磁粉檢測(cè)工藝規(guī)程

1、xxxxqc procedures程序文件doc. no. 文件號(hào)：qcd-08-045edition版 本：2011shop construction pressure vessels and parts to asme boiler and pressure vessel code section viii division 1按asme規(guī)范第卷第1分冊(cè)建造壓力容器revision修訂號(hào)：0magnetic particle examination procedure磁粉檢驗(yàn)工藝規(guī)程page頁(yè)碼：14 of 14magnetic particle examination procedure

2、磁粉檢驗(yàn)工藝規(guī)程prepared by編制: date日期: reviewed by審核: date日期: approved by批準(zhǔn): date日期: certification演示證實(shí)聲明this is certified that this procedure has been demonstrated to the satisfaction of the authorized inspector in accordance with the requirements of t-150 of section v.本規(guī)程已按asme規(guī)范第卷t150的要求，在帶缺陷試板上進(jìn)行了演示。演示結(jié)果

3、得到了ai的認(rèn)可。certified by date級(jí)證明人： 日期：witnessed by date授權(quán)檢驗(yàn)師： 日期：1 scope范圍1.1 this procedure is applied to the magnetic particle examination of ferromagnetic materials and welds for asme code items.本規(guī)程適用于asme規(guī)范產(chǎn)品鐵磁性材料和焊縫的磁粉檢驗(yàn)。1.2 the magnetic particle examination method is suitable for detecting cracks

4、 and other discontinuities on or near the surface in ferromagnetic materials.磁粉探傷方法適用于檢測(cè)鐵磁性材料表面或近表面裂紋及其它不連續(xù)性。1.3 this procedure is applied to wet continuous magnetization by yoke. 本規(guī)程適用于磁軛濕粉連續(xù)磁化法。1.4 this procedure shall be demonstrated to the satisfaction of the ai prior to implementation. when con

5、struction code specified, a change of a requirement in appendix i identified as an essential variable from the specified value, or range of values, requalification of this procedure shall be required. when a change of requirement in appendix i identified as an nonessential variable from the specifie

6、d value, or range of values, requalification of this procedure is not required. all changes of essential or nonessential variables from the value, or range of values, specified by this procedure shall require revision of, or addendum to, this procedure.本規(guī)程應(yīng)按照asme規(guī)范第卷t-150的要求向ai做演示證明。當(dāng)規(guī)定了規(guī)程鑒定時(shí)，附錄中重要變

7、素規(guī)定值的變更引起所要求的變化，本規(guī)定應(yīng)重新鑒定。對(duì)于非重要變素規(guī)定值或數(shù)值范圍的變更引起的要求變化，本規(guī)定不需要重新鑒定。所有重要變素或非重要變素?cái)?shù)值或數(shù)值范圍的改變，應(yīng)修訂增補(bǔ)進(jìn)本規(guī)程。2 personnel人員2.1 the nde personnel who engage in magnetic particle examination shall be qualified and certified according to xxxkld written practice for qualification and certification of nondestructive ex

8、amination (nde) personnel based on the requirements of snt-tc-1a (2006) and asme code section i, viii division 1.從事磁粉檢驗(yàn)的nde人員應(yīng)按本公司按照snt-tc1a（2006）及asme規(guī)范第卷、第-1卷編制的無損檢測(cè)人員培訓(xùn)考評(píng)及認(rèn)證實(shí)施細(xì)則進(jìn)行培訓(xùn)、考試、資格鑒定和認(rèn)證。3 description of method方法描述3.1 in principle, the magnetic particle examination method involves magnetizi

9、ng an area to be examined, and applying ferromagnetic particles to the surface. the particles will form patterns on the surface where cracks or other discontinuities cause distortions in the normal magnetic field. these patterns are usually characteristic of the type of discontinuity that is detecte

10、d.磁粉檢驗(yàn)法的原理，是使被檢驗(yàn)區(qū)域磁化，并將鐵磁性粉末（檢驗(yàn)介質(zhì)）施加到此區(qū)域的表面上，此時(shí)表面上有裂縫及其他不連續(xù)性的地方因使正常磁場(chǎng)產(chǎn)生畸變而使磁粉構(gòu)成一定的圖形，這些圖形通常是以所探測(cè)的不連續(xù)性類型為特征的。3.2 the sensitivity of the magnetic particle examination is greatest for surface discontinuities and diminishes rapidly with increasing depth of discontinuities below the surface. therefore, t

11、his method can only be used for detecting the discontinuities on or near the surface of the material or parts to be tested.此方法對(duì)表面不連續(xù)性最靈敏，而隨表面以下的近表面不連續(xù)性埋藏深度的增大，其靈敏度迅速降低。因此，此方法僅適用于探測(cè)材料或零件近表面的不連續(xù)性。4 magnetization equipment and calibration磁化設(shè)備及校驗(yàn)4.1 the mt equipment to be used shall be selected from the

12、 following table.磁化設(shè)備應(yīng)在下表中選取。table 1 mt equipment表1 磁化設(shè)備制造商manufacturer型號(hào)type電流限制current limitation備注note射陽縣強(qiáng)達(dá)探傷設(shè)備制造廠sheyang qiangda flaw detection equipment facdtorycje-215a-4.2 calibration of magnetizing equipment磁化設(shè)備的校驗(yàn)4.2.1 frequency of calibration: each magnetizing equipment shall be calibrated

13、 at least once a year, or whenever the equipment has been subjected to a major electric repair, periodic overhaul or damage. if equipment has not been in use for a year or more, calibration shall be done prior to first use.校驗(yàn)周期：磁化設(shè)備至少每年用安培表校準(zhǔn)一次，或當(dāng)設(shè)備進(jìn)行重要電氣修理、周期大修或損壞時(shí)，必須進(jìn)行校準(zhǔn)。如果設(shè)備停止使用一年或更長(zhǎng)時(shí)間，則應(yīng)在其第一次使用前

14、應(yīng)進(jìn)行校準(zhǔn)。4.2.2 calibration for mt equipment meters: the accuracy of the mt equipment meter shall be verified annually by equipment traceable to a national standard. comparative readings shall be taken for at least three different current output levels encompassing the usable range. the equipment meter

15、reading shall not deviate by more than ±10% of full scale, relative to the actual current value as shown by the test meter.磁化設(shè)備儀表：磁化設(shè)備儀表應(yīng)使用可溯源至國(guó)家標(biāo)準(zhǔn)的設(shè)備每年進(jìn)行一次校驗(yàn)。必須以有效范圍內(nèi)三次輸出電平的最低值比較讀數(shù)。儀表讀數(shù)偏差應(yīng)不大于測(cè)試儀表顯示的實(shí)際電流值相關(guān)的整個(gè)刻度的±10%。4.2.3 calibration for lifting power of the yoke: the lifting power will b

16、e calibrated with the methods of lifting a standard weight cake. alternating current electromagnetic yokes shall have a lifting power of at least 10 lb. (4.5 kg) at the maximum spacing of the yoke. 磁軛提升力的校驗(yàn)：提升力用標(biāo)準(zhǔn)重塊提升法來校驗(yàn)。當(dāng)使用磁軛最大間距時(shí)，每個(gè)交流磁軛至少應(yīng)有10lb.（4.5kg）的提升力。4.3 calibration of light meter光度計(jì)的校驗(yàn)4.3.

17、1 light meter shall be calibrated at least once a year or whenever the meter has been repaired. if meters have not been in use for one year or more calibration shall be done before being used.光度計(jì)應(yīng)每年或修理后校驗(yàn)一次。如果光度計(jì)有一年或一年以上沒有使用，使用前應(yīng)對(duì)其進(jìn)行校驗(yàn)。5 examination medium檢驗(yàn)介質(zhì)5.1 the examination medium shall be the

18、finely divided ferromagnetic particles which have high permeability and low retentivity. the size and shape of the magnetic particles shall be suitable for forming magnetic particle indications.檢驗(yàn)介質(zhì)應(yīng)為具有高導(dǎo)磁率和低頑磁性的細(xì)鐵磁粉，其尺寸和形狀必須易于形成磁痕。5.2 the black or red color wet magnetic particles as listed in table

19、 2 are used according to the workpiece to be tested.表2 所列黑色或紅色濕磁粉按照檢測(cè)工件選用。table 2 magnetic particles- wet magnetic particle (non-fluorescent)表2 磁粉濕磁粉（非熒光）manufacturer制造商type型號(hào)color顏色 上海新美達(dá)探傷有限公司shanghai xinmeida flaw detection material co., ltd / 黑磁膏black5.3 the fluid medium for the magnetic suspens

20、ion fluid shall be transformer oil, smell less kerosene or water. the temperature of the wet particle suspension and the surface of the part shall not exceed 135 (57).磁懸液的液體介質(zhì)必須是變壓器油、無味煤油或水。磁懸液的溫度和工件表面溫度均不得超過135 (57 0c)。5.4 concentration of wet magnetic particle suspensions濕磁粉懸浮液的濃度5.4.1 the initial

21、 bath concentration of suspended magnetic particles should be as specified or as recommended by the manufacturer and shall be checked by settling volume measurements and maintained at the specified concentration on a daily basis. if the concentration is not maintained properly, test results can vary

22、 greatly.磁懸液濃度應(yīng)按制造廠推薦，用沉淀量值驗(yàn)證，務(wù)使日常濃度一定。濃度不當(dāng)，會(huì)大大影響探傷結(jié)果。5.4.2 the bath concentration shall be maintained within 1.2 to 2.4 ml per 100 ml of vehicle for non-fluorescent particles unless otherwise specified by the particle manufacturer.除制造廠另有規(guī)定外，非熒光磁粉懸浮液濃度應(yīng)為每100ml 1.2-2.4ml的水平。5.4.3 bath concentration i

23、s normally determined by measuring its settling volume through the use of an astm pear-shaped centrifuge tube with a 1.5-ml stem (0.1-ml divisions) for non-fluorescent suspensions. before sampling, run the suspension through the re-circulating system for at least 30-min to assure thorough mixing of

24、all particles which could have settled on the sump screen and along the sides or bottom of the tank. take a 100-ml portion of the suspension from the hose or nozzle and allow it to settle for approximately 30 min. the volume settling out at the bottom of the tube is indicative of the particle concen

25、tration in the bath. if the bath concentration is low in particle content, add a sufficient amount of particle materials to obtain the desired concentration. if the suspension is high in particle content, add sufficient vehicle to obtain the desired concentration.槽中磁懸浮液濃度通常是用astm的梨形離心管測(cè)定其沉淀值來確定的，對(duì)非熒

26、光磁粉懸液為1.5ml芯柱（0.1ml刻度）的沉淀柱；在取樣以前，將懸浮液在再循環(huán)系統(tǒng)中至少流動(dòng)30分鐘，以保證所有磁粉的完全混合，否則磁粉可能在油盤濾網(wǎng)和沿槽的壁或底沉淀下來，從軟管或管嘴取100ml懸浮液并使它沉淀大約30分鐘，大管底沉淀的體積是槽底磁粉濃度指示值；假如磁懸浮中磁粉濃度太低，加足夠量的磁粉以獲得所需濃度；假如磁懸浮液中磁粉濃度太高，則加足夠液體介質(zhì)以獲得所需濃度。5.4.4 if the settled particles appear to be loose agglomerates rather than a solid layer, take a second sam

27、ple. if still agglomerated, the particles may have become magnetized, replace the suspension.假如沉淀磁粉表現(xiàn)為松散的團(tuán)塊，而不是緊密的敷層，則應(yīng)作第二次取樣試驗(yàn)，如果還是團(tuán)塊，說明磁粉可能已被磁化，這里需更換懸浮液。6 magnetization procedure磁化過程6.1 yoke technique磁軛法6.1.1 the alternating current electromagnetic yokes shall be used for localized magnetization t

28、o form a longitudinal magnetic field.可采用交流的電磁軛來磁化一個(gè)局部區(qū)域，形成一個(gè)縱向磁場(chǎng)。6.1.2 direction of magnetization: at least two separate examinations shall be carried out on each area. the second examination shall be with the lines of magnetic flux approximately perpendicular to those used for the first examination

29、 in that area.磁化方向：每一區(qū)域應(yīng)至少進(jìn)行兩次分別檢驗(yàn)。在第二次檢驗(yàn)中，磁通線的方向應(yīng)大致與第一次檢驗(yàn)區(qū)域所采用的方向相垂直。6.1.3 the area to be examined shall be restricted to the area which is equal to 1/4 maximum pole spacing on both sides of the line through two poles. the pole spacing shall at least have 1 in. (25 mm) overlap each time.受檢區(qū)域應(yīng)限制在兩磁極

30、連線的雙側(cè)，相當(dāng)于1/4最大磁極間距的范圍內(nèi)，磁極間距每次至少有1in.（25mm）的搭接。7 magnetic field strength磁場(chǎng)強(qiáng)度7.1 the special carbon steel / copper plate type field indicator is used to verify that an adequate field strength and direction for the surface of part is obtained. if the clear magnetic particle pattern is shown on the copp

31、er plate side of the field indicator, it indicates that adequate field strength is obtained.使用專用的碳鋼/銅板磁場(chǎng)指示器來校驗(yàn)零件表面的磁場(chǎng)強(qiáng)度和方向是否滿足要求。如果銅板邊有清晰的磁粉線條，則表明磁場(chǎng)強(qiáng)度是足夠的。8 examination requirements檢驗(yàn)要求8.1 surface preparation表面制備8.1.1 satisfactory results are usually obtained in the as-welded, as-rolled, as-cast, or

32、 as-forged conditions. however, surface preparation by grinding or machining may be necessary where surface irregularities could mask indications due to discontinuities.經(jīng)焊接、軋制、鑄造、鍛造等加工的零件，一般會(huì)取得滿意的效果。然而，表面不平（不均勻）會(huì)掩飾缺陷的顯示，這些地方則需要通過打磨或機(jī)加工進(jìn)行表面制備。8.1.2 prior to magnetic particle examination, the surface

33、to be examined and all adjacent areas within at least 1 in. (25 mm) shall be dry and free of all dirt, grease, lint, scale, welding flux and spatter, oil, or other extraneous matter that could interfere with the examination.在磁粉檢驗(yàn)之前，被檢驗(yàn)的表面及其附近至少1 in.（25mm）的區(qū)域內(nèi)應(yīng)是干燥的，并且沒有任何污垢、纖維屑、銹皮、焊劑和焊接飛濺、油污或其他會(huì)妨礙檢驗(yàn)的

34、外來物。8.1.3 cleaning may be accomplished using detergents, organic solvents, descaling solution, paint removers, vapor degreasing, sand or grit blasting, or ultrasonic cleaning methods.可使用去污劑、有機(jī)溶劑、除銹劑、除銹液、去漆劑、蒸汽除油、噴吵或超聲波清洗等方法達(dá)到清潔的目的。8.1.4 unless specified on the drawings or other technical documentati

35、on, the magnetic particle examination shall be carried out on the parts with finished surface condition, or finished-machined condition and final heat treatment condition.除非圖紙或其他技術(shù)文件中另有規(guī)定，任何零件均應(yīng)在完工的表面狀態(tài)，或最終機(jī)加工狀態(tài)，或最終熱處理狀態(tài)下進(jìn)行磁粉探傷。8.1.5 the small opening, slots or holes in the parts can be blocked to p

36、revent the magnetic particle from getting into.零件上的小開口、槽或孔，應(yīng)檢驗(yàn)前堵塞好以防磁粉進(jìn)入。8.2 magnetic particles shall be applied by spraying. examination shall be done by the continuous method that is the magnetizing current remains on while the examination medium is being applied and while excess of the examinatio

37、n medium is being removed.磁粉的施加采用噴淋的方法。檢驗(yàn)采用連續(xù)法，在施加磁化電流時(shí)施加濕磁粉，同時(shí)去除多余堆聚的磁粉。8.3 examination shall be conducted with sufficient overlap (at least 10%) to assure 100% coverage at the established sensitivity.檢驗(yàn)時(shí)應(yīng)有足夠的重疊（至少10%），保證受檢零件在規(guī)定的靈敏度下能得到100%的覆蓋。8.4 the repaired area shall be reexamined according to

38、the original examination procedure.受檢工件上經(jīng)返修的區(qū)域，應(yīng)按原來的檢驗(yàn)程序重新檢驗(yàn)。8.5 the intensity of the visual light at the surface of the part / work piece undergoing examination shall be a minimum of 100 foot candles (1000 lx). to ensure such minimum light intensity, 6 v 15w (cs-205) bulb or (km 8209) torch shall b

39、e used as a light source and the distance from the bulb to the surface to be examined shall not exceed 400 mm.受檢工件表面的觀察亮度必須至少為100fc（1000lx）。為保證得到最低光強(qiáng)度，使用6v15w的燈泡km 8209手電筒作為光源，光源至受檢表面的距離應(yīng)不超過400mm。9 evaluation of indications and acceptance standards顯示評(píng)定及合格標(biāo)準(zhǔn)9.1 evaluation of indications磁粉顯現(xiàn)評(píng)定indicati

40、ons will be revealed by retention of magnetic particles. all such indications are not necessarily imperfections, however, since excessive surface roughness, magnetic permeability variations (such as at the edge of heat affected zones), etc., may produce similar indications.磁粉保留一段時(shí)間回顯示出磁線，并不是所有顯示出來的都

41、是缺陷，因受檢表面粗燥（如在熱影響區(qū)邊緣），導(dǎo)磁發(fā)生變化等原因，會(huì)產(chǎn)生類似于缺陷的顯示。an indication is the evidence of a mechanical imperfection. only indications which have any dimension greater than 1/16 in. (1.6 mm) shall be considered relevant.只有被確認(rèn)為機(jī)械缺陷的顯示，且顯示的尺寸大于1/16英寸（1.6mm）時(shí)才被認(rèn)為有效顯示；a. a linear indication is one having a length gre

42、ater than three times the width.線形顯示是指其長(zhǎng)度超過寬度3倍的顯示。b. a rounded indication is one of circular or elliptical shape with a length equal to or less than three times the width.圓形顯示是指一個(gè)圓形和橢圓的長(zhǎng)度或等于寬度的3倍的顯示。c. any questionable or doubtful indications shall be reexamined to determine whether or not they are

43、 relevant.可疑的、有爭(zhēng)議的顯示均應(yīng)重新檢驗(yàn)以決定它們是否為有效顯示。d. broad areas of particle accumulation which might mask indications from discontinuities are prohibited, and such areas shall be cleaned and reexamined.主要區(qū)域被積聚的不連續(xù)的磁粉遮蓋是不允許的，對(duì)這些區(qū)域應(yīng)重新檢驗(yàn)。9.2 acceptance standards (per a-260 of section i and appendix 6 of section

44、viii div.1)合格標(biāo)準(zhǔn)（根據(jù)第卷a-260及第卷第一分冊(cè)附錄6）all surfaces to be examined shall be free of:所有受檢表面不允許有如下缺陷顯示。a. relevant linear indications;有效的線形顯示；b. relevant rounded indications greater than 3/16 in. (4.8mm);尺寸大于3/16英寸(4.8mm)有效的面形顯示；c. four or more relevant rounded indications in a line separated by 1/16 in.

45、 (1.6mm) or less, edge to edge;一條直線上邊緣間隔等于或小于1/16in.(1.6mm)的4個(gè)或更多的有效的面形顯示。d. an indication of an imperfection may be larger than the imperfection that causes it; however, the size of the indication is the basis for acceptance evaluation.缺陷顯示可能大于缺陷本身，但是以顯示尺寸作為合格評(píng)價(jià)的基礎(chǔ)。10 demagnetization退磁when residual

46、 magnetism in the part could interfere with subsequent processing or usage, the part shall be demagnetized any time after completion of the examination.當(dāng)剩磁對(duì)零件附加工或使用有影響時(shí)，該零件在磁粉檢驗(yàn)后應(yīng)及時(shí)進(jìn)行退磁。11 cleaning清潔post-test cleaning is necessary where magnetic particle material could interfere with subsequent proc

47、essing or usage.磁粉材料會(huì)妨礙后繼加工或使用時(shí)，檢驗(yàn)后應(yīng)進(jìn)行清理。12 records and report記錄和報(bào)告12.1 the examination details and results shall be recorded by the operator. for each examination, the following information shall recorded:操作員應(yīng)記錄檢驗(yàn)詳情和結(jié)果。對(duì)于每次檢驗(yàn)，應(yīng)記錄以下信息：a) procedure identification and revision;規(guī)程的名稱和修改版本；b) magnetic particle equipment and type of current;磁粉檢驗(yàn)裝置和電流類型；c) magnetic particles (visible or fluorescent, wet or dry);磁粉（目視或熒光、干或濕）；d) examination personnel identity and if required by referencing code section, qualification level;檢驗(yàn)人員的身份，資格等級(jí)，如果相關(guān)卷要求的話；e)