A leading aerospace components manufacturer, supplying aero engine and airframe original equipment manufacturers (OEMs) and their Tier 1 suppliers worldwide, faced challenges in maintaining their non-destructive testing (NDT) booth.
The facility relied on outdated UV-A fluorescent tubes for inspection lighting, but sourcing replacements had become increasingly difficult due to market shortages and advances in UV technology.
The client reached out to explore modern UV-A LED solutions that could enhance reliability, reduce maintenance, and ensure compliance with safety regulations. The project aimed to upgrade the lighting system while improving performance and worker safety.
Initial consultation
During the initial phone consultation, the client’s engineering team outlined their requirements, including minimum UV irradiance levels critical for effective NDT inspections. They highlighted that their existing UV-A lamps, mounted behind protective screens due to their non-waterproof design, were prone to frequent failures, disrupting production schedules.
We discussed the potential of UV-A LED technology, which offers longer lifespans and greater energy efficiency. Key topics included mounting configurations, compatibility with existing safety controls, and compliance with the Control of Artificial Optical Radiation at Work Regulations 2010. We recommended a site visit to assess the booth’s setup and demonstrate LED solutions.
Site visit
Our consultancy team conducted a detailed site visit to evaluate the NDT booth’s lighting system and operational environment. We demonstrated a range of UV-A LED units, showcasing their superior brightness and durability compared to fluorescent tubes. Using precise measurement tools, we assessed the current UV irradiance levels and determined the optimal quantity and positioning of new units to achieve the client’s required coverage.
Discussions with the client’s health and safety manager focused on personal UV exposure risks, emphasising compliance with UK regulations. We identified gaps in existing safety protocols, particularly around staff training and exposure monitoring, which needed addressing to ensure a safe working environment.
Recommendations and solutions
Based on our assessment, we proposed installing six Enigma XL UV-A LED units, designed specifically for industrial NDT applications. These units offered high-intensity output, energy efficiency, and a lifespan exceeding 40,000 hours, significantly reducing maintenance needs.
We also developed a comprehensive plan to measure and assess personal UV exposure levels within the booth, including recommendations for operator training. The solution ensured compliance with the Control of Artificial Optical Radiation at Work Regulations 2010 while optimising inspection performance.
Implementation
The client accepted our quotation and procured the six units. Their in-house engineering and electrical teams handled the installation. The transition was seamless, with the new units integrated into the existing booth setup without requiring structural modifications. The protective screens were retained as a precautionary measure, though the waterproof design of the LEDs added an extra layer of durability.
Follow-up services
Post-installation, our team conducted a thorough UV safety assessment to verify compliance with regulatory standards. This included evaluation of technical and administrative controls, measurement of personal UV exposure levels, and ensuring proper implementation of safety measures.
We delivered tailored training sessions for operators and maintenance engineers, covering the risks of UV exposure, adherence to exposure limits, and the importance of maintaining control measures. The training addressed previous oversights in safety education, empowering staff to work confidently and safely with the new system.
Outcomes
The upgraded UV-A LED system transformed the client’s NDT operations. The Enigma XL units delivered consistent, high-intensity UV irradiance, improving the reliability and accuracy of inspections. The LED extended lifespan eliminated the frequent tube replacements that had previously disrupted production, reducing maintenance costs in the process. Energy consumption dropped due to the LED efficiency, contributing to the client’s sustainability goals.
The safety assessment provided peace of mind, confirming full compliance with UK regulations. An action plan for ongoing training was implemented, addressing prior gaps and enhancing workplace safety. The client reported increased confidence in their inspection process and regulatory adherence.
Conclusion
This project showcased the power of specialised UV consultancy in delivering high-performance, safety-focused solutions for complex industrial challenges. By leveraging UV-A LED technology, expert guidance, and comprehensive safety training, we enabled the client to modernise their NDT booth while safeguarding their workforce.
The result was a more reliable, efficient, and compliant operation, reinforcing the value of tailored UV solutions. Businesses seeking to enhance their UV systems can contact us to explore customised consultancy services.