Product Overview

Summary: This Non Destructive Testing (NDT) Safe Operating Procedure sets out clear, safe and compliant methods for conducting inspections without damaging plant, structures or components. It helps Australian businesses control the significant WHS risks associated with NDT activities while ensuring reliable, traceable test results that support asset integrity and regulatory compliance.

Non Destructive Testing is critical to verifying the integrity of welds, pressure equipment, structural steel, pipelines and critical plant—without taking assets out of service or causing damage. However, NDT methods such as radiography, ultrasonic testing, magnetic particle testing, dye penetrant testing and eddy current testing introduce their own set of safety, quality and compliance risks. This SOP provides a structured, step‑by‑step framework for planning, conducting and documenting NDT activities in line with Australian WHS duties and relevant technical standards.

By implementing this procedure, your organisation can demonstrate that NDT work is controlled, repeatable and defensible under audit or investigation. It sets out how to manage hazards such as ionising radiation, electrical equipment, chemicals, confined spaces and work at height while still achieving reliable inspection results. The SOP also standardises test preparation, calibration, acceptance criteria and reporting, reducing re‑work, disputes with clients and the risk of missing critical defects that could lead to costly failures, environmental incidents or serious injuries down the track.

Key Benefits

• Ensure NDT activities are carried out safely and compliantly in accordance with Australian WHS legislation and relevant AS/NZS standards.
• Reduce the risk of radiation exposure, chemical contact, electrical incidents and other hazards associated with NDT methods.
• Standardise inspection techniques, acceptance criteria and reporting to improve reliability and repeatability of test results.
• Streamline training and onboarding for new NDT technicians, supervisors and contractors through clear, practical instructions.
• Demonstrate due diligence and robust risk management during client audits, regulator inspections and third‑party certifications.

Who is this for?

• Non Destructive Testing Technicians
• Level 2 and Level 3 NDT Inspectors
• Maintenance Supervisors
• Engineering Managers
• WHS Managers and Advisors
• Quality Assurance Managers
• Fabrication and Welding Supervisors
• Asset Integrity Engineers
• Mining and Resources Site Supervisors
• Construction Project Managers

Hazards Addressed

• Exposure to ionising radiation during industrial radiography
• Chemical exposure from penetrant, developer, cleaner and magnetic particle consumables
• Electrical shock and burns from portable NDT equipment and power supplies
• Manual handling injuries from moving test equipment, cables and test pieces
• Slips, trips and falls around test areas, especially in workshops and construction sites
• Working at height or in awkward positions to access test locations
• Confined space hazards when testing inside tanks, vessels or pipelines
• Fire and explosion risks when using flammable aerosols or working in hazardous areas
• Noise exposure from some ultrasonic and associated mechanical operations
• Eye strain and ergonomic issues from prolonged visual inspection and screen work

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and NDT Methods Covered (RT, UT, MT, PT, ET and Visual)
• 3.0 Applicable Legislation, Standards and Codes of Practice
• 4.0 Roles, Responsibilities and Competency Requirements (including NDT certification levels)
• 5.0 Pre‑Job Planning and Risk Assessment (JSEA/SWMS requirements)
• 6.0 Equipment Selection, Calibration and Verification
• 7.0 Site Preparation, Isolation and Exclusion Zones
• 8.0 Personal Protective Equipment (PPE) Requirements for Each NDT Method
• 9.0 Safe Work Procedures – Radiographic Testing (RT)
• 10.0 Safe Work Procedures – Ultrasonic Testing (UT)
• 11.0 Safe Work Procedures – Magnetic Particle Testing (MT)
• 12.0 Safe Work Procedures – Dye Penetrant / Liquid Penetrant Testing (PT)
• 13.0 Safe Work Procedures – Eddy Current and Other Advanced Methods
• 14.0 Control of Hazardous Chemicals and Aerosols
• 15.0 Working in Confined Spaces, at Heights and in Hazardous Areas
• 16.0 Quality Control, Acceptance Criteria and Re‑test Requirements
• 17.0 Documentation, Traceability and Record Keeping
• 18.0 Emergency Procedures and Incident Response (including radiation incidents and chemical spills)
• 19.0 Housekeeping, Decontamination and Waste Disposal
• 20.0 Training, Induction and Competency Verification
• 21.0 Audit, Review and Continuous Improvement of the NDT SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth and harmonised state and territory laws)
• Work Health and Safety Regulations 2011 (and state/territory equivalents)
• Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace Code of Practice
• Safe Work Australia – Managing Noise and Preventing Hearing Loss at Work Code of Practice
• AS/NZS 1170 series – Structural design actions (context for structural integrity assessments)
• AS/NZS 1554 series – Structural steel welding (inspection and acceptance criteria context)
• AS 2177 series – Non-destructive testing – Radiography of welds
• AS 2207 – Non-destructive testing – Ultrasonic testing of fusion welded joints in carbon and low alloy steel
• AS 4037 – Pressure equipment – Examination and testing
• AS/NZS ISO 9712 – Non-destructive testing – Qualification and certification of NDT personnel
• AS/NZS 2243.4 – Safety in laboratories – Ionizing radiations
• ARPANSA Radiation Protection Series (RPS) documents for industrial radiography
• AS/NZS 4801 or ISO 45001 – Occupational health and safety management systems