Carbon Footprint NDT Systems Emissions Profiling

Carbon Footprint NDT

Carbon footprint for everything in the world is a big issue now and rightly so this blog will look at how ATH NDT is looking to reduce the carbon emissions used on PFD lines / systems.

ATH NDT have just signed up to have their new electrostatic penetrant system assessed via an outside organisation to see how friendly it is to the environment compared to other PFD equipment.

 

We have decided to go the extra mile and include the following on our latest system as a minimum,

  • Extra insulation on the oven that ensures the oven takes less time to get to temperature.
  • Fans for extraction that can be adjusted from 1% – 100% usage why use one constant setting
  • Pumps used for the water back extraction can also be adjusted within a working range of 1% – 100%
  • We have made a design that can apply the penetrant / wash off and apply the developer in one booth instead of using and extra booth solely for application of the electrostatic developer.

Large multinational organisations in the UK are now making it mandatory that all the equipment they purchase is doing everything they possibly can to reduce carbon emissions.

ATH NDT can say they are doing everything in their power to help the present and future environment, in our August blog we will publish the results of the external emissions profiling.

 

27/07/2023

A.T.Heaton Managing Director

ATH NDT Ltd

NDT Trainees (Part 3) Yes / No

NDT Trainees

We have covered in the previous 2 blogs the following aspects in relation to employing NDT trainees.

 

  • Financing NDT Experience
  • NDT Courses
  • NDT Examinations

 

Total cost for all the above aspects when employing a person 23 years of age and on the UK minimum wage = £12,324

Conclusion

As a company ATH NDT have only once gone down the route of taking a person on as a NDT trainee that was Jordan who is now an integral part of our organisation.

Hence, we would always recommend taking on an NDT trainee the main thing is to chose the right trainee during the interview process, set limits such as minimum qualifications required.

I hope you have found these blogs of interest and return to read and learn more in the coming months.

Thanks

A.T. Heaton Managing Director ATH NDT Ltd

NDT Trainees (Part 2) Training & Examinations

NDT Testing

In this blog we look at the training and examination elements required for NDT Trainees and what is available in the industry related cost and what is involved as far as costs and timescales are concerned.

There are multiple NDT training organisations in the UK and charges differ from each organisation we will look at the costs for a Level 2 Penetrant Testing course initially.

  • Course duration = 4 days
  • Course cost = £700
  • Trainee’s wages / accommodation / expenses = (£385.54) (£555) (£250) = £1,190.54 + course cost = £1,890.54

 

Once the NDT training course has been passed the employer will need to assess which type of examination, they want the NDT trainee to be qualified too.

PCN examinations are where the employer is conducting NDT for general engineering organisations, these approvals can be taken with the employee.

NAS 410 / EN4179 & SNT TC1A examinations are employer based where the individual must take an examination each time they move companies.

Examination Costs

  • PCN = £468
  • EN4179 etc = £200
  • Both of the above will involve a day off work plus travelling cost let’s say £100
  • If the EN4179 etc examination is to be carried on site at the trainee’s company an extra fee will be in the region of £700.

Looking at the above we can calculate the cost for the Training & Examination

Total cost for all the above to gain a PCN Level 2 approval = in the region of £ 2349,54

Total cost for all the above to gain a EN4179 Level 2 approval = in the region of £ 2190,54

The next blog will look at the total costs so far and whether it is viable taking on a NDT apprentice, along with the positives / negatives.

Non-Destructive Testing (NDT) Services Offer Numerous Benefits Across Various Industries

NDT Testing

Here are some of the key advantages:

Safety: NDT helps ensure the safety of structures, components, and systems by identifying defects, weaknesses, or anomalies without causing damage or compromising their integrity. This is particularly critical in industries such as aerospace, oil and gas, and nuclear power.

Cost-effectiveness: NDT allows for the detection of flaws and defects early on, reducing the risk of failures and accidents. By identifying issues before they escalate, companies can avoid costly repairs, downtime, and potential legal liabilities associated with accidents or product failures.

Quality assurance: NDT plays a vital role in quality control and assurance. By examining materials, products, and structures, NDT techniques verify their compliance with industry standards, specifications, and regulations. This helps ensure that products and components meet the required quality criteria and perform as intended.

Extended lifespan: Through regular NDT inspections, potential flaws and defects can be detected and addressed promptly. By identifying and repairing these issues, the lifespan of structures, equipment, and components can be significantly extended, reducing the need for premature replacements.

Enhanced reliability: NDT services provide valuable information about the condition and reliability of assets. By assessing the integrity of critical components and systems, businesses can make informed decisions regarding maintenance and repair schedules, thereby reducing the risk of unexpected failures and optimizing operational efficiency.

Non-invasive: Unlike traditional destructive testing methods, NDT techniques are non-invasive, meaning they do not damage or alter the tested object. This makes NDT ideal for inspecting delicate or expensive components, ensuring that they remain intact and functional throughout the testing process.

Time-saving: NDT can quickly identify defects or weaknesses in materials or structures, allowing for efficient troubleshooting and faster decision-making. This reduces the time required for inspections and enables prompt corrective actions, minimizing downtime and optimizing productivity.

Environmental friendliness: NDT methods are non-destructive, meaning they do not generate waste or cause environmental harm. By minimizing the need for destructive testing and associated waste production, NDT contributes to sustainable practices and reduces the overall environmental impact.

Compliance with regulations: Many industries are subject to strict regulations and standards concerning the quality and safety of their products and services. NDT services help companies comply with these requirements by providing accurate and reliable inspection results, ensuring adherence to industry regulations and legal obligations.

 

ATH NDT Big Move

ATH NDT

The start of March 2023 was a big deal for ATH NDT we moved premises to a new location away from the town we first started the company 13 years previous, read more below as to the reasons why.

ATH NDT decided to look for bigger premises at the start of 2023 we had an idea of what we wanted.

  • A facility of around 4 – 5k square feet in size
  • Good loading bay area
  • Good location for all employees (local to where they live)
  • Larger offices for clerical staff
  • Larger canteen

We searched around the West Craven area of Lancashire for 10 weeks without finding what we wanted this included Earby / Barnoldswick and further afield in Colne.

Luckily Jordan received a call from a transport company we use from Keighley, and we found our perfect industrial unit in Skipton to be more precise Engine Shed Lane.

From March 1st 2023 we moved our existing equipment to our new location and are now awaiting the following to be installed.

  • State of the art Electrostatic Penetrant System that will be used to process components and also be used to show prospective customers the kind of equipment we design / manufacture and install.
  • State of the art Powder Coating system again to show prospective customers the quality of work we provide.
  • Roller Penetrant Line again which will process components for our valued customers and again be seen by customers looking for a smaller processing system.
  • A new piece of equipment we will also have installed, and working is a Spay Bake Paint Oven again so we can showcase to prospective clients.
  • Along with a pre penetrant etch processing line this will enable us to set out on the business plan we have put together for the next 5 years.

All of the above will be able to be viewed in running by the third quarter of this year we will be having an open day to showcase all the above products along with a few nibbles and refreshments.

Please keep visiting the ATH NDT website along with our various social media platforms for updates, these are exciting times for us and the industries we supply.

NDT Trainees (Part 1) Financing

NDT Trainees

Employing an NDT trainee may be a good idea but a lot of things need to be considered over the next few blogs we will look at the costs / pro & cons and then decide if it is really worth the time money and hassle.

In general, a minimum experience for even the basic of NDT methods will take at least 6 months, a company will be taking a big risk taking on a member of staff be it as a teenager or mature candidate.

Let’s look at the figures and options for an employer.

  • 6 months wages at the governments current minimum wage guidance for over 23 year olds working a 37 hour week = £10,024,04

This means an employer will not be able to charge for the trainees work for 6 months and will have to pay on top of the wages pensions PAYE etc.

As can be seen from the above for an employer such as ATH NDT this is a massive commitment financially.

In the second instalment of this blog, we take a look at the other costs involved taking on a NDT Trainee courses exams etc

Why choose ATH NDT Ltd for your Penetrant system?

JOSCAR is a collaborative tool used by the aerospace, defence, and security industry
  • Manufactured in the UK

 

  • Multiple Level 3 personnel approved to EN4179 / NAS410 & ISO9712

 

  • Multiple Level 3 personnel approved for Aerospace primes to name a few Rolls Royce / Honeywell / BAE / Airbus

 

  • JOSCAR approved

JOSCAR is a collaborative tool used by the aerospace, defence, and security industry to act as a single repository for pre-qualification and compliance information. Using JOSCAR can determine if a supplier is “fit for business”. https://hellios.com/joscar/

  • Sister company Craven NDT NADCAP approved.

Nadcap (National Aerospace and Defence Contractors Accreditation Program) is an industry-managed approach to conformity assessment of ‘special processes’ that brings together technical experts from prime contractors, suppliers and representatives from government to work together and establish requirements for approval. https://p-r-i.org/nadcap/

  • Employees with a combined experience of more than 100 years’ experience combined at Level 2 & 3 to help assist companies to design the best equipment for their products.

 

 

  • Sister company Craven NDT AS9100 approved a set of guidelines for implementing a Quality Management System for use by aviation, space, and defence organizations https://en.wikipedia.org/wiki/AS9100

 

  • Multiple PT systems designed / built and installed across the UK including electrostatic / dip tanks and semi automated roller systems.

 

  • State of the art show room to showcase actual working PT electrostatic systems.

 

Still unsure? Contact ATH NDT to either call in and see us or book us in to visit you at your site.

See below contact details.

https://www.athndt.uk/

 

 

Understanding the Benefits of Liquid Penetrate Inspection

Understanding the Benefits of Liquid Penetrate Inspection

Dye penetration testing is also known as liquid penetrate inspection, alias LPI. These tests are carried out to see if there are any breaking defects found on the surface. There are multiple use cases for these tests. Most of the time, they are used upon metals, plastics, non-porous materials and even ceramics. The test is famous for its non-destructive processes and low cost nature. Whenever a new product is ought to be produced, it would be made to go through dye penetration testing. It identifies all possible leaks and fatigue cracks.

Principle of Dye Penetrant Inspection

As suggested by its name, this inspection focuses on the penetration capabilities of the dye. As the dye is made to flow through the surface, it will be absorbed by the discontinuities and defects. The dye is also identified as a draw penetrant. It is usually applied using common techniques like brushing, dipping, and spraying. Once the penetrant is removed from the surface, the developer is applied. The developer acts as a visual inspector. The liquid penetrant inspection tests are great for spotting irregularities. Additionally, they can also be used to ensure on the durability of the material.

Benefits of using Liquid Penetrant Inspect

  1. Multiple Use cases: First things first, you can use this form of testing on a variety of geometric shapes. Since the test depends on the level of absorption, the surface doesn’t have to be even. Even if the shape of the surface is complicated, irregularities will absorb the liquid. Eventually, it will be possible to see the presence of defects on the surface.
  2. Compact: Unlike many other testing methods, the chemicals used as a part of these tests are very compact. It is quite simple to store and use them during the tests.
  3. Sensitivity: The test is capable of testing the small discontinuities on the surface. It is quite famous for its highly sensitive nature. Most of the times, industries in hunt for testing methods that can spot impurities which are both tiny, and unevenly spread. This form of testing meets both these requirements
  4. Flexibility: The liquid penetrant test can be used on a variety of materials. In includes both non-metallic and non-metallic surfaces, conductive and non-conductive objects, and even magnetic and non-magnetic surfaces. All these materials can be tested flawlessly.
  5. Visualisation: The test helps engineers visualize the flaw. The indications are drawn directly on the surface.
  6. Cost: The test is very cost-effective. Each material used in the test, are individually cost effective.

 

Liquid Penetrant Inspection Line

Liquid Penetrant Inspection Line

Liquid Penetrant Inspection also is known as Dye penetrant is an inspection method used for checking cracks or leakage in non-porous materials. This method is commonly used since it is cheaper. Liquid penetrant inspection is used with both ferrous and non-ferrous materials such as plastic, ceramics, and metals. This method detects defects such as cracks, leakage, forging and casting.

How it works

The process uses the principle of capillary action. The penetrant is applied to a test component then it is given enough time for penetration. The penetrant will flow through the cracks and then the excess component is removed. A developer is applied to make the penetrant visible on the test component. Inspection is done on the test component either via white light or ultraviolet.

The Inspection Process

Cleaning – This is the first step in the inspection process. It involves the removal of paint, dirt or grease that might hinder observation during the inspection process. Cleaning can be done using solvents, media blasting or vapour degreasing.

Application of penetrant – This should be done carefully on the surface of the test item. Give the penetrant enough time for enough penetration. It should take 5-30 minutes for the penetrant to penetrate the item being tested. This will differ in various situations depending on the material and the penetrant being used.

Excess penetrant removal – The excess penetrant should be removed to prevent altering of the inspection results. There are different methods of removing the excess penetrant from the item being tested. Each method will depend on the penetrant used. Emulsifiers are the common choice since they will work with many penetrants. Types of penetrants include lipophilic, solvent removable, water-washable and hydrophilic.

Application of developer – Examples of developers include water-suspendable, dry powder, water-soluble and non-aqueous wet developer. The choice of the developer will depend on its compatibility with the penetrant. This is due to the differences in solubility of penetrants. The main role of the developer is to draw penetrant from the defects into the surface. This forms visible indications called bleed-out which are used to indicate the type of defect mostly when using an LPI penetrant line.

Inspection -Fluorescent penetrant examinations will require ultraviolet light for carrying out the inspection. Dye penetrant uses visible light that has an adequate intensity of about 1100 Aux. Other than this the bleed-outs should be used to interpret the possible defect types on the tested material.

Post cleaning – This is the last step that should follow the recording of test findings. The tested material should be thoroughly cleaned after the process to facilitate efficient future liquid penetrant inspections.

There are many advantages of using DP inspection one being quicker testing times and this method has similar attributes with NDT supplies [non-destructive testing]. Contact ATH NDT on 01282 842624 to discuss your requirements.