液体渗透检测工艺规程

LIQUIDPENETRANTEXAMINATIONPROCEDURE液体渗透检测工艺规程PreparedBy编制:Date日期:ReviewedBy审核:Date日期:ApprovedBy批准:Date日期:StatementofDemonstrationCertification演示证实声明WeherebycertifythattheLiquidPenetrantExaminationProcedure(QCNP-04,2023/Rev.0)hasbeendemonstratedonatestspecimenwithknowndefectstothesatisfactionoftheAIaccordingtoASMECodeSectionV,T-150asrequiredbytheAppendix8ofSectionVIII,Div.1.兹证明该《液体渗透检测工艺规程》已按照ASME规范第Ⅴ卷T-150和第Ⅷ-1卷强制性附录8的规定，在带缺陷试板上进行了演示。演示结果令AI满意。SpecimenNo.:试板编号：Demo.ReportNo.:演示报告编号：CertifiedbyNDELevelIII:Date:Ⅲ级证明人AI:Date:授权检查师：1General概述1.1ThisprocedureisappliedtodyeliquidpenetrantexaminationofmetalmaterialandweldmentforASMECodeitems.本规程合用于ASME规范产品金属材料和焊件着色液体渗透探伤。1.2Thisprocedureisonlysuitablefordetectingthedefectsthatareopentothesurfaceofmaterialorweldment.本规程仅合用于探测材料或焊件表面开口类缺陷。1.3ThisprocedureshallbecertifiedbydemonstrationtothesatisfactionoftheAIpriortoimplementation.本规程在执行之前，需通过演示令AI满意。2Personnel人员Thepersonnelengagedinthepenetrantexaminationshallbequalifiedandcertifiedinaccordancewiththerequirementofthecompany’s“WrittenPracticeforNDEPersonnelTraining,Qualification&Certification”(TC/QP-8-1Ed.2023Rev.0).从事液体渗透探伤的人员应为按本公司《无损检测人员培训考评及认证实行细则》(TC/QP-8-1Ed.2023Rev.0）进行资格考核和认证的合格人员。3WrittenProcedureRequirements书面规程Requirements规定：Liquidpenetrantexaminationshallbeperformedinaccordancewiththewrittenprocedure(andtheinstructioncardsassupplementarymeans),whichshall,asaminimum,containtherequirementslistedinTable1.Thewrittenprocedureshallestablishasinglevalue,orrangeofvalues,foreachrequirement.液体渗透检查须按书面规程进行（辅以探伤专用工艺卡）。书面规程至少涉及表一中的内容。书面规程应对每一项规定都给出数值或数值范围以作定量评价。ProcedureQualification规程评估：Whenprocedurequalificationisspecified,achangeofrequirementinTable1identifiedasanessentialvariablefromthespecifiedvalue,orrangeofvalues,shallrequirerequalificationofthewrittenprocedure.Achangeofarequirementidentifiedasnonessentialvariablefromthespecifiedvalue,orrangeofvalues,doesnotrequirerequalificationofthewrittenprocedure.Allchangesofessentialornonessentialvariablesfromthevalue,orrangeofvalues,specifiedbythewrittenprocedureshallrequirerevision,oranaddendumto,thewrittenprocedure.规定对规程进行评估的时候，表1中重要素的数值发生变化时，需要对书面规程进行重新评估。副要素的数值发生变化时，不需要对规程进行重新评估。重要素或副要素的数值发生变化都将规定对书面规程进行修改或补充。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液体渗透检查规程的规定序号要求重要素副要素备注*【1】●4.2【2】表面修整(精加工及清洗,涉及清洗剂种类)●5.2【3】渗透剂施加方法●5.4.1【4】表面多余渗透剂的去除方法●5.5【5】显像剂施加方法●5.6【6】干燥前渗透剂最小和最大滞留时间●5.3.25.4.35.6.1【7】渗透剂滞留时间的减少●5.4.3【8】显像剂滞留时间的增长(评估时间)●5.7.2【9】最小光照度●5.7.3【10】超过41°F~125°F(5℃~●5.4.2【11】操作演示（需要时）●1.3，3.2【12】人员资格规定○2.1【13】被检工件的材料、形状、尺寸及检查范围○1.1，5.2，表3【14】检查后清理方法○5.8*在本规程中出现的相关条款。4PenetrantMaterials渗透材料Thepenetrantmaterialsareintendedtoincludeallpenetrants,solventsorcleaningagents,developers,etc,usedintheexaminationprocess.渗透材料涉及探伤过程中使用的所有渗透剂、溶剂或清洗剂、显像剂等。TheliquidpenetrantexaminationmaterialsshallbedesignatedandrecommendedasshowninTable2.Thematerialsusedforexaminationshallbethesametype.Intermixingofpenetrantmaterialsfromdifferentfamiliesordifferentmanufacturersisnotpermitted.液体渗透探伤材料，指定用表2所示牌号。探伤使用的材料应为是同一类型的。不同类型或不同制造厂的渗透材料严禁混用。Table2ManufacturerMaterialModelMarktecFlawDetectionMaterialCo.,Ltd.,PenetrantDPT-5(P)DeveloperDPT-5(D)CleaningAgentDPT-5(C)表2制造单位材料型号美柯达探伤器材有限公司渗透剂DPT-5(P)显像剂DPT-5(D)清洗剂DPT-5(C)Whenexaminingausteniticorduplexstainlesssteelortitanium,allmaterialsshallbeanalyzedindividuallyforchlorineandfluorinecontentinaccordancewiththeprocedureshowninPara.Ⅱ-642ofMandatory,AppendixⅡofArticle6ofASMECodeSectionV.Thetotalchlorineplusfluorinecontentshallnotexceed1%oftheresiduebyweight.Thecertificateofcompliancebybatchwithtestresultsfrommanufacturershallbeobtained.探测奥氏体不锈钢或钛材时，应按ASME规范第Ⅴ卷Ⅱ-642规定的方法，对所有渗透材料分别分析氯和氟的含量。残留氯和氟总含量不得超过残留物重量的1%，应有制造单位签发的合格证。Whenexaminingnickelbasealloys,allmaterialsshallbeanalyzedindividuallyforsulfurcontentinaccordancewiththeprocedureshowninPara.Ⅱ-641ofMandatory,AppendixⅡofArticle6ofSectionV.Thesulfurcontentshallnotexceed1%oftheresiduebyweight.Thecertificateofcompliancebybatchwithtestresultsfrommanufacturershallbeobtained.探测镍基合金时，应按照ASME规范第Ⅴ卷Ⅱ-641规定的方法，对所有渗透材料分别分析硫含量。硫含量不得超过残留物重量的1%。应有制造单位的合格证。5ExaminationProcess检查程序ExaminationflowchartasshowninFigure1.SurfacePreparationDryingSurfacePreparationDryingDevelopmentandInspectionPrecleaningandDryDevelopmentandInspectionPrecleaningandDryEvaluationandRecordPenetrantApplication`EvaluationandRecordPenetrantApplicationPostCleaningExcessPenetrantRemovalPostCleaningExcessPenetrantRemovalFig.1PT程序流程图见图1SurfacePreparation:Priortoallpenetrantexamination,thesurfacetobeexaminedandalladjacentareaswithinatleast1in.(25.4mm)shallbedryandfreeofdirt,grease,lint,scale,weldingflux,weldspatter，paint，oilandotherextraneousmatter.Ifnecessary,surfaceshallbepreparedbygrindingormachining.表面制备:渗透探伤前，被探工件表面及其附近至少1英寸(25.4mm)区域内都应干燥，不得有任何污物、油脂、纤维屑、氧化皮、焊剂、油和其它外来物。必要时，应对表面进行打磨或机加工。Precleaning预清洗Theareastobeexaminedandadjacentareaswithinatleast1in.(25mm)shallbecleanedusingcleaningagentbeforethepenetrantisapplied.施加渗透剂前，被探区域及其附近至少为1英寸(25mm)区域内均需用清洗剂进行清洗。Aftercleaning,dryingofthesurfacetobeexaminedshallbeaccomplishedbynormalevaporationorwithforcedair,asappropriate.Theminimumdryingtimeshallbe5minutestoensurethatthecleaningsolutionhasevaporatedpriortoapplicationofthepenetrant.清洗后，通过适当方法(自然挥发或逼迫通风)，使被探伤表面干燥。最短干燥时间为5分钟,以保证在施加渗透剂前清洗剂已挥发。PenetrantApplication施加渗透剂Thepenetrantmaybeappliedonthesurfaceofworkpiecestobeexaminedbysprayingmethod.用喷涂法在被探伤工件表面施加渗透剂。Thetemperatureofthepenetrantandthesurfacetobeexaminedshallnotbebelow40°F(5℃)orabove125°F(探伤时，渗透剂和被探伤表面的温度≮40°F(5℃)，也≯125°F(52℃)。渗透检查不能在上述温度范围内进行时，应按ASME规范第V卷T-653的规定，使用有淬火裂纹的铝试块验证Penetrationtimeiscritical.TheminimumdwelltimeisshowninTable3.Forsuitabletemperature,theareabeingexaminedshallremainlywettedbythepenetrantforthedwelltime.严格控制渗透时间，最少滞留时间见表3。在适当的温度条件下，在滞留时间内，被探伤区域需用渗透剂保持湿润。Table3MaterialFormDwellTimes(min)*PenetrantAluminum,magnesium,steel,brassorbronze,titaniumandhightemperaturealloysCastings&welds5Wroughtmaterialextrusions,forgings,plate10*Fortemperaturerangefrom10℃to52℃.Fortemperaturesfrom5℃to10℃,minimumpenetrantdwelltimeshallbe2timesthevaluelisted.表3材料成型方式滞留时间（min）（10℃~52℃渗透剂铝，镁，钢，黄铜，青铜，钛，高温合金铸造和焊接5锻造材料—挤压件，锻件，板材10*对于温度从10℃～52℃范围内执行上述渗透时间.若是在5℃ExcessPenetrantRemoval多余渗透剂的清除Excesssolventremovablepenetrantshallberemovedbywipingwithaclothorabsorbentpaper,repeatingtheoperationuntilmosttracesofpenetranthavebeenremoved.Theremainingtracesshallberemovedbylightlywipingthesurfacewithaclothorabsorbentpapermoistenedwithsolvent.Toavoidoverremoving,flushingthesurfacewithsolventshallbeprohibited.多余渗透剂要用布或吸水纸擦去，剩下的液痕要蘸有溶剂的布或吸水纸在表面轻轻地擦去。为防过度清除，禁用溶剂冲洗表面。DeveloperApplication施加显像剂Thedevelopershallbeappliedassoonaspossibleafterpenetrantremoval.Thetimeintervalshallnotexceed5min.Whenexceedthemax.permittedtimeinterval,theexaminationshallbeperformedinincrementswhichallowtocompletetheexaminationwithinthespecifiedtimeinterval.多余渗透剂被清除且工件干燥后，应尽快地施加显像剂。其间隔时间不得超过3分钟，假如清洗时间隔时间超过最大允许范围，那么就得将渗透探伤提成几部分，使每一部分的清洗时间不超过最大允许值。5.6.2Thedevelopershallbeappliedbyspraying.Auniformthincoatingshallbeprovidedandthecoatingthicknessshallbesuitable.用喷涂法施加显像剂，涂层薄而均匀。5.6.3P在施加水湿显像剂至工件表面前，显像剂应充足摇匀。5.6.4Dippingorfloodingthepartwithnon-aqueousdeveloperisprohibited,sinceitwilldissolvethepenetrantinthediscontinuitiesthroughitssolventaction.禁用非水湿显像剂浸泡工件，因非水湿显像剂会通过溶解作用将缺陷中的渗透剂溶解掉。Interpretation评判5.7.1Developingtimeforfinalinterpretationbeginsassoonasawetdevelopercoatingisdry.Theminimumdevelopingtimenotlessthan10min.湿显像剂涂层一干，最终评判显像时间即开始。显像时间不少于10分钟。5.7.2Finalinterpretationshallbemadewithin10to60minaftertherequirementsofPara.5.7.1aresatisfied.满足5.7.1规定后，应在10-60分钟内做出最终评判。5.7.3Thedevelopingtracecanbeexaminedeitherbynaturallightorartificiallight.Aminimumlightintensityof100fc(1000Lx)isrequiredonthesurfacetobeexaminedtoensureadequatesensitivityduringtheexaminationandevaluationofindications.Thelightsource,techniqueusedandlightlevelverificationisrequiredtobedemonstratedonetime,documentedandmaintainedonfile.显像痕迹可借助于自然光或人工白光进行检查，规定光强度至少为100fc(1000Lx)，以保证在检查和评价显示过程中有足够的灵敏度。5.7.4Thesurfaceshallbedividedintoseveralpartstobeexaminedifthesurfaceissolargethattheexaminationcannotbefinishedwithinthegiventime.Thedevelopingconditioncanbeobservedeitherbyeyesorbymeansofamagnifier.若被探表面太大，无法在规定期间内完毕检查，则应将表面提成几个区进行检查。显像情况可以用肉眼或放大镜进行观测。Post-cleaning检查后清洗Thepostcleaningmustbeperformedifremainingpenetrantand/ordevelopermaterialscanresultincorrosionbythecombinationwithothermaterialsduringtheoperation.PT后，应清除工件上的渗透材料，若残余渗透材料在操作过程中与其它材料混合后会导致腐蚀，则必须进行后清洗。可采用适当的清洗方法如用水冲洗、机械清除、溶剂浸泡等。Thesuitablecleaningprocessshallbeadoptedforpostcleaningsuchasflushingwithwater,mechanicalcleaning,solventsoaking,etc.Thecleaningshallbeconductedassoonaspossibleafterevaluationanddocumentation.若工件规定作后清洗，则PT后应尽快进行，以免显像剂凝固在工件上。6EvaluationofIndications显像评价Anindicationofanimperfectionthatcausesit;however,thesizeoftheindicationisthebasisforacceptanceevaluation.Onlyindicationswithmajordimensionsgreaterthan1/16in.(1.5mm)shallbeconsideredrelevant.显示是机加工瑕疵的证据。只有主尺寸大于1/6in（1.5㎜）的显示才可认为是有关的，不允许存在也许掩盖不连续指示的大范围残存着色区。这些区域应清洗干净，并重新做检查。Alinearindicationisonehavingalengthgreaterthanthreetimesthewidth;线性显示是指长度大于宽度三倍的显示。Aroundedindicationisoneofcircularorellipticalshapewiththelengthequaltoorlessthanthreetimesthewidth;圆形显示是指长度等于或小于宽度三倍的圆形或椭圆形显示。Anyquestionableordoubtfulindicationsshallbereexaminedtodeterminewhetherornottheyarerelevant.任何有疑问或难以判断的迹象应作进一步检查以确认是否是缺陷。7AcceptanceStandards合格标准ForPressureVessels压力容器的合格标准：AccordingtoAppendix8ofASMECodeSectionⅧ,Div.1thefollowingrelevantindicationsareunacceptable:下列相关指示是不合格的：Anycracksorrelevantlinearindications;任何裂纹或线性指示；Relevantroundedindicationsgreaterthan3/16in.(5.0mm)