Introduction
A prominent aerospace component supplier, serving major aero engine and airframe manufacturers worldwide, faced operational challenges with their four UV dye penetrant wash stations used for non-destructive testing (NDT). These stations relied on outdated UV-A fluorescent tube lighting, which was increasingly difficult to source due to supply chain disruptions.
The non-waterproof tubes, susceptible to damage in the wet wash station environment, caused frequent failures and maintenance delays. The client contacted our UV consultancy to explore robust UV-A LED solutions that could ensure consistent performance, enhance durability, and comply with safety regulations, including the Control of Artificial Optical Radiation at Work Regulations 2010.
Initial consultation
In the initial phone consultation, the client’s NDT manager outlined the need for reliable UV-A lighting to maintain inspection quality across all four wash stations. They emphasized the importance of achieving minimum UV irradiance levels for effective dye penetrant testing and expressed concerns about water damage to the existing tubes. We discussed the advantages of IP 67 rated UV-A LED technology, which offers waterproofing and longevity. Key topics included station layouts, existing safety measures, and regulatory compliance. We proposed a site visit to assess the stations and demonstrate suitable LED solutions.
Site visit
Our team conducted a thorough site visit to evaluate the four wash stations, each equipped with aging UV-A fluorescent tubes. We observed water ingress issues that compromised the tubes’ performance, leading to inconsistent irradiance and frequent replacements. Using UV-A LED units, we demonstrated their resilience and brightness, tailored for wet environments. Precise measurements confirmed the number and placement of LEDs needed to achieve the required UV irradiance across each station’s inspection area. Discussions with the client’s safety officer highlighted the need for updated UV exposure protocols and staff training to align with UK regulations.
Recommendations and solutions
We recommended installing two Titan UV-A LED units (IP 67 rated) per wash station, totalling eight units across the facility. These high-intensity, waterproof LEDs were designed for harsh industrial environments, ensuring reliable performance in the wet conditions of dye penetrant testing. The solution included a detailed installation plan to optimize coverage and a strategy to assess and mitigate personal UV exposure risks. We also proposed enhanced safety controls and a training program to ensure compliance with the Control of Artificial Optical Radiation at Work Regulations 2010.
Implementation
The client approved the purchase of eight Titan UV-A LED units, which were installed by their in-house maintenance team with our technical guidance. The IP 67 rating eliminated the need for protective enclosures, simplifying the setup and reducing costs. The installation was staggered across the four stations to minimize downtime, with each station completed over a single shift. The LEDs integrated seamlessly with existing electrical systems, and their compact design improved accessibility for operators.
Follow-up services
Post-installation, we conducted a comprehensive UV safety assessment to verify regulatory compliance. The visit evaluated technical controls and measured personal UV exposure levels to ensure operator safety. We delivered tailored training for multiple NDT technicians and maintenance staff, covering UV exposure risks, safe operation of the new units, and adherence to exposure limits. The training addressed previous gaps in safety awareness, reinforcing the importance of updated protocols to protect workers.
Outcomes
The Titan UV-A LED units significantly enhanced the reliability of the dye penetrant wash stations. The waterproof design eliminated water-related failures, reducing maintenance costs. The LEDs 40,000-hour lifespan minimised replacement needs, ensuring consistent irradiance for high-quality inspections. Energy consumption dropped due to the LEDs efficiency, supporting the client’s sustainability objectives. The safety assessment confirmed full compliance with UK regulations, providing peace of mind. Staff feedback highlighted improved ease of use and confidence in the new system, while the training program strengthened workplace safety culture.
Conclusion
This project underscored the value of specialized UV consultancy in addressing complex challenges in aerospace NDT. By deploying robust, IP 67 rated UV-A LED technology, providing expert installation support, and delivering comprehensive safety training, we enabled the client to modernize their wash stations while prioritising performance and compliance. The result was a more efficient, durable, and safe inspection process, reinforcing the benefits of tailored UV solutions. Businesses seeking to upgrade their UV systems can contact us to discuss customised consultancy services.