液體滲透檢測工藝規(guī)程

LIQUIDPENETRANTEXAMINATIONPROCEDURE液體滲透檢測工藝規(guī)程PreparedBy編制:Date日期:ReviewedBy審核:Date日期:ApprovedBy批準(zhǔn):Date日期:StatementofDemonstrationCertification演示證實聲明WeherebycertifythattheLiquidPenetrantExaminationProcedure(QCNP-04,2023/Rev.0)hasbeendemonstratedonatestspecimenwithknowndefectstothesatisfactionoftheAIaccordingtoASMECodeSectionV,T-150asrequiredbytheAppendix8ofSectionVIII,Div.1.茲證明該《液體滲透檢測工藝規(guī)程》已按照ASME規(guī)范第Ⅴ卷T-150和第Ⅷ-1卷強制性附錄8的規(guī)定，在帶缺陷試板上進行了演示。演示結(jié)果令A(yù)I滿意。SpecimenNo.:試板編號：Demo.ReportNo.:演示報告編號：CertifiedbyNDELevelIII:Date:Ⅲ級證明人AI:Date:授權(quán)檢查師：1General概述1.1ThisprocedureisappliedtodyeliquidpenetrantexaminationofmetalmaterialandweldmentforASMECodeitems.本規(guī)程合用于ASME規(guī)范產(chǎn)品金屬材料和焊件著色液體滲透探傷。1.2Thisprocedureisonlysuitablefordetectingthedefectsthatareopentothesurfaceofmaterialorweldment.本規(guī)程僅合用于探測材料或焊件表面開口類缺陷。1.3ThisprocedureshallbecertifiedbydemonstrationtothesatisfactionoftheAIpriortoimplementation.本規(guī)程在執(zhí)行之前，需通過演示令A(yù)I滿意。2Personnel人員Thepersonnelengagedinthepenetrantexaminationshallbequalifiedandcertifiedinaccordancewiththerequirementofthecompany’s“WrittenPracticeforNDEPersonnelTraining,Qualification&Certification”(TC/QP-8-1Ed.2023Rev.0).從事液體滲透探傷的人員應(yīng)為按本公司《無損檢測人員培訓(xùn)考評及認(rèn)證實行細(xì)則》(TC/QP-8-1Ed.2023Rev.0）進行資格考核和認(rèn)證的合格人員。3WrittenProcedureRequirements書面規(guī)程Requirements規(guī)定：Liquidpenetrantexaminationshallbeperformedinaccordancewiththewrittenprocedure(andtheinstructioncardsassupplementarymeans),whichshall,asaminimum,containtherequirementslistedinTable1.Thewrittenprocedureshallestablishasinglevalue,orrangeofvalues,foreachrequirement.液體滲透檢查須按書面規(guī)程進行（輔以探傷專用工藝卡）。書面規(guī)程至少涉及表一中的內(nèi)容。書面規(guī)程應(yīng)對每一項規(guī)定都給出數(shù)值或數(shù)值范圍以作定量評價。ProcedureQualification規(guī)程評估：Whenprocedurequalificationisspecified,achangeofrequirementinTable1identifiedasanessentialvariablefromthespecifiedvalue,orrangeofvalues,shallrequirerequalificationofthewrittenprocedure.Achangeofarequirementidentifiedasnonessentialvariablefromthespecifiedvalue,orrangeofvalues,doesnotrequirerequalificationofthewrittenprocedure.Allchangesofessentialornonessentialvariablesfromthevalue,orrangeofvalues,specifiedbythewrittenprocedureshallrequirerevision,oranaddendumto,thewrittenprocedure.規(guī)定對規(guī)程進行評估的時候，表1中重要素的數(shù)值發(fā)生變化時，需要對書面規(guī)程進行重新評估。副要素的數(shù)值發(fā)生變化時，不需要對規(guī)程進行重新評估。重要素或副要素的數(shù)值發(fā)生變化都將規(guī)定對書面規(guī)程進行修改或補充。Table1RequirementsofLiquidPenetrantExaminationProcedureNo.RequirementEssentialVariableNonessentialVariableNotes*【1】Identificationofandanychangeintypeorfamilygroupofpenetrantmaterialsincludingdevelopers,emulsifiers,etc●4.2【2】Surfacepreparation(finishingandcleaning,includingtypeofcleaningsolvent)●5.2【3】Methodofapplyingpenetrant●5.4.1【4】Methodofremovingexcesssurfacepenetrant●5.5【5】Methodofapplyingdeveloper●5.6【6】Minimumandmaximumtimeperiodsbetweenstepsanddryingaids●5.3.25.4.35.6.1【7】Decreaseinpenetrantdwelltime●5.4.3【8】Increaseindeveloperdwelltime(Interpretationtime)●5.7.【9】Minimumlightintensity●5.7.3【10】Surfacetemperatureoutside41°Fto125°F(5℃to●5.4.2【11】Performancedemonstration,whenrequired●1.33.2【12】Personnelqualificationrequirements○2.1【13】Materials,shapes,orsizestobeexaminedandtheextentofexamination○1.15.2Table3【14】Postexaminationcleaningtechnique○5.8*Therelatedclausestipulatingtherequirement.表1液體滲透檢查規(guī)程的規(guī)定序號要求重要素副要素備注*【1】●4.2【2】表面修整(精加工及清洗,涉及清洗劑種類)●5.2【3】滲透劑施加方法●5.4.1【4】表面多余滲透劑的去除方法●5.5【5】顯像劑施加方法●5.6【6】干燥前滲透劑最小和最大滯留時間●5.3.25.4.35.6.1【7】滲透劑滯留時間的減少●5.4.3【8】顯像劑滯留時間的增長(評估時間)●5.7.2【9】最小光照度●5.7.3【10】超過41°F~125°F(5℃~●5.4.2【11】操作演示（需要時）●1.3，3.2【12】人員資格規(guī)定○2.1【13】被檢工件的材料、形狀、尺寸及檢查范圍○1.1，5.2，表3【14】檢查后清理方法○5.8*在本規(guī)程中出現(xiàn)的相關(guān)條款。4PenetrantMaterials滲透材料Thepenetrantmaterialsareintendedtoincludeallpenetrants,solventsorcleaningagents,developers,etc,usedintheexaminationprocess.滲透材料涉及探傷過程中使用的所有滲透劑、溶劑或清洗劑、顯像劑等。TheliquidpenetrantexaminationmaterialsshallbedesignatedandrecommendedasshowninTable2.Thematerialsusedforexaminationshallbethesametype.Intermixingofpenetrantmaterialsfromdifferentfamiliesordifferentmanufacturersisnotpermitted.液體滲透探傷材料，指定用表2所示牌號。探傷使用的材料應(yīng)為是同一類型的。不同類型或不同制造廠的滲透材料嚴(yán)禁混用。Table2ManufacturerMaterialModelMarktecFlawDetectionMaterialCo.,Ltd.,PenetrantDPT-5(P)DeveloperDPT-5(D)CleaningAgentDPT-5(C)表2制造單位材料型號美柯達探傷器材有限公司滲透劑DPT-5(P)顯像劑DPT-5(D)清洗劑DPT-5(C)Whenexaminingausteniticorduplexstainlesssteelortitanium,allmaterialsshallbeanalyzedindividuallyforchlorineandfluorinecontentinaccordancewiththeprocedureshowninPara.Ⅱ-642ofMandatory,AppendixⅡofArticle6ofASMECodeSectionV.Thetotalchlorineplusfluorinecontentshallnotexceed1%oftheresiduebyweight.Thecertificateofcompliancebybatchwithtestresultsfrommanufacturershallbeobtained.探測奧氏體不銹鋼或鈦材時，應(yīng)按ASME規(guī)范第Ⅴ卷Ⅱ-642規(guī)定的方法，對所有滲透材料分別分析氯和氟的含量。殘留氯和氟總含量不得超過殘留物重量的1%，應(yīng)有制造單位簽發(fā)的合格證。Whenexaminingnickelbasealloys,allmaterialsshallbeanalyzedindividuallyforsulfurcontentinaccordancewiththeprocedureshowninPara.Ⅱ-641ofMandatory,AppendixⅡofArticle6ofSectionV.Thesulfurcontentshallnotexceed1%oftheresiduebyweight.Thecertificateofcompliancebybatchwithtestresultsfrommanufacturershallbeobtained.探測鎳基合金時，應(yīng)按照ASME規(guī)范第Ⅴ卷Ⅱ-641規(guī)定的方法，對所有滲透材料分別分析硫含量。硫含量不得超過殘留物重量的1%。應(yīng)有制造單位的合格證。5ExaminationProcess檢查程序ExaminationflowchartasshowninFigure1.SurfacePreparationDryingSurfacePreparationDryingDevelopmentandInspectionPrecleaningandDryDevelopmentandInspectionPrecleaningandDryEvaluationandRecordPenetrantApplication`EvaluationandRecordPenetrantApplicationPostCleaningExcessPenetrantRemovalPostCleaningExcessPenetrantRemovalFig.1PT程序流程圖見圖1SurfacePreparation:Priortoallpenetrantexamination,thesurfacetobeexaminedandalladjacentareaswithinatleast1in.(25.4mm)shallbedryandfreeofdirt,grease,lint,scale,weldingflux,weldspatter，paint，oilandotherextraneousmatter.Ifnecessary,surfaceshallbepreparedbygrindingormachining.表面制備:滲透探傷前，被探工件表面及其附近至少1英寸(25.4mm)區(qū)域內(nèi)都應(yīng)干燥，不得有任何污物、油脂、纖維屑、氧化皮、焊劑、油和其它外來物。必要時，應(yīng)對表面進行打磨或機加工。Precleaning預(yù)清洗Theareastobeexaminedandadjacentareaswithinatleast1in.(25mm)shallbecleanedusingcleaningagentbeforethepenetrantisapplied.施加滲透劑前，被探區(qū)域及其附近至少為1英寸(25mm)區(qū)域內(nèi)均需用清洗劑進行清洗。Aftercleaning,dryingofthesurfacetobeexaminedshallbeaccomplishedbynormalevaporationorwithforcedair,asappropriate.Theminimumdryingtimeshallbe5minutestoensurethatthecleaningsolutionhasevaporatedpriortoapplicationofthepenetrant.清洗后，通過適當(dāng)方法(自然揮發(fā)或逼迫通風(fēng))，使被探傷表面干燥。最短干燥時間為5分鐘,以保證在施加滲透劑前清洗劑已揮發(fā)。PenetrantApplication施加滲透劑Thepenetrantmaybeappliedonthesurfaceofworkpiecestobeexaminedbysprayingmethod.用噴涂法在被探傷工件表面施加滲透劑。Thetemperatureofthepenetrantandthesurfacetobeexaminedshallnotbebelow40°F(5℃)orabove125°F(探傷時，滲透劑和被探傷表面的溫度≮40°F(5℃)，也≯125°F(52℃)。滲透檢查不能在上述溫度范圍內(nèi)進行時，應(yīng)按ASME規(guī)范第V卷T-653的規(guī)定，使用有淬火裂紋的鋁試塊驗證Penetrationtimeiscritical.TheminimumdwelltimeisshowninTable3.Forsuitabletemperature,theareabeingexaminedshallremainlywettedbythepenetrantforthedwelltime.嚴(yán)格控制滲透時間，最少滯留時間見表3。在適當(dāng)?shù)臏囟葪l件下，在滯留時間內(nèi)，被探傷區(qū)域需用滲透劑保持濕潤。Table3MaterialFormDwellTimes(min)*PenetrantAluminum,magnesium,steel,brassorbronze,titaniumandhightemperaturealloysCastings&welds5Wroughtmaterialextrusions,forgings,plate10*Fortemperaturerangefrom10℃to52℃.Fortemperaturesfrom5℃to10℃,minimumpenetrantdwelltimeshallbe2timesthevaluelisted.表3材料成型方式滯留時間（min）（10℃~52℃滲透劑鋁，鎂，鋼，黃銅，青銅，鈦，高溫合金鑄造和焊接5鍛造材料—擠壓件，鍛件，板材10*對于溫度從10℃～52℃范圍內(nèi)執(zhí)行上述滲透時間.若是在5℃ExcessPenetrantRemoval多余滲透劑的清除Excesssolventremovablepenetrantshallberemovedbywipingwithaclothorabsorbentpaper,repeatingtheoperationuntilmosttracesofpenetranthavebeenremoved.Theremainingtracesshallberemovedbylightlywipingthesurfacewithaclothorabsorbentpapermoistenedwithsolvent.Toavoidoverremoving,flushingthesurfacewithsolventshallbeprohibited.多余滲透劑要用布或吸水紙擦去，剩下的液痕要蘸有溶劑的布或吸水紙在表面輕輕地擦去。為防過度清除，禁用溶劑沖洗表面。DeveloperApplication施加顯像劑Thedevelopershallbeappliedassoonaspossibleafterpenetrantremoval.Thetimeintervalshallnotexceed5min.Whenexceedthemax.permittedtimeinterval,theexaminationshallbeperformedinincrementswhichallowtocompletetheexaminationwithinthespecifiedtimeinterval.多余滲透劑被清除且工件干燥后，應(yīng)盡快地施加顯像劑。其間隔時間不得超過3分鐘，假如清洗時間隔時間超過最大允許范圍，那么就得將滲透探傷提成幾部分，使每一部分的清洗時間不超過最大允許值。5.6.2Thedevelopershallbeappliedbyspraying.Auniformthincoatingshallbeprovidedandthecoatingthicknessshallbesuitable.用噴涂法施加顯像劑，涂層薄而均勻。5.6.3P在施加水濕顯像劑至工件表面前，顯像劑應(yīng)充足搖勻。5.6.4Dippingorfloodingthepartwithnon-aqueousdeveloperisprohibited,sinceitwilldissolvethepenetrantinthediscontinuitiesthroughitssolventaction.禁用非水濕顯像劑浸泡工件，因非水濕顯像劑會通過溶解作用將缺陷中的滲透劑溶解掉。Interpretation評判5.7.1Developingtimeforfinalinterpretationbeginsassoonasawetdevelopercoatingisdry.Theminimumdevelopingtimenotlessthan10min.濕顯像劑涂層一干，最終評判顯像時間即開始。顯像時間不少于10分鐘。5.7.2Finalinterpretationshallbemadewithin10to60minaftertherequirementsofPara.5.7.1aresatisfied.滿足5.7.1規(guī)定后，應(yīng)在10-60分鐘內(nèi)做出最終評判。5.7.3Thedevelopingtracecanbeexaminedeitherbynaturallightorartificiallight.Aminimumlightintensityof100fc(1000Lx)isrequiredonthesurfacetobeexaminedtoensureadequatesensitivityduringtheexaminationandevaluationofindications.Thelightsource,techniqueusedandlightlevelverificationisrequiredtobedemonstratedonetime,documentedandmaintainedonfile.顯像痕跡可借助于自然光或人工白光進行檢查，規(guī)定光強度至少為100fc(1000Lx)，以保證在檢查和評價顯示過程中有足夠的靈敏度。5.7.4Thesurfaceshallbedividedintoseveralpartstobeexaminedifthesurfaceissolargethattheexaminationcannotbefinishedwithinthegiventime.Thedevelopingconditioncanbeobservedeitherbyeyesorbymeansofamagnifier.若被探表面太大，無法在規(guī)定期間內(nèi)完畢檢查，則應(yīng)將表面提成幾個區(qū)進行檢查。顯像情況可以用肉眼或放大鏡進行觀測。Post-cleaning檢查后清洗Thepostcleaningmustbeperformedifremainingpenetrantand/ordevelopermaterialscanresultincorrosionbythecombinationwithothermaterialsduringtheoperation.PT后，應(yīng)清除工件上的滲透材料，若殘余滲透材料在操作過程中與其它材料混合后會導(dǎo)致腐蝕，則必須進行后清洗?？刹捎眠m當(dāng)?shù)那逑捶椒ㄈ缬盟疀_洗、機械清除、溶劑浸泡等。Thesuitablecleaningprocessshallbeadoptedforpostcleaningsuchasflushingwithwater,mechanicalcleaning,solventsoaking,etc.Thecleaningshallbeconductedassoonaspossibleafterevaluationanddocumentation.若工件規(guī)定作后清洗，則PT后應(yīng)盡快進行，以免顯像劑凝固在工件上。6EvaluationofIndications顯像評價Anindicationofanimperfectionthatcausesit;however,thesizeoftheindicationisthebasisforacceptanceevaluation.Onlyindicationswithmajordimensionsgreaterthan1/16in.(1.5mm)shallbeconsideredrelevant.顯示是機加工瑕疵的證據(jù)。只有主尺寸大于1/6in（1.5㎜）的顯示才可認(rèn)為是有關(guān)的，不允許存在也許掩蓋不連續(xù)指示的大范圍殘存著色區(qū)。這些區(qū)域應(yīng)清洗干凈，并重新做檢查。Alinearindicationisonehavingalengthgreaterthanthreetimesthewidth;線性顯示是指長度大于寬度三倍的顯示。Aroundedindicationisoneofcircularorellipticalshapewiththelengthequaltoorlessthanthreetimesthewidth;圓形顯示是指長度等于或小于寬度三倍的圓形或橢圓形顯示。Anyquestionableordoubtfulindicationsshallbereexaminedtodeterminewhetherornottheyarerelevant.任何有疑問或難以判斷的跡象應(yīng)作進一步檢查以確認(rèn)是否是缺陷。7AcceptanceStandards合格標(biāo)準(zhǔn)ForPressureVessels壓力容器的合格標(biāo)準(zhǔn)：AccordingtoAppendix8ofASMECodeSectionⅧ,Div.1thefollowingrelevantindicationsareunacceptable:下列相關(guān)指示是不合格的：Anycracksorrelevantlinearindications;任何裂紋或線性指示；Relevantroundedindicationsgreaterthan3/16in.(5.0mm)