无损检测工艺规程液体渗透模板.doc

NJBST Co.,Ltd.QCD-015Rev.:0Page:1 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATIONPROCEDURE FOR LIQUID PENETRANT EXAMINATION液 体 渗 透 检 验 工 艺 规 程CONTROLLED 在控本 UNCONTROLLED 非在控本 COPY NO 副本编号：PREPARED BY 编制： DATE 日期： REVIEWED BY 审核： DATE 日期： APPROVED BY 同意： DATE 日期： NJBST Co.,Ltd.QCD-015Rev.:0Page:2 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATIONDEMONSTRATION CERTIFICATION This is to certify that this procedure has been demonstrated on a test specimen with known defects to the satisfaction of the Authorized Inspector according to ASME Code Section V, T-150 as required by the Section Div.1, Appendix 8. Test Specimen No.: Demo. Report No.: NDE Level : AI: NJBST Co.,Ltd.QCD-015Rev.:0Page:3 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATION制造厂 材料 牌号上海沪 渗透剂 HD-RS船助剂 显像剂 HD-XS 厂 清洗剂 HD-BX 1. General 1.1 This procedure is applied to dye liquid penetrant examination of metal material and weldment for ASME Code items. 1.2 This procedure is only suitable for detecting the defects that are open to the surface of material or weldment. 1.3 This procedure shall be demonstrated to the satisfaction of the AI prior to implementation.2. Personnel 2.1 The personnel engaged in the penetrant examination shall be qualified and certified in accordance with the requirement of NJBST Co., Ltd.s“Written Practice for NDE Personnel Training Examination, Qualification and Certification”(No.:QCD-011). 3. Penetrant Materials 3.1 The penetrant materials is intended to include all penetrants, solvents or cleaning agents, developers, etc, used in the examination process. 3.2 The liquid penetrant examination materials shall be designated and recommended, as shown in Table 3.2. The materials used for examination shall be the same type. Intermixing of penetrant materials from different families or different manufacturers is not permitted. Table 3.2 Manufacturer Material Model Shanghai Penetrant HD-RS (Ship Brand) Developer HD-XS Cleaning Agent HD-BX 3.3 When examining austenitic stainless steel or titanium, all materials shall be analyzed individually for chlorine and fluorine content in accordance with the procedure shown in T-641(b) of ASME Code Section V. The total chlorine plus fluorine content shall not exceed 1%of the residue by weight. The certificate of compliance from manufacturer shall be obtained. 3.4 When examining nickel base alloys, all materials shall be analyzed individually for sulphur content in accordance with the procedure shown in T-641(a) of Section V.The sulphur content shall not exceed 1%of the residue by weight. The certificate of compliance from manufacturer shall be obtained. 1 概述 11 本规程适适用于ASME规范产品金属材料和焊件着色液体渗透检验。 12 本规程仅适适用于探测材料或焊件表面开口类缺点。 13 本规程在实施之前，须演示至AI满意。 2 人员 2.1 从事液体渗透检验人员必需是依据南京定色钛业(资料号：QCD-011)进行考试和资格任命合格人员。 3. 渗透材料 3.1 渗透材料包含检验过程中使用全部渗透剂、溶剂或清洗剂、显像剂等。 3.2 液体渗透探伤材料，必需是指定和推荐，见表3.2。检验使用材料必需是同一类型。不许可用不一样类型或不一样制造厂渗透材料混合使用表3.2 3.3 当检验奥氏体不锈钢或钛材时，必需依据ASME规范第卷T-641(b)中程序，对全部材料分别分析氯和氟含量。残留氯和氟总含量不得超出残留物重量1%，必需有制造厂对应合格证。 3.4 当检验镍基合金时，必需根据ASME规范第卷T-641(a)中程序，对全部材料分别分析硫含量。硫含量不得超出残留物重量1%。必需有制造厂对应合格证。NJBST Co.,Ltd.QCD-015Rev.:0Page:4 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATION后清洗评定、统计显像、检验干燥清洁施加渗透剂预清洗，干燥表面制备Post CleaningEvaluation and RecordDevelopment and InspectionDryingCleaningPenetrant ApplicationPrecleaning and DryingSurface Preparation 4. Examination Procedure 4.1 Examination Flow Chart as shown in Fig.4.1. Fig. 4.1 4.2 Surface Preparation Prior to all penetrant examination, the surface to be examined and all adjacent areas within at least 1in. (25.4mm) shall be dry and free of dirt, grease,lint, scale, welding flux, weld spatter， paint， oil and other extraneous matter. If necessary, surface shall be prepared by grinding or machining. 4.3 Precleaning 4.3.1 The areas to be examined and adjacent areas within at least 1in. (25.4mm) shall be cleaned using cleaning agent before the penetrant is applied. 4.3.2 After cleaning, drying of the surface to be examined shall be accomplished by normal evaporation or with forced air, as appropriate. The minimum drying time shall ensure that the cleaning solution has evaporated prior to application of the penetrant. 4.4 Penetrant Application 4.4.1 The penetrant may be applied on the surface 4. 检验程序 4.1 检验程序步骤图见图4.1 图4.1 4.2 表面制备 全部渗透检验前，被检工件表面及其周围最少为1英寸(25.4mm)区域内全部应干燥清洗洁净，不得有任何脏物、纤维屑、氧化皮、焊剂、油和其它外来物。必需时，应对表面进行打磨或机加工。 4.3 预清洗 4.3.1 在施加渗透剂之前，被检区域及其周围最少为1英寸(25.4mm)区域内均需用清洁剂进行清洗。 4.3.2 清洗后，经过合适方法(自然挥发或人工通风)，对被检表面进行干燥；最少干燥时间以确保在施加渗透剂之前清洁剂已完全挥发为界。 4.4 施加渗透剂 4.4.1 能够用浸渍、涂刷或喷涂等任一适宜方法，在被检工件NJBST Co.,Ltd.QCD-015Rev.:0Page:5 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATION 滞留时间材料 型式 (min) 渗透剂 显象剂铝、镁、 铸件和焊缝 5 7钢、黄铜、青铜、钛 轧材-挤压件 10 7高温合金 锻件，板材 Material Form Dwell Times (min) Penetrant DeveloperAluminum, magn- Castings & welds 5 7esium. steel, brass or bronze, titanium Wrought material- and high temperature extrusions, forgings, 10 7alloys plate of workpieces to be examined by any suitable means such as dipping, brushing or spraying. 4.4.2 The temperature of the penetrant and the surface to be examined shall not be below 500F(100C) nor above 1250F(520C) throughout the examination period. When it is not practical to conduct a liquid penetrant examination within above temperature range, the examination procedure at the proposed lower or higher temperature range shall be qualified using a quench cracked aluminum block according to ASME Code Section V, T-653. 4.4.3 Penetration time is critical. The minimum dwell time is shown in Table 4.4.3. For suitable temperature, the area being examined shall remain wetted by the penetrant for the dwell time.Table 4.4.3 Recommended minimum dwell times 4.5 Excess Penetrant Removal Excess solvent removable penetrant shall be removed by wiping with a cloth or absorbent paper. The remaining traces shall be removed by lightly wiping the surface with a cloth or absorbent paper moistened with solvent. To avoid over removing, flushing the surface with solvent shall be prohibited. 4.6 Developer Application 4.6.1 The developer shall be applied as soon as possible after excess penetrant removal and drying surface. The surface may be dried by normal evaporation before the developer is applied. The drying time shall be within 5 to 20 min. 4.6.2 The developer shall be applied by spraying. A uniform thin coating shall be provided and the coating thickness shall be suitable. 4.6.3 Prior to applying wet developer to the surface, the developer must be thoroughly agitated. 4.6.4 Dipping or flooding the part with non-aqueous developer is prohibited, since it will dissolve the penetrant in the discontinuities through its solvent action. 4.7 Interpretation 4.7.1 Developing time for final interpretation begins表面施加渗透剂。 4.4.2 在整个检验期间，渗透剂和被检表面温度不得低于500F(100C)，不得高于1250F(520C)。当在上述温度范围内不能满足时，则根据ASME规范第V卷T-653，对提议采取温度范围，使用有淬火裂纹铝试块进行验证。 4.4.3 严格控制渗透时间，最小滞留时间见表4.4.3。合适温度条件下，在滞留时间内，被检区域必需用渗透剂保持潮湿。表4.4.3 推荐最少滞留时间 4.5 多出渗透剂清除 多出渗透剂必需用布或吸纸擦去，剩下痕迹必需用蘸有溶剂布或纸在表面轻轻地擦去。为了预防清洗过分，严禁用溶剂清洗表面。 4.6 施加显像剂 4.6.1 多出渗透剂被清除且工件干燥后，必需立即地施加显像剂。显像剂施加之前，工件表面能够自然挥发干燥，干燥时间必需在5-20分钟以内。 4.6.2 施加显像剂必需采取喷涂法，薄且均匀，涂层厚度适中。 4.6.3 在施加湿型显像剂至工件表面之前，显像剂必需充足搅拌。 4.6.4 禁用非水湿显像剂浸渍或灌洗工件，因非水湿显像剂会经过溶解作用将缺点中渗透剂溶解掉。 4.7 判定 4.7.1 最终判定显像时间应从施加NJBST Co.,Ltd.QCD-015Rev.:0Page:6 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATIONas soon as a wet developer coating is dry. The minimum developing time shall be 7min. 4.7.2 Final interpretation shall be made within 7 to 60 min after the requirements of Para. 4.7.1 are satisfied. 4.7.3 The developing trace can be examined either by natural light or artificial light. A minumum light intensity of 50 fc (500Lx) is required to ensure adequate sensitivity during the examination and evaluation of indications. 4.7.4 The surface shall be divided into several parts to be examined if the surface is so large that the examination can not be finished within the given time. The developing condition can be observed either by eyes or by means of a magnifier. 4.8 Post-cleaning The penetrant materials shall be clearly removed away from parts after examination. The post cleaning must be performed if remaining penetrant materials can result in corrosion by the combination with other materials during the operation. The suitable cleaning process shall be adopted for post cleaning such as flushing with water, mechanical cleaning, solvent soaking, etc. The developer shall be cleaned as soon as possible after examination if the part requests the post cleaning so as to avoid it condensed on the part. 5. Evaluation of Indications 5.1 Broad areas of pigmentation which could mask indications of discontinuities are unacceptable and such areas shall be cleaned and reexamined. 5.2 An indication is the evidence of a mechanical imperfection. Only indications with major dimensions greater than 1/16in (1.6mm) shall be considered relevant. 5.3 Linear indications are those indications in which the length is more than three times the width . Rounded indications are indications which are circular or ellipsoidal with the length less than three times the width. 5.4 Any questionable or doubtful indications shall be reexamined to determine whether or not they are relevant. Surface conditioning may proceed before the reexamination. 5.5 The indication of a discontinuity may be larger than the discontinuity that causes it; however, the size of the indication is the basis of acceptance or rejection. 6. Acceptance Standards The following relevant indications are unacceptable:a. any cracks or relevant linear indications; b. relevant rounded indications greater than 3/16in. (4.8mm); c. four or more relevant rounded indications in a line separated by 1/16 in. (1.6mm) or less (edge to edge);干显像剂后或从湿显像剂涂层干燥后立即起算，不得少于7分钟。 4.7.2 在满足4.7.1 要求后，最终判定必需在7-60分钟内作出。 4.7.3 显像痕迹能够经过自然光或人工白光进行检验，要求最小灯光强度为50fc(500LX)，以确保在检验和评价显示过程中有充足灵敏度。 4.7.4 假如受检表面太大，无法在要求时间内完成检验，则应将表面分成多个部进行检验。显像情况能够用肉眼或放大镜进行观察。 4.8 后清洗 检验后，必需完全清除工件上渗透材料，假如残余渗透材料在操作过程中和其它材料混合后会造成腐蚀，则必需进行后清洗。能够采取如用水冲洗、机械清洁、溶剂浸泡等合适清洁工作 ，来进行后清洗。 假如需要后清洗，则检验后必需立即进行，以免显像剂凝固在工件上。 5. 显示评价 5.1 大面积颜料沉淀会掩盖缺点显示，是不合格，这些区域应清洗洁净并重新检验。 5.2 显著机械性不连续为其显现特征，只有在显示关键尺寸大于1/16英寸(1.6mm)时，才是缺点显示。 5.3 线性缺点是指长度大于三倍宽度缺点。面形缺点是指长度小于3倍宽度圆形或椭圆形缺点。 5.4 任何有疑问或难以判定显示，必需重新检验以确定是否是缺点显示，重新检验前可先作表面修整。 5.5 缺点显示可能大于缺点本身，不过以显示尺寸作为合格是否依据。 6. 合格标准 下列缺点显示为不合格： a.任一裂纹或对应线性缺点; b.大于3/16英寸（4.8mm）面形缺点； c.一条直线上有4个或4个以上面形缺点，其边界到边界间距离等于或小于1/16英寸(1.6mm)NJBST Co.,Ltd.QCD-015Rev.:0Page:7 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATION 7. The repaired area shall be reexamined according to the original examination procedure. 8. Report The liquid penetrant examination report shall include examination condition, used penetrant material and a sketch of parts examined and examination results. The report shall be prepared by the operator, reviewed by the NDE Level II or III, and approved by the Level III prior to submission to the AI for acceptance.9. Report form，see Page 8 of 8. 7.返修区应按原PT探伤工艺重新探伤。8. 汇报 液体渗透检验汇报必需包含检验条件、使用渗透材料、被检部件草图和检验结果；此汇报由操作员编制，由NDEII级或III级人员审核，并在提交给AI确定之前由NDEIII级人员同意。9. 汇报形式见第8页。