CP-02-PT液體滲透檢測

1、JSSN江蘇世能化工 設(shè)備有限公司Quality Control Procedure程序文件DOC. No. ：JSSN/CP-02文件號Edition版本： 2014Shop Construction and Field Site Assembly of Power Boilers and Pressure Vessels & Parts and Pressure Piping in accordance with ASME Boiler and Pressure Vessel Code Section I, Section VIII Division 1 and ASME Code B31

2、.1按ASME規(guī)范第I卷、第卷第1冊及B31.1在工廠建造與現(xiàn)場安裝鍋爐、壓力容器及其部件和壓力管道Revision No.修訂號：1Liquid Penetrant Examination Procedure 液體滲透檢測工藝規(guī)程Page： PAGE 16 of NUMPAGES 16第16頁 共16頁Liquid Penetrant Examination Procedure液體滲透檢測工藝規(guī)程1REV.NO. 修訂號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

3、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.茲證明該規(guī)程已按照ASME規(guī)范第卷T-150的要求，在帶缺陷試板上進(jìn)行了演示。演示結(jié)果令A(yù)I滿意。Specimen No.: 試板編號 Demo. Report No.:演示報(bào)告編號Certified by Date級證明人： 日期：Witnessed by Date授權(quán)檢驗(yàn)師

4、： 日期：1 General概述1.1 This procedure is applied to dye liquid penetrant examination of metal material and weldment for ASME Code Items.本規(guī)程適用于ASME規(guī)范產(chǎn)品金屬材料和焊件著色液體滲透探1.2 This procedure is only suitable for detecting the defects that are open to the surface of material or weldment. 本規(guī)程僅適用于探測材料或焊件表面開口類缺陷。1

5、.3 This procedure shall be certified by demonstration to the satisfaction of the AI prior to implementation. 本規(guī)程在執(zhí)行之前，需通過演示令A(yù)I滿意。2 Personnel 人員 The personnel engaged in the penetrant examination shall be qualified and certified in accordance with the requirement of the companys “Written Practice for

6、 NDE Personnel Training, Qualification & Certification” ( JSSN/CX-10 ). 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(shí)施細(xì)則（文件號：JSSN/CX-10）進(jìn)行資格考核和認(rèn)證的合格人員。3 Written Procedure Requirements 書面規(guī)程 Requirements 要求：Liquid penetrant examination shall be performed in accordance with the written procedure (and the instruction

7、 cards as supplementary means), which shall, as a minimum, contain the requirements listed in Table 1. The written procedure shall establish a single value, or range of values, for each requirement. 液體滲透檢驗(yàn)須按書面規(guī)程進(jìn)行（輔以探傷專用工藝卡）。書面規(guī)程至少包括表一中的內(nèi)容。書面規(guī)程應(yīng)對每一項(xiàng)要求都給出數(shù)值或數(shù)值范圍以作定量評價(jià)。 Procedure Qualification 規(guī)程評定：Wh

8、en procedure qualification is specified, a change of requirement in Table 1 identified as an essential variable from the specified value, or range of values, shall require requalification of the written procedure. A change of a requirement identified as nonessential variable from the specified value

9、, or range of values, does not require requalification of the written procedure. All changes of essential or nonessential variables from the value, or range of values, specified by the written procedure shall require revision, or an addendum to, the written procedure.要求對規(guī)程進(jìn)行評定的時候，表1中主要素的數(shù)值發(fā)生變化時，需要對書

10、面規(guī)程進(jìn)行重新評定。副要素的數(shù)值發(fā)生變化時，不需要對規(guī)程進(jìn)行重新評定。主要素或副要素的數(shù)值發(fā)生變化都將要求對書面規(guī)程進(jìn)行修改或補(bǔ)充。Table 1 Requirements of Liquid Penetrant Examination ProcedureNo.RequirementEssentialVariableNonessentialVariableNotes*【1】Identification of and any change in type or family group of penetrant materials including developers, emulsifier

11、s, etc4.2【2】Surface preparation(finishing and cleaning, including type of cleaning solvent)5.2【3】Method of applying penetrant 5.4.1【4】Method of removing excess surface penetrant5.5【5】Method of applying developer5.6【6】Minimum and maximum time periods between steps and drying aids 5.3.25.4.3 5.6.1【7】D

12、ecrease in penetrant dwell time5.4.3【8】Increase in developer dwell time (Interpretation time)5.7.2【9】Minimum light intensity5.7.3【10】Surface temperature outside 41F to 125F (5 to 52) or as previously qualified5.4.2【11】Performance demonstration, when required1.33.2【12】Personnel qualification requirem

13、ents2.1【13】Materials, shapes, or sizes to be examined and the extent of examination1.15.2Table 3【14】Post examination cleaning technique5.8* The related clause stipulating the requirement.表1 液體滲透檢驗(yàn)規(guī)程的要求序號要求主要素副要素備注*【1】4.2【2】表面修整(精加工及清洗,包括清洗劑種類)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】顯象劑施加方法5.6【6】干燥前滲透

14、劑最小和最大滯留時間 5.3.25.4.3 5.6.1【7】滲透劑滯留時間的減少5.4.3【8】顯象劑滯留時間的增加(評定時間)5.7.2【9】最小光照度5.7.3【10】超出41F125F( 552)或預(yù)定的表面溫度5.4.2【11】操作演示（需要時）1.3，3.2【12】人員資格要求2.1【13】被檢工件的材料、形狀、尺寸及檢驗(yàn)范圍1.1，5.2，表3【14】檢驗(yàn)后清理方法5.8* 在本規(guī)程中出現(xiàn)的相關(guān)條款。4 Penetrant Materials滲透材料The penetrant materials are intended to include all penetrants, sol

15、vents or cleaning agents, developers, etc, used in the examination process.滲透材料包括探傷過程中使用的所有滲透劑、溶劑或清洗劑、顯像劑等。The liquid penetrant examination materials shall be designated and recommended as shown in Table 2. The materials used for examination shall be the same type. Intermixing of penetrant materials

16、 from different families or different manufacturers is not permitted.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禁止混用。Table 2ManufacturerMaterialModelShanghai Xinmeida Flaw Detection-Material Co., Ltd.PenetrantDPT-5DeveloperDPT-5Cleaning AgentDPT-5表2制造單位材料牌號上海新美達(dá)探傷器材有限公司滲透劑DPT-5顯像劑DPT-5清洗劑DPT-

17、5 When examining austenitic or duplex stainless steel or titanium, all materials shall be analyzed individually for chlorine and fluorine content in accordance with the procedure shown in Para.-642 of Mandatory, Appendix of Article 6 of ASME Code Section V. The total chlorine plus fluorine content s

18、hall not exceed 1% of the residue by weight. The certificate of compliance by batch with test results from manufacturer shall be obtained.探測奧氏體不銹鋼或鈦材時，應(yīng)按ASME規(guī)范第卷-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。When examining nickel base alloys, all materials shall be analyzed individual

19、ly for sulfur content in accordance with the procedure shown in Para.-641 of Mandatory, Appendix of Article 6 of Section V. The sulfur content shall not exceed 1% of the residue by weight. The certificate of compliance by batch with test results from manufacturer shall be obtained.探測鎳基合金時，應(yīng)按照ASME規(guī)范第

20、卷-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。5 Examination Process檢驗(yàn)程序Surface Preparation表面處理Precleaning and Dry清洗干燥Penetrant ApplicationSurface Preparation表面處理Precleaning and Dry清洗干燥Penetrant Application滲透Cleaning清洗Drying干燥Development Inspection顯像檢查Evaluation record評定記錄Post Cleaning后處理Fig.

21、1Surface Preparation: Prior to all penetrant examination, the surface to be examined and all adjacent areas within at least 1in. ( 25.4 mm ) 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

22、 by grinding or machining. 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(jìn)行打磨或機(jī)加工。Precleaning 預(yù)清洗The areas to be examined and adjacent areas within at least 1 in. ( 25mm ) shall be cleaned using cleaning agent before the penetrant is applied. 施加滲透劑前，被探區(qū)域及其附近至少為1英寸(2

23、5mm)區(qū)域內(nèi)均需用清洗劑進(jìn)行清洗。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 be 5 minutes to ensure that the cleaning solution has evaporated prior to application of the penetrant.清洗后，通過適當(dāng)方法(自然揮發(fā))

24、，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)。Penetrant Application 施加滲透劑The penetrant may be applied on the surface of work pieces to be examined by spraying method. 用噴涂法在被探傷工件表面施加滲透劑。The temperature of the penetrant and the surface to be examined shall not be below 41F (5 ) or above 125 F (52) throughout

25、the examination period. Where 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 ( comparator ) according to ASME Code Secti

26、on V, T-653. 探傷時，滲透劑和被探傷表面的溫度41F(5)，也125F(52)。滲透檢驗(yàn)不能在上述溫度范圍內(nèi)進(jìn)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(yàn)證指定使用更高或更低溫度范圍的探傷工藝的影響。Penetration time is critical. The minimum dwell time is shown in Table 3. For suitable temperature, the area being examined shall remainly wetted by the penetrant for the dwell time

27、. 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。Table 3MaterialFormDwell Times (min) *PenetrantAluminum, magnesium, steel, brass or bronze, titanium and high temperature alloysCastings & welds5Wrought materialextrusions, forgings, plate10* For temperature range from 10 to 52. For temperatures f

28、rom 5 up to 10,minimum penetrant dwell time shall be 2 times the value listed.表3材料成型方式滯留時間 （min）（1052）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1052范圍內(nèi)執(zhí)行上述滲透時間.若是在510范圍內(nèi)，滲透時間至少為上述值的2倍。Excess Penetrant Removal 多余滲透劑的清除Excess solvent removable penetrant shall be removed by wiping with a cloth or

29、 absorbent paper, repeating the operation until most traces of penetrant have been removed. 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. 多余滲透劑

30、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?jiān)诒砻孑p輕地擦去。為防過度清除，禁用溶劑沖洗表面。Developer Application 施加顯像劑The developer shall be applied as soon as possible after penetrant removal. The time interval shall not exceed 5 min. When exceed the max. permitted time interval, the examination shall be performed in increments which all

31、ow to complete the examination within the specified time interval.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5分鐘，如果清洗時間隔時間超過最大允許范圍，那么就得將滲透探傷分成幾部分，使每一部分的清洗時間不超過最大允許值。5.6.2 The developer shall be applied by spraying. A uniform thin coating shall be provided and the coating thickness shall be suitable.用噴涂法施加顯像劑

32、，涂層薄而均勻。5.6.3 Prior to applying wet developer to the surface, the developer must be thoroughly agitated. 在施加水濕顯像劑至工件表面前，顯像劑應(yīng)充分搖勻。5.6.4 Dipping or flooding the part with non-aqueous developer is prohibited, since it will dissolve the penetrant in the discontinuities through its solvent action. 禁用非水濕顯

33、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5.7.1 Developing time for final interpretation begins as soon as a wet developer coating is dry. The minimum developing time not less than 10 min. 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。5.7.2 Final interpretation shall be made within 10 to 40 min after the

34、 requirements of Para. 5.7.1 are satisfied. 滿足5.7.1 要求后，應(yīng)在10-40分鐘內(nèi)作出最終評判。5.7.3 The developing trace can be examined either by natural light or artificial light. A minimum light intensity of 100 fc (1000Lx) is required on the surface to be examined to ensure adequate sensitivity during the examinatio

35、n and evaluation of indications. The light source, technique used and light level verification is required to be demonstrated one time , documented and maintained on file. 顯像痕跡可借助于自然光或人工白光進(jìn)行檢驗(yàn)，要求光強(qiáng)度至少為100fc(1000 Lx)，以保證在檢驗(yàn)和評價(jià)顯示過程中有足夠的靈敏度。5.7.4 The surface shall be divided into several parts to be ex

36、amined if the surface is so large that the examination cannot be finished within the given time. The developing condition can be observed either by eyes or by means of a magnifier.若被探表面太大，無法在規(guī)定時間內(nèi)完成檢驗(yàn)，則應(yīng)將表面分成幾個區(qū)進(jìn)行檢驗(yàn)。顯像情況可以用肉眼或放大鏡進(jìn)行觀察。Post-cleaning 檢驗(yàn)后清洗The post cleaning must be performed if remainin

37、g penetrant and/or developer 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 cleaning shall be conducted as soo

38、n as possible after evaluation and documentation.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(jìn)行后清洗?？刹捎眠m當(dāng)?shù)那逑捶椒ㄈ缬盟疀_洗、機(jī)械清除、溶劑浸泡等。若工件要求作后清洗，則PT后應(yīng)盡快進(jìn)行，以免顯像劑凝固在工件上。6 Evaluation of Indications顯象評價(jià)An indication of an imperfection that causes it; however, the size of the indication is the basis for accepta

39、nce evaluation. Only indications with major dimensions greater than 1/16in. (1.5mm) shall be considered relevant.顯示是機(jī)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.不允許存在可能掩蓋不連續(xù)指示的大范圍殘存著色區(qū)。這些區(qū)域應(yīng)清洗干凈，并重新做檢驗(yàn)。A linear indication is one having a length greater than three times the width;線性顯示是指長度大于寬度三倍的顯示。A rounde

40、d indication is one of circular or elliptical shape with the length equal to or less than three times the width;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。Any questionable or doubtful indications shall be reexamined to determine whether or not they are relevant.任何有疑問或難以判斷的跡象應(yīng)作進(jìn)一步檢驗(yàn)以確認(rèn)是否是缺陷。7 Acceptance Standards合格標(biāo)

41、準(zhǔn)Acceptance standards (per A-270 of Section I and Appendix 8 of Section VIII Div.1)合格標(biāo)準(zhǔn)（根據(jù)第卷A-270及第卷第一分冊附錄8）All surfaces to be examined shall be free of:所有被檢表面不應(yīng)有：Any cracks or relevant linear indications; 任何裂紋或線性指示；Relevant rounded indications greater than 3/16in. (5.0mm); 尺寸大于3/16 in.(5.0 mm)的圓形指示

42、；Four or more relevant rounded indications in a line separated by 1/16 in. (1.5mm) or less (edge to edge);在同一直線上的四個或四個以上的圓形指示，其邊緣間的距離等于或小于1/16 in. (1.5 mm)；7.2 Acceptance standards for ASME B31.1.(136.4.4)對ASME B31.1動力管道驗(yàn)收標(biāo)準(zhǔn)All surfaces to be examined shall be free of:所有被檢表面不應(yīng)有：a Any cracks or relev

43、ant linear indications;任何裂紋或線性指示；b Relevant rounded indications greater than 3/16in. (5.0mm);尺寸大于3/16 in.(5.0 mm)的圓形指示；C Four or more relevant rounded indications in a line separated by 1/16 in. (2.0mm) or less (edge to edge); 在同一直線上的四個或四個以上的圓形指示，其邊緣間的距離等于或小于1/16 in. (2.0 mm)；d Ten or more rounded indications in any 6 sq in.(3870mm2 ) of surface with the major dimension of th