into the photoflo solution for 30 seconds approximately.
 Put the film in the drying cabinet and let it dry. The temperature of the drying cabinet
will not be more than 40C. If drying cabinet is not available film may be dried in
open clean air.

Evaluation of Radiographs
Quality of Radiographs
All radiographs will be free from mechanical, chemical, or other blemishes to the extent that they
do not mask and are not confused with the image of any discontinuity in the area of interest of
the object being radiographed. Such blemishes include, but are not limited to:
 Fogging (Density of unexposed film will not be more than 0.3).
 Processing defects such as streak, watermarks, or chemical stains.
 Scratches, finger marks, kinks, dirtiness, or tears.
  False indications due to defective screens.
Radiographic Density
Density Limitations
The transmitted film density through the radiographic image adjacent to the designated wire of a
wire IQI and the area of interest will be 1.8 minimum for single film viewing
for radiographs made with an X ray source and 2.0 minimum for radiographs made with a
gamma ray source. For composite viewing of multiple film exposures, each film of the
composite set will have a minimum density of 1.3. The maximum density will be 4.0 for either
single or composite viewing. A tolerance of 0.05 in density is allowed for variations between
densitometer readings.
Density Variation
If the density of the radiograph anywhere through the area of interest varies by more than minus
15% or plus 30% from the density adjacent to the designated wire of a wire IQI, within the
minimum/maximum allowable density ranges then an additional IQI will be used for each
exceptional area or areas and the radiograph retaken. When calculating the allowable variation in
density, the calculation may be rounded to the nearest 0.1
IQI Sensitivity
Radiography will be performed with a technique of sufficient sensitivity to display the
designated wire of a wire IQI (Annexure-II & III). The radiographs will also display the
identifying numbers and letters of the selected IQI.
Excessive Backscatter
If a light image of the letter “B” appears on a darker background of the radiograph, protection
from backscatter is insufficient and the radiograph will be considered unacceptable. A dark
image of the letter “B” on a lighter background is not cause for rejection.

Accept/Reject Criteria
Defects revealed in the radiographs will be evaluated according to relevant accept/reject criteria
of applicable code or any other document provided by the client.

Post Examination Requirements

When the testing activities are ended, all examined areas will be as clean as that before testing
(adhesive tape etc. is removed).

Reports/Records
Logbook and radiographic testing reports are prepared for official record. Results of the RT
inspection are reported in a proper format. A typical Report Form may include the following as a
minimum:
 Unique report number
 Test specimen characteristics such as material, dimensions, wall thickness, sketch.
 RT equipment type and settings.
 RT technique/s followed along with sketches.
 Film type and processing procedure followed.
 Types of screens and filters used.
 Results obtained.
 Signing personnel.
 Report distribution.
 Storage of Unexposed RT Films
i) Radiographic films will be stored in cool and dry place.
ii) Radiographic films will be protected from light, heat, radiation, humidity and
fumes.

Limitations of Radiograohic Testing Method

 X-rays and gamma rays are hazardous to human health.
 It cannot detect planar defects readly.
 Thickness range that can be inspected is limited.
 Certain areas in many specimens cannot be inspected because of geometric
considerations.
 Sensitivity of inspection decreases with thickness of test specimen
 It is more costly.
 It cannot be easily automated.
 It requires considerable skill for the interpretation of radiographs.
 Depth of discontinuity not indicated.
 The area has to be evacuated and no other work is possible within specified area
during radiographic testing.
 Access to both sides of the test specimen is required.

8.2. Specific test procedures

8.3. Non-standard test procedures
8.4. Updating and circulation of procedures
8.5. Procedures for work order control
8.6. Safety procedures (these have been given under RT procedure)
8.7. Others???????????????

9.0. Handling inspection samples and items

9.1. Identification of items
9.2. Initial assessment of suitability of items for inspection
9.3. Handling and storage of the items

HANDLING, STORAGE, PACKAGING,

PRESERVATION & DELIVERY
The identification of materials/ equipment, where it is not obvious, is confirmed by the presence
of a manufacturers/ suppliers part number or description label, or other marking for each item.
The identification of the item may be on the packaging or on the item itself, and this
identification remains in place for as long as possible, provided it does not hamper effective use
of the item. Materials and consumables are not identified by the company where they are obvious
to a trained/ experienced employee, however, should a risk of misinterpretation exist between
two or more types of material these will be marked in a suitable manner to ensure that no
ambiguity exists.

All items with serial numbers are recorded individually.

Materials and goods received, whether the property of the company or others, will, as far
as practicable, be protected and their quality preserved until such time as they are
transferred to a customer, or disposed of to a third party. The objective is to prevent
deterioration and damage whilst in storage, or in the process of transportation,
installation, commissioning or maintenance. Handling of industrial jobs is explained in
Chapter seven. The tests are initiated by the written application of the client. The client
specifies the information related to the test object, the test and defect assessment method.
The section head informs the client about the possibility of performing the tests, cost and
tentative time schedule of the tests by an official letter. Then, he/she assigns a job-
number and forwards the necessary information to the assigned test personnel. The
section head properly informs the director about the test assignments and submits the
necessary documents for his signature.

In the laboratory, the test specimens are accepted with a "Specimen Acceptance and
Return Form", and are also recorded on the log-sheets. Before testing, the specimens are
numbered and marked for clearly identification. Care must be exercised for the proper
handling and storage of specimens so that they are not damaged in any way during their
presence in the premises. Also, necessary precautions are taken for the prevention of the
exposure of test specimens to the third parties. Similar measures are taken for tests
performed outside the premises of the Centre. The authorised staff performs the tests
according to the specifications of the client. The necessary confidentiality with respect to
the test results is obeyed. The reports are prepared by the level-I test operator and signed
by the NDT level-II or level-III personnel. In the case of the tests that will be performed
outside the Centre, the necessary equipment and accessories are taken from the related
laboratory. Before going outside the Centre for testing, the test operator checks the
method-related list given in the annex (A.7) and completes the equipment and
accessories. The test reports prepared and signed by the respective test personnel are
submitted to the related section head. The section head prepares a cover page for the
reports giving brief information about the test. Sample test reports are given in the annex
(A.6). The section head signs this cover page enclosing the corresponding test reports. If
the personnel of Centre perform only supervision, then a single report may be issued
carrying the signatures of the section head and the person who performed the supervision.
The originals of the reports are given to the client, and copies of them are kept in the
Centre. Rules of confidentiality are obeyed with the personnel and test reports will not be
disclosed to third parties without written approval of the client. Reports are stored for a
period of five years.

Industrial jobs can be subcontracted to other institutions performing similar activities in

accordance with EN 45001, after acceptance of the client. If the tests are subcontracted
partly or fully, first the client should be informed. After the acceptance of the client, the
Centre conducts the supervision and/or monitoring of activities subcontracted. The
 director and the respective section head jointly decide on subcontracting and its terms.
Detailed information on subcontracting is written on the test reports. The respective
section head keeps records of all subcontracted work done.

10.0. Inspection reports and inspection certificates

10.1. Preparation of inspection reports (04 copies may be prepared, one each for client, QA Manager,
Technical Manager/Director, Inspecting Section)
10.2. Authorization for signing of reports and certificates
10.3. Corrections into the reports and certificates
10.4. Preservation of reports and certificates

11.0 Records
11.1. Identification of essential records
(Read through the document and identify records)
Master list showing identification numbers of all equiipment and accessories.

11.2. Care and security of records

RECORDS
Storage facilities are allocated which ensure that all stored records are identifiable and
retrievable, and the storage areas are free from damp and other agents which could cause
premature deterioration.

Where records are maintained on computer magnetic media, and these are subject to "back-up" at
regular intervals, with the "back-up" information being stored in a protected location to ensure
security from loss/ damage of active data.

All records are retained for a minimum of 2 years.

12.0. Complaints and appeals

TO EDIT BELOW

The procedure is available to SCS clients, applicants, and third-party individuals or organizations
who perceive a stake in the affairs of SCS and who have reason to question either the actions of
SCS itself or the actions of an SCS client in regards to conformance with relevant requirements.
The procedure is applicable to any formal decision rendered by SCS or actions taken by a client
where such actions are believed to conflict with the terms and/or conditions of the client’s
engagement with SCS.The formal processes outlined herein should be employed only in the
event that less formal measures do not achieve resolution.

12.1. Procedures for receipt of complaints

4.1 To have standing under this procedure, the formal complaint/appeal must include the
following information:
 Contact information for the complainant/appellant;
 A clear description of the aggrieved action or basis of the appeal (date, place, nature of
action) and which parties or individuals are associated with the action;
 An explanation as to how the action is alleged to violate or be inconsistent with a
requirement, being as specific as possible with respect to the applicable requirements;
 In the case of formal complaints against the actions of an SCS client, rather than SCS
itself, the complainant’s description of efforts taken to resolve the matter directly with that party;
and
 A proposal of what actions would, in the opinion of the complainant/appellant, rectify the
matter.
4.2 Upon receipt of a formal complaint or appeal, the SCS Quality Assurance Manager (or
designee) will undertake the following actions:
 Open a formal complaint/appeal file in which all materials and correspondence associated
with the formal complaint/appeal will be maintained;
 Acknowledge receipt of the formal complaint/appeal within five (5) business days,
informing the complainant/appellant that its formal complaint/appeal is being reviewed for
standing;
 Provide a written response to the complainant/appellant within two (2) weeks of receipt
of the formal complaint/appeal, informing complainant/appellant as to whether or not the formal
complaint/appeal qualifies for investigation under this procedure, and outlining the investigation
process and the recourse available to the complainant/appellant;
 Should the formal complaint/appeal qualify for an investigation, select an individual to
investigate who is independent of the:
o certification evaluation at issue; and
o associated certification decision.

4.2 The assigned investigator will undertake the following tasks:

 Inform the complainant/appellant, and relevant certificate holder (where applicable) of
this assignment;
 Solicit and collect any additional information necessary to investigate the formal
complaint/appeal. The investigation will be based primarily upon written documentary evidence
supplied by the complainant/appellant. It is the complainant’s /appellant’s burden to establish
that there has been an action taken in contravention of a requirement. Typically, the investigator
will augment the documentary evidence submitted by the complainant/appellant with telephone
and email interviews. The investigator, if authorized by the SCS Quality Assurance Program
Manager, may elect to conduct a field inspection to augment the documentary evidence.
 Prepare a written report in which the inspector’s findings and recommendations are
presented. Under normal circumstances, the report will be completed within 120 days of receipt
of the formal complaint/appeal.
 Submit the report to the SCS Quality Assurance Manager.

4.3 The SCS Quality Assurance Managerwill then:

 Forward the report to the relevant SCS Executive Team representative and/or the SCS
Advisory Board for review and consultation, if appropriate.
 Render a decision as to the proposed disposition of the formal complaint/appeal,
including actions such as:
o Denial of the formal complaint/appeal;
o Reversal of the action that is the focus of the formal complaint/appeal; or
o Issuance of non-conformity reports (NCR), corrective action requests (CAR) and/or
recommendations aimed at rectifying the situation.
 Inform in writing the complainant/appellant and other relevant parties (e.g., certificate
holder, relevant external parties) of the disposition of the formal complaint/appeal and, where
appropriate, provide the report, or a summary thereof, to all parties along with the final decision.

4.5 If the complainant/appellant accepts the proposed decision or action, then the decision or
action is carried out and recorded.
4.6 If the complainant/appellant rejects the proposed decision or action, then the formal
complaint/appeal will remain open. This will be recorded as a dispute and the
complainant/appellant will be informed of the procedure for bringing the dispute before a
Dispute Panel named by the SCS Advisory Board, or the dispute procedure of the governing
body, if other than SCS (e.g., FSC, PEFC, SQF), who will be promptly notified.
4.7 The Quality Assurance Program Manager is responsible for monitoring the progress of
open formal complaints and appeals until all reasonable internal and external options of recourse
are exhausted or the complainant/appellant is satisfied.
4.8 SCS shall ensure that decisions on appeals do not result in any discriminatory actions
against the claimant/appellant.

12.2 Redressal of complaints

5.1 If the complainant/appellant rejects the proposed decision or action related to an SCS
service, the SCS Quality Assurance Program Manager (or designee) will provide notice of the
dispute to the SCS Advisory Board within seven (7) business days of receipt of the
complainant/appellant’s rejection. The SCS Quality Assurance Program Manager (or designee)
will convey the formal complaint/appeal file in which all materials and correspondence
associated with the formal complaint/appeal, including the proposed decision or action, to the
Advisory Board.
5.2 The SCS Advisory Board will select a Dispute Panel to consist of one member of the
Advisory Board and at least one technical expert who is independent of the:
 certification evaluation at issue;
 associated certification decision; and
 day-to-day implementation of the policies of the relevant SCS service.
5.3 The formal complaint/appeal file, including all evidence provided by the
complainant/appellant, along with the proposed decision or action prepared by the SCS Quality
Assurance Program Manager (or designee), will be provided to the Dispute Panel.
5.4 The Dispute Panel shall, at its sole discretion, request additional information by telephone
or written correspondence of the parties. Based on its review of the facts, the Dispute Panel shall
then prepare a written report of its findings, which shall be submitted to the SCS Quality
Assurance Program Manager, the complainant/appellant, and any additional affected parties. The
report should be completed within 120 days of receipt of the notice of dispute.
5.5 Final disposition of the dispute, and written confirmation thereof, will generally take
place within thirty (30) days of receipt of the report.
6 Confidentiality
6.1 Personally identifiable information concerning the complainant is available only where
needed for the purposes of addressing the complaint/formal complaint within the organization
and is actively protected from disclosure except to those Parties directly involved, unless the
client or complainant expressly consents to its disclosure.
7 Costs of Investigation
7.1 While SCS is committed to the principle of broad access to the assessment process,
including but not limited to this procedure, undue costs associated with investigating a formal
complaint/appeal cannot be borne by SCS. Depending upon the nature of the formal
complaint/appeal, SCS reserves the right to charge a fee to cover at least a portion of the costs of
the investigation. Such fees will only be considered in situations where the time required to
investigate the formal complaint/appeal is expected to be substantial.
7.2 For formal complaints against the actions of a certificate holder or verification/validation
statement recipient, SCS reserves the contractual right to charge that party for time and expenses
incurred in investigating the formal complaint. Failure to agree to pay these additional charges or
to otherwise cooperate in the investigation of the formal complaint can be grounds for
termination of certification or loss of verification/validation status.
7.3 SCS is committed to duly considering substantive complaints or informal complaints
from any party that is committed to the long-term goals of SCS. However, in the event that this
procedure is being employed by a “vexatious litigant” for reasons in conflict with the long term
goals of SCS, SCS reserves the right to turn the matter immediately over to an appropriate
external body for further disposition or, as appropriate, to reject the complaint as without merit.

12.3. Records of complaints and appeals

13.0. Cooperation

14.0 References

ISO/IEC 17020:1998: General criteria for the operation of various types of bodies performing
inspection

IAEA TRAINING COURSE SERIES No. 3: Industrial Radiography—Manual for the Syllabi
contained in IAEA TECDOC 628, IAEA, Vienna, 1992.
IAEA TRAINING COURSE SERIES N0. 9: Non Destructive Testing—A Guidebook for
Industrial Management and Quality Control Personnel, IAEA, Vienna, 1999.

IAEA TRAINING COURSE SERIES No. 10: Ultrasonic Testing of Materials at Level 2
—Manual for Syllabi Contained in IAEA TECDOC 628, IAEA, Vienna, 1999.

IAEA TRAINING COURSE SERIES No. 11: Liquid Penetrant and Magnetic Particle
Testing: Manual for the syllabus contained in IAEA TECDOC 628, IAEA, Vienna, 2000.

Asghar Ali Khan ; H. Vera Ruiz,

Industry's indispensable tools: Training and certification for Non destructive Testing, IAEA
Bulletin, Vol. 43, No. 1, 2001.

Asghar Ali Khan ; H. Vera Ruiz,

The Role of IAEA for the Promotion of NDT Technology around the World, Proceedings of 15
th World Conference on NDT held in Rome from 15-21 October, 2000. Industrial Applications
& Chemistry Section, Division of Physical & Chemical Sciences, International Atomic Energy
Agency, Vienna, Austria.

IAEA TECDOC 628/Rev 2 (2008): Training guidelines in non-destructive testing techniques,

IAEA, Vienna, 2008.

ASME Code Section V, Non destructive Examination (Radiographic Testing),Articles 1, 2 and

22, 2010.
 Annex 1

2.1. Definitions and terminology

Add relevant defintions and terminology from ISO/IEC Guide 2:1986 and relevant
standard in EN 45000 series.
Penetrant Materials: The penetrant materials include all penetrants, emulsifiers, solvents or cleaning
agents, developers, etc. used in liquid penetrant examination.
Water Washable Penetrant: A type of penetrant used where the excess penetrant is removed directly
from the surface of the part with water washing by using manual, semi-automatic, automatic water
spray or immersion the part or removed by swabbing action.
Solvent Removable Penetrant: A type of penetrant used where the excess penetrant is removed from
the surface of the part by wiping using solvent cleaner.
Post-Emulsifiable Penetrant: Post-emulsifiable penetrants are not directly water washable and they
require the use of an emulsifier (oil-base or water-base) to make the penetrant water washable. After
the required penetration time the excess penetrant on the part is emulsified by dipping, flooding or
spraying the parts with the required emulsifier.
Emulsifier: A material which applied over the film of penetrant on the surface of a part mixes with the
penetrant and enables it to be washed off the surface with water.
Bleed Out: The action of an entrapped liquid penetrant in surfacing from discontinuities to form
indications.
Indication: In liquid penetrant examination, the visible results of penetrant bleed out.
Frequency: The number of cycles per second of alternating electric current induced in the tubular
product.
Indications: Eddy current signals caused by any change in the uniformity of a tube. These changes in
uniformity affect the electric characteristic of the tube.
Sensitivity Control: The control in the instrument which adjusts the amplifier gain and is one of the
factors that determines the capacity to detect discontinuities.
Non-Quantifiable Indication: A non-quantifiable indication is a reportable indication that cannot be
characterized. The indication shall be considered a flaw until resolved future inspections or
otherwise.
Edge/End Effect: The losses in sensitivity to discontinuities located near the extreme ends or edges of
the tube or surface as test coil enter or leave the test specimen.
Inspection: Inspections are the quality control functions, which are carried out by an “authorized
inspector.
Examination and Testing: Examination and testing are those quality control functions, which are
carried out by a qualified person who is the employee of the manufacturer.
Exposure Chart: An exposure chart is a graph relating the exposure to the material thickness.
Image Quality Indicator (IQI): The device used to evaluate the quality of a radiograph is called
image quality indicator (IQI) or penetrameter.
Object to film distance (OFD): It is the distance between the surface of the object on the source side
and the plane of the recording medium i.e. film.
Source to film distance (SFD): It stands for Source to Film Distance. It is the distance between the
radiation producing area of the source and the film.
Minimum Source to film distance (SFD(min): The minimum source to film distance that will give
rise to unsharpness within the limiting values for any defect present in a given specimen.
Permissible Dose: It is a dose of ionizing radiation that, in the light of present knowledge and in the
opinion of competent medical authority, is not expected to cause appreciable bodily injury to a person
at any time during his lifetime and carries negligible probability of genetic malformations.
Radiographic Density: It is the degree of blackness of radiograph.
Scattered Radiation: The radiation that deviates from its primary path is called scattered radiation.
Geometric unsharpness (Ug ): It stands for Geometric Unsharpness. It is the area of the film, which is
partially exposed. This gives rise to the unsharpness of the image and is undesirable in radiography.
Client: The client, company is/are the person(s) who is/are owner of the organization for which
inspection or examination and testing is performed by the inspection team.
Inspection Team: The inspection team is the group of persons (from NCNDT) who shall carry out
inspection or examination and testing works required by the client or company.
TO EDIT BELOW

Complaint: An expression of dissatisfaction by any person or organization, relating to the activities of

SCS services, personnel and/or representatives of an SCS client, where a response from SCS is expected.
Formal Complaint: A written expression of dissatisfaction, other than appeal, by any person or
organization, relating to the activities of SCS services, personnel and/or representatives of an SCS client,
where a response from SCS is requested in accordance with the company’s Investigation process.
Appeal: A request by a client or applicant for formal reconsideration of any adverse decision made by
SCS related to its desired status, to be resolved by SCS in accordance with the company’s investigation
process.
Dispute: A complaint, formal complaint, or appeal that cannot be satisfactorily resolved by SCS, such
that the matter is referred on to an external body — i.e., the governing body (e.g., FSC, PEFC, SQF) or, if
there is no external governing body, a Dispute Panel named by the SCS Advisory Board.

2.2. Abbreviations

Following abbreviations will be used in this Quality Manual:

AEA – Atomic Energy Authority (of Sri Lanka)

SLAB – Sri Lanka Accreditation Board
NCNDT – National Centre for Non-Destructive Testing
IAF – International Accreditation Forum.
IAEA – International Atomic Energy Agency
ICNDT – International Committee for Non destructive Testing.
RCA – Regional Cooperative Agreement
QM – Quality Manual
TM – Technical Manager
QAM – Quality Assurance Manager
QA – Quality assurance
QC – Quality control
NDT – Non-destructive testing
PT - Liquid penetrant testing
MT - Magnetic particle testing
ET - Eddy current testing
UT - Ultrasonic testing
RT - Radiographic testing
IQI – Image quality indicator
D – Radiographic film density
IACS. – International Annealed Copper Standard
OP - Operating Procedure
ASTM - American Society for Testing and Material
ASME - American Society of Mechanical Engineers
UV – Ultraviolet (light or lamp)
IQI - Image Quality Indicator
OFD - Object to film distance
SFD - Source to film distance
SFD(min) - Minimum Source to film distance

Annex 02

Standard OperatingProcedures

Title: Procedure for Document Control at the NCNDT

Scope: This procedure details the methodology adopted in controlling all documents of NCNDT
pertaining to ISO/ IEC 17020:1998 standard including, documents of external origin, such as codes and
standards.

Responsibility: Manager Quality Assurance Division will be responsible to implement and maintain this
procedure.

Document Numbering: Each document will have a unique number. The document numbering scheme
will be finalized in a joint meeting of Manager Quality Assurance with the Heads of Divisions and chaired
by the Technical Manager/Director NCNDT. A master list of all important documents will be finalized.

 Quality Manual (NCNDT/INS/DOC-01(QM)/00)

 Procedure for document control (NCNDT/INS/P-02(DC)/00)
 Procedure for recruitment, training and certification of all personnel in NCNDT. (NCNDT/INS/P-
03(RTC)/00)
 Procedure for procurement of equipment and accessories (including selection of suppliers).
(NCNDT/INS/P-04(PRO)/00)
 All the purchase orders containing specifications of the ordered equipment and
accessories(NCNDT/INS/P-05(PUR)/00)
 Procedure for review of requests, tenders and contracts (NCNDT/INS/P-06(TC)/00)
 All the contracts signed with clients (NCNDT/INS/P-07(CON)/00)
 Procedure for actual inspection jobs for VT(NCNDT/INS/P-08(VT)/00)
 Procedure for actual inspection jobs forPT(NCNDT/INS/P-09(PT)/00)
  Procedure for actual inspection jobs for MT(NCNDT/INS/P-10(MT)/00)
 Procedure for actual inspection jobs for ET (NCNDT/INS/P-11(ET)/00)
 Procedure for actual inspection jobs for UT(NCNDT/INS/P-12(UT)/00)
 Procedure for actual inspection jobs for RT(NCNDT/INS/P-13(RT)/00)
 Procedure for the care and maintenance of equipment (NCNDT/INS/P-14(CME)/00)
 Procedure for storage of equipment(NCNDT/INS/P-15(SE)/00)
 Procedure for dealing with defective equipment(NCNDT/INS/P-16(DDE)/00)
 Procedure for performing non-standard inspections(NCNDT/INS/P-17(PNI)/00)
 Procedure for handling and avoid damage to the inspected items.(NCNDT/INS/P-18(HDI)/00)
 Procedure for dealing with complaints(NCNDT/INS/P-19(COM)/00)
 Procedure for dealing with appeals against the results of inspection.(NCNDT/INS/P-20(APP)/00)
 Procedure for feedback from the clients(NCNDT/INS/P-21(FEED)/00)
 Procedure for control of non-conforming work(NCNDT/INS/P-22(NON-CON)/00)
 Procedure for internal auditing including audit plans (NCNDT/INS/P-23(IAUD)/00)
 Procedure for calibration of equipment(NCNDT/INS/P-24(CAL)/00)
 Procedure for records control(NCNDT/INS/P-25(RC)/00)
 Procedure for sub-contracting of jobs (NCNDT/INS/P-26(SUB-CONT)/00)
 All the reports containing results of inspection(NCNDT/INS/P-27(IR)/00)
 Procedure for management review(NCNDT/INS/P-28(MR)/00)

Document Development Cycle: Most documents related to technical aspects will be drafted by
designated team of personnel from the relevant Division. These will be reviewed by the Head of the
relevant Technical Division as well as the Manager QA Division. The documents will be approved by the
Technical Manager/Director NCNDT.

Custody and Distribution of Documents: Each document after preparation and approval by the
designated authority is issued by Manager QA through “Document Control Register” to ensure that
obsolete and irrelevant documents are not used, after affixing “Controlled Copy” stamp in green
coloured ink to differentiate from the photocopied copies.

Document Revision: Documents may need changes due to various reasons such as changes in the
applicable standard, suggestions and/or customer complaints or suggestions from the NCNDT members
& associates. All proposed changes will be requested through a Document Revision Slip which will have
signatures of the individualproposing the change as well as the concerned Head of the Division. The
change is discussed in the meeting of a committee whose members comprise of all Heads of Divisions
and if agreed to by at least 3/4th of the members is sent to Technical Manager/Director for approval. In
case the change is approved, it is incorporated in the document by Manager QA and the revision
number is upgraded to the next higher number.

Redistribution of Revised Documents: Manager QA prepares copies of the document and issues the
same to the users after withdrawal of the previous revision.

Disposal of Withdrawn Documents: The copies of the withdrawn document are destroyed by the
Manager QA except for one copy, which is clearly stamped “OBSOLETE” on all pages and retained by
Manager QA for future reference.
Validity of Documents: The documents will be subjected to scrutiny and approval by Manager QA once
every 3 years, irrespective of whether they have undergone any change.

Uncontrolled Documents: Documents that do not have a restricted circulation may be termed as
Uncontrolled. These are distributed with the stamp “Uncontrolled copy”. Uncontrolled copies are not
up dated and are distributed without copy numbers.
Procedure for review of requests, tenders and contracts (NCNDT/INS/P-06(TC)/00)
 The client will send a written request to the Technical Manager of NCNDT, giving all the
specifications of the job to be done.
 The Technical Manager sends this request to the relevant Head of the Division.
 Head of the Division appoints a team (UT, RT,...etc.) designating a team leader and all its
members in writing. This team is given the responsibitity for looking intothe feasibility to
undertake the job.
 The team will visit the client’s premises to study the feasibility to undertake the job and
come back, and prepare the feasibility report and the quotation.
 The quotation including cost and other terms and conditions will be sent to the client after
approval of the Technical Manager.
 The client will send his agreement in written to accept these terms and conditions.
 Then the inspection team will proceed the cllient premises to undertake the job.
 If the client desires to get additional work done he will need to define such work in
writing and agree to terms and conditions including cost prior to execution of the work.
Procedure for Subcontracting (NCNDT/INS/P-26(SUB-CONT)/00)

NCNDT maintains a list of registered subcontractors who are selected on the basis of certified
manpower, equipment holdings and the jobs undertaken by them in the past.
CAR 573.11 describes who an AMO may sub-contract work to and how the work is to be controlled and
supervised.

Many companies contract work to other organizations because facilities or personnel are unavailable or
because the work is specialized. The contractors are either Approved (AMO) or Unapproved. The AMO
must develop specific approval procedures governing maintenance arrangements and describe these
procedures in its MPM. Should an AMO choose not to include these procedures in their MPM, each
specific maintenance arrangement will have to be submitted to Transport Canada for individual
approval.

Approved and Unapproved differ in certification and quality assurance. Their contracts are similar in
terms of including the usual who, what, when, where, and how.

In a contract with an Approved organization, the organization must specify the task, the work standard,
and the time frame. The authority of the AMO provides assurance of certification and quality.

In a contract with an unapproved organization, the contract must specify the task, the work standard,
the time frame, and how quality assurance will be secured.

With unapproved organizations, the AMO is responsible for:

Providing technical data to the contractor.

Direct supervision of the work.
Quality control of the work.
All certification of the work.

For quality assurance purposes, it is recommended that an organization representative reviews an

Unapproved contractor’s work in progress, and inspects the completed project thoroughly.

Example:

From time to time, work may be contracted to specialist companies. These fall into two categories;
Approved Organizations, and Unapproved Organizations that are not approved by Transport Canada.

Subcontracts to Approved Organizations:

Each subcontract will be documented in a Purchase Order that details:

The work to be performed.
The standard to be used in the performance of the work.
Any special requirements.

Details of each subcontract will be entered in each work package as required by section 11 of this
manual.
Subcontracts to Unapproved Organizations:

In addition to the above requirements, Acme Aero will retain responsibility for:

Assuring technical information appropriate to the work is available to the subcontractor.

Completion of form 1.
Direct supervision of the work.
Quality control of the work.
All certification of work performed.