Quality Control Office

(QCO)

Name : W.A.P.N Athukorala

Service No : 7906059
University : Sri Lanka Institute of Information Technology (SLIIT)
W.A.P.N Athukorala 7906059

Contents
Introduction ..................................................................................................................................... 3
Non-destructive Testing (NDT) ...................................................................................................... 4
Visual Inspection ........................................................................................................................ 5
Dye Penetrant Inspection/Testing (DPI) ..................................................................................... 5
Magnetic Particle Inspection (MPI) ............................................................................................ 8
Ultrasonic Testing (UT) ............................................................................................................ 10
Radiographic Testing ................................................................................................................ 13
Trainee Evaluation Form .............................................................................................................. 14

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Introduction
The Quality Control Office/Department (QCO) of the Colombo Dockyard PLC is one of
the most important departments responsible for ensuring that naval vessels and maritime
operations comply with international and national regulations and standards. The primary goals of
this department include inspecting vessels, certification, documentation, investigating incidents,
and ensuring the safety and protection of vessels, personnel, etc.

The QCO is responsible for issuing the following certifications,

• Welding Performance Qualification Record (WPQR)

• Welding Procedure Specification (WPS)
• Inspection Test Plan (ITP)

A typical quality record document issued by the QCO includes all the necessary tests for
the vessel or the specimen inspected. These tests include all the Non-destructive tests (NDT) and
destructive tests performed. The document states whether the specimen has successfully passed
these tests or additional tests are required. After completion, an overall certification is issued to
the client.

This report mainly focuses on the different types of non-destructive testing methods I was
involved in during my stay. Furthermore, additional details related to these testing methods and
key highlights of what I have researched and encountered have been included.

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Non-destructive Testing (NDT)

I was assigned to this workshop for two weeks and I got an in-depth experience of the Non-
destructive testing (NDT) performed by the QCO that contributes to accomplishing the above goals
mentioned in the Introduction. In simple terms, NDT is defined as inspection techniques or
methods utilized to collect data about a material without damaging it. These tests are capable of
exposing defects such as,
• Fractures
• Cracks
• Grinding Defects
• Incomplete Fusion
• Defects in Joints
• Porosity etc.

The importance of NDT is that it ensures no damage to the material thus saving money and
resources, NDT is harmless to humans (except radiographic testing), materials can be quickly
evaluated, and accurate and predictable results are assured. (FLYABILITY, n.d.)
NDT methods are widely used in many industries such as Power Generation, Mining,
Automotive, Maritime, Aerospace, etc. These tests can be used for many kinds of inspections, but
in cases such as boiler and pressure vessel inspections specific laws and inspection codes must be
followed by the inspecting personnel since boilers and pressure vessels can be highly dangerous.
These codes and standards must be followed during inspections conducted periodically by
a certified inspector. The following includes some organizations in the world that create NDT
codes and standards.
• API (American Petroleum Institute)
• ASME (American Society for Mechanical Engineers)
• ASTM (American Society for Testing and Materials)
• ASNT (American Society For Nondestructive Testing)
• COFREND (French Committee for Non-destructive Testing Studies)
• CSA Group (Canadian Standards Association)
• CGSB (Canadian General Standards Board)
(FLYABILITY, n.d.)

The QCO of the Colombo Dockyard engages in the following non-destructive testing methods,
• Visual Inspection
• Dye Penetrant Testing/Inspection (DPI)
• Magnetic Particle Inspection (MPI)
• Ultrasonic Testing (UT)
• Radiographic Testing

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Visual Inspection
A visual inspection test is carried out throughout any inspection from the beginning to the
end. Flashlights and other visual elements are used to easily identify defects, deviations, and
deformations.

Dye Penetrant Inspection/Testing (DPI)

As the name suggests, this inspection method applies a dye or liquid to the material surface
to identify defects. This non-destructive testing method is commonly used because inspectors can
use it without permanently damaging the object. Surface defects such as fractures, cracks,
incomplete fusion, defects in joints, and grinding defects can be identified. (ONESTOPNDT,
2022)

Figure 1 Cracks identified from Source: https://www.onestopndt.com/

DPI is a cost-effective testing method used in ferrous and non-ferrous elements. Cast iron,
Steel, Brass, Aluminum, Copper, Magnesium, Carbides, Ceramics, and Plastics are some examples.
The basic principle behind this method is the capillary action. The fluid with the low surface
tension penetrates a clean, dry surface to identify flaws.

Figure 2 General Steps for conducting a DPI Source: https://www.onestopndt.com/

The following is a general procedure of how a dye penetrant test is performed,

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1. The material surface was cleaned so that all the dirt, oil, paint, and grease would not
restrict the penetrant from doing its work or give out false information.

Cleaning methods such as alkaline cleaning steps, vapor reading, media blasting, or solvents
can be utilized. Here at QCO a solvent cleaner/remover named SKC-S (flammable aerosol) is
used.
2. After the surface was cleaned, the penetrant is applied to the surface of the material.
The penetrant is allowed to soak into the defects for up to 10 to 15 minutes.

QCO uses a red penetrant named SKL-SP2. The time allowed for the penetrant to soak into
the defects is known as the “dwell time”. The dwell time typically ranges from 5-20 minutes.
(ONESTOPNDT, 2022)

3. Excess penetrant present on the surface was then removed.

A key highlight that should be noted is if the excess penetrant is not removed and the developer
is applied, then this leads to masking up defects.

4. The developer was applied.

A white developer named SKD-S2 is used in the QCO. The developer is responsible for
drawing out the penetrant. This is known as the “Bleed Out”.

5. The material surface was inspected for defects.

After allowing some time for the developer to draw out the penetrant, if defects are present red
penetrant can be observed in the defected area confirming the presence of a defect. In some
cases, visible light with an adequate intensity should be used to visualize these defects.

6. The material surface was cleaned.

Figure 3 Red Penetrant (SKL-SP2) Figure 5 Solvent Cleaner (SKC-S) Figure 4 Developer (SKD-S2) Source:
Source: QCO CDPLC Source: QCO CDPLC QCO CDPLC

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The following pictures include the different types of DPI tests that were performed during
my time at the QCO.

Figure 7 Developer applied on a propeller blade Source:

CDPLC
Figure 6 Red Penetrant applied on propeller
blades Source: CDPLC

Figure 8 Red penetrant applied on a weld run Figure 9 Developer applied on Crane hook and
Source: CDPLC Chain block Source: CDPLC

Figure 10 DPI done for a ICCP

of a ship Source: CDPLC

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Magnetic Particle Inspection (MPI)

Magnetic Particle Inspection is an NDT method used to identify defects on the surface of
a ferromagnetic material by inducing a magnetic current. The types of defects that can be exposed
by a MPI are cracks, pores, cold laps, and insufficient fusion in welds.

Figure 11 Magnetic Particle Inspection Source : https://www.flyability.com/

Some of the most common techniques to perform an MPI are,

• Electromagnetic yoke
• Current flow probes
• Permanent magnet
• Flexible coil
• Adjacent cable
(FLYABILITY, n.d.)
The QCO uses electromagnetic yokes and permanent magnets for MP inspections.

MPI is quick and relatively inexpensive. MPI is widely used on steel, cobalt, iron, and
nickel surfaces. As mentioned earlier the basic principle behind this method is to run a magnetic
current through the material being inspected.

When the current encounters a defect, the magnetic field generated spreads outwards from
that point creating secondary magnetic fields thus indicating its presence. To visualize these
magnetic fields, magnetic powder or liquid is spread over the surface. These particles then gather
around the field, exposing the defect to the naked eye. (FLYABILITY, n.d.)

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The following includes the general procedure followed by the Dockyard personnel for a Magnetic
Particle Inspection.

1. The testing surface was thoroughly cleaned and prepared for the inspection.
2. White contrast paint (WCP-2) was sprayed all over the surface of the inspection.
3. The magnetic yoke was powered, and its yoke arms were placed on the surface to create a
magnetic field.
4. Black Magnetic Ink (7HF) was sprayed around the arms of the yoke to visualize the
magnetic fields.
5. The fields were inspected for secondary magnetic fields that confirms the presence of
defects.

Figure 14 White Contrast Paint (WCP- Figure 12 Solvent Cleaner (SKC-S)

Figure 15 Black Magnetic Ink (7HF)
2) Source: QCO CDPLC Source: QCO CDPLC
Source: QCO CDPLC

I assisted with an MPI done for an anchor windlass of a ship during the workshop period.

Figure 13 Anchor Windlass of a ship Source: https://dieselship.com/

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Ultrasonic Testing (UT)

Ultrasonic Testing is another NDT method widely used in many industries, such as
manufacturing, construction, aerospace, maritime, etc. This method is suitable for identifying
internal defects and the thickness of a test subject. Some common applications of UT testing are,
• Plate Testing
• Weld Testing
• Thickness Measurement
• Immersion Testing
• Through transmission Testing

To inspect a material or to identify flaws, high frequency waves or ultrasonic waves are
sent through the material. The frequency of these waves typically ranges from 0.1 to 15 Mhz.
(ONESTOPNDT, 2022).

Flaw Detection

Figure 16 Instance 02
Figure 17 Instance 01 Source: Source:
https://www.onestopndt.com/ https://www.onestopndt.com
/

The basic principle of a UT is to send a sound wave into a test piece by a probe as shown
in the first instance. There are two signs, one from the probe's first pulse and the other from the
back wall echo. As shown in the second instance: A fault produces the third indication while also
lowering the amplitude of the back wall indicator. The ratio D/Ep determines the depth of the flaw.
(ONESTOPNDT, 2022)

Figure 18 Ultrasonic Flaw Detector Source : CDPLC

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The following includes a procedure for UT flaw detection for a weld run

1. The surface was cleaned to remove dust, dirt, and debris.

2. A sketch of lines was drawn marking dimensions.
3. The area where UT has to be done was marked.
4. Couplant gel was applied to the test area.
5. The probe was placed on the surface at multiple points and evaluated.
6. The screen of the flaw detector was observed for defects.

Figure 19 UT Flaw Detector Source:

CDPLC

Figure 20 The pulse-echo UT Source: https://www.flyability.com/

Figure 22 Sketch Drawn around the Figure 21 Detecting flaws Source:

weld run Source : CDPLC CDPLC

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There are three types of probes used for UT testing,

• Straight beam probes (4Mhz ⌀10 at QCO)
• Angle Probes (70° 4Mhz, 60° 4Mhz at QCO)
• TR Probes (Transmitter Receiver Probes)

Angle probes are used for flaw detection inspections. Straight beam probes are used for thickness
measurements.

Thickness Measurement

Thickness measurement is another use of Ultrasonic testing. The thickness of plates is

measured using UT thickness gauges. The same principle of ultrasonic waves is used in this
scenario as well. A UT thickness gauge, coupling gel, and a probe are used for this inspection.

Figure 23 UT thickness probe Source: CDPLC

Figure 24 UT Thickness gauge Source: CDPLC

Figure 25 Couplant Gel Source : CDPLC

Thickness measurements of deck plates, the cylindrical structure of a light tower, and a double-
bottom cell were performed during my time at the QCO.

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Radiographic Testing
This method uses X-rays and gamma rays for the inspection of internal structures and
defects of materials and components. Detailed images of the test material are obtained without
causing damage to the material. Various industries especially the maritime industry utilize
radiography to expose defects. Defects such as cracks, porosity, inclusions, and other
discontinuities can be observed.

The principle involved in radiography is differential absorption. In simple terms, it

describes the difference between the X-ray photons that are absorbed photoelectrically versus
those that penetrate the body. A digital detector or a radiographic film is used to analyze this
phenomenon. The denser the material, the more radiation is absorbed.

The following includes a general procedure involved in an X-ray test,

1. A suitable film type and size is chosen.

2. Lights are switched off and the x-ray films are checked in the darkroom under a red light
and prepared.
3. The x-ray machine is warmed up.
4. The test piece is placed directly below the machine.
5. The laser beam in the machine is aligned and positioned correctly.
6. The lead numbering with dates, identification numbers & the IQI (Image Quality Indicator)
card is placed above the test piece, and the film (with cover) below the specimen.
7. The participants left the exposure room and it was securely shut.
8. Parameters such as the distance between the specimen and the source, thickness, density,
film type, material, voltage, and current values were set in the control box.
9. The x-ray machine was started.
10. The film was securely brought to the dark room for inspection. (It was recommended to
wait for some time after the process completion before entering the room)
11. It was placed on a tray and dipped into the developer bath for 5 minutes at 20°C.
12. The tray was then rinsed in water for 1-2 minutes.
13. Then the film was dipped into the fixer bath, keeping it twice the time kept in the developer
bath, and then rinsed again.
14. Finally, the film was hung and allowed to dry.
15. Finally, using a film viewer the defects are examined in the dark room.

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Trainee Evaluation Form

Name W.A.P.N Athukorala

Service Number 7906059
Department / Workshop Quality Control Office
Duration From : To :

Description Poor Average Good (6 Excellent Total

(0 marks) (3marks) marks) (10
marks)
Punctuality
Work Knowledge
Quality of Work
Application & Efficiency
Safety Consciousness
Cooperation with Superiors
Cooperation with Other Trainees
Adherence to CDPLC Rules & Regulations
Maintenance of Trainee Record Book
Situational Flexibility
Total

Remarks

……………………………………………………
Signature of the Department Head/ Workshop Engineer

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