渗透检测工艺规程penetrantinspectprocedureWord格式文档下载.docx
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目录Content
章节Chapter题目subject页码Page
1目的Intent2
2适用范围Scope2
3引用标准Quotedstandard2
4检测时机Testtime3
5检测人员Inspector4
6检测材料Inspectionmaterial4
7试块Comparativereferencepanel5
8检测前的准备Preparationbeforetest6
9渗透探伤检验程序Testprocedure6
10渗透显示的评定Classificationofindications10
11验收标准Acceptancecriteria11
12返修Repair12
13安全Safety12
14检测报告格式Inspectionreport13
1.目的Intent
本工艺是根据LR规范及IACS焊接质量和无损探伤检测指南要求制定的焊缝渗透检测质量控制程序。
TheworkmanshipisbasedonthequalitycontrolprocedureofseampenetratetestingoftheruleofLRandIACSguidelineofweldingqualityandNDTofshipsteelwelds.
2.适用范围Scope
本工艺适用于所有铁质材料和非铁质材料(非多孔性)表面开口缺陷的检测。
Thisstandardappliestoallferrousandnonferrousmaterials(non-porosity)fordetectingopenflawonthesurface.
3.职责Obligation
3.1参照程序ThestandardscitedinthisStandardareasfollows:
(a)LR新建船入级及建造规范
(b)ENISO5817(2003)
(c)船舶钢焊缝渗透检测工艺和质量分级CB3958-2004
(d)IACSGuidelineNon-destructivetestingofshiphullsteelwelds
3.2合格标准Acceptancecriteria
(a)LR船舶入级规范和规则
(a)LRsteelseagoingshipclassificationandbuildingrule
(b)IACS焊接质量和无损探伤检测指南
(b)IACSGuidelineNon-destructivetestingofshiphullsteelwelds
4.检测时机Testtime
4.1渗透检测安排在焊缝冷却至环境温度并且在采用焊后热处理之后进行。
Testshallbearrangeduntilweldingseamiscooleddowntoenvironmentaltemperatureandafterweldingheattreatmentisexecuted.
4.2对有延迟裂纹倾向的焊缝或材料应在焊后24(强度大于400MPa或碳当量大于0.41的钢应在焊后48小时)小时以后进行。
Testshallbeproceededin24(steelthatбs>
400MPaorCev>
0.41shouldbe48)hoursafterweldingfortheweldingseamsormaterialintendedtodelayedcrack.
5.检测人员Inspector
5.1从事渗透检测人员应具有必要的专业知识,并经过技术培训,必须持有中国船级社或有关部门颁发的并与其工作相适应等级的无损检测技术资格证书,在有效期范围内。
Theinspectorswhoperformthetestshallhavetherequiredqualificationorsufficientknowledge,skill,andexperienceequaltothatofthequalifiedengineerandshallholdnondestructivetestingqualifiedcertificateissuedbyCCSorrelativeauthorities,itshouldbeinvalidtime.
无损检测人员应取得按有关规程或技术条件的规定严格的培训和考核,并持有国家有关部门(CCS等)颁发的并与其工作相适应的等级资格证书。
进行检测的人员应当根据国家公认的认证计划或按照等同于ISO9712,SNT-TC-1A,EN473或ASNTACCP进行二级资格鉴定和认证。
一级资质的操作人员可以二级或三级资质人员的管理下进行测试。
获得国家公认的认证计划或按照等同于ISO9712,SNT-TC-1A,EN473或ASNTACCP认证的三级资质人员有责任准备和认可无损探伤操作程序。
OperatorsshouldbequalifiedaccordingtoanationallyrecognisedschemewithagradeequivalenttolevelIIqualificationofISO9712,SNT-TC-1A,EN473orASNTCentralCertificationProgram(ACCP).OperatorsqualifiedtolevelImaybeengagedinthetestsunderthesupervisionofpersonnelqualifiedtolevelIIorIII.
PersonnelresponsibleforthepreparationandapprovalofNDTproceduresshouldbequalifiedaccordingtoanationallyrecognisedschemewithagradeequivalenttolevelIIIqualificationofISO9712,SNT-TC-1A,EN473orASNTCentralCertificationProgram(ACCP).
5.2检测人员的视力应每年检查一次,矫正视力不低于1.0,无色盲和色弱。
Theinspectorsshalltesteyesightannually.Theircorrectedvisionshallnotlessthan1.0,noachromatopsiaorcolorweakness.
6.检测材料inspectionmaterial
6.1探伤剂包括渗透剂(着色)、清洗剂、显像剂。
应具有足够的缺陷检测能力,对被检件无腐蚀作用、对人体无害。
Testagentincludespenetrant(dyeing),rinseandobservation.Itshouldbesufficientlyabletodetecttheflaws.
6.2对奥氏体不锈钢制件检测时,每种探伤剂的氯和氟含量之和不得大于1%。
Testingtheausteniticstainlesssteelelements,thecontentofchlorineandfluorineshallnotmorethan1%foreachtypeoftestagent.
6.3探伤剂应配套使用,不同厂家、不同型号的探伤剂不能混用。
Testagentshallbeappliedaccordingtothespecifiedandshallnotmixedwithothertypesorothermaker’s.
6.4探伤剂应放在温度为10℃~50℃的暗处保存,并应避免阳光照射。
Testagentshallbekeptinshadowplaceattemperaturebetween10℃~50℃andtoavoidfromsunshine.
7.试块referencepiece
7.1铝合金试块(A型对比试块)Aluminumalloyreferencepiece(Atype)
铝合金试块尺寸如图1所示,试块由同一试块剖开后具有相同大小的两部分组成,并打上相同序号,分别以A、B记号,A、B试块上均应具有细密相对称的裂纹图形。
DimensionofreferencepieceasshowninFig.1,dividedintotwoequalpartsandmarkedwithAandBseparately.
TypeAandTypeBareoppositeincracks.
主要用于:
Mainlyusedfor:
a)在正常使用情况下,检验渗透探伤剂能否满足要求,以及比较两种渗透探伤剂性能的优劣。
Normally,thereferencepieceisusedtoexaminetheperformanceofthetestagentandwhetheritcanfulfilltherequirementornot.
b)对于非标准温度下(大于52℃、小于10℃,但大于4℃)的渗透探伤方法作出鉴定。
Intheabnormaltemperaturecondition(morethan52℃orlessthan10℃,butnotlessthan4℃),testthepenetrant-inspection.
图1铝合金试块Fig.1Aluminumalloycomparativereferencepanel
7.2不锈钢镀铬试块尺寸如图2所示,主要用于检验操作工艺正确性和检测系统灵敏度。
StainlesschromeplatedsteelreferencepieceasshowninFig.2.Itispurposedtotestcorrectnessofoperationprocedureanditssensitivity.
图2不锈钢镀铬试块Stainlesschromeplatedsteelreferencepiece
7.3试块使用后要用丙酮进行彻底清洗。
清洗后将其置于1︰1的丙酮和乙醇溶液的密闭容器中保存。
Afterusingthereferencepiece,itshouldberinsedthoroughlywithacetone.Thenkeepitinaclosedcontainerof1:
1proportionofacetoneandgrainalcoholsolution.
7.4当发现试块有堵塞或灵敏度与原先比较有下降时,应及时更换。
Incaseofanyblockageorlesssensitivethanbefore,thereferencepieceshallbeimmediatelyrenewed.
8.检测前的准备Preparationfortest
8.1工件表面不得有铁锈、氧化皮、焊接飞溅、铁屑、毛刺以及各种防护层。
Allrust,oxideskin,weldingsplash,ironscurf,burandkindsofprotection.
8.2被检工件机加工表面粗糙度Ra值为6.3µ
m;
被检工件非机加工表面粗糙度Ra值为12.5µ
m.但对不能打磨的工件可适当放宽。
Themachiningsurfaceroughnessoftestobject–Ravalueshallbe6.3µ
m,andforun-machiningsurfaceroughnessoftestobject–Ravalveshallbe12.5µ
m.Forthetestobjectwhichcannotbegrinded,theRavaluecanbeevenmore.
8.3局部检测时,准备工作范围应从检测部位四周向外扩展25mm。
Whenmakingpartialtest,theareaofpreparationshallbefromtestobjectandtospreadoutof25mm.
9.渗透探伤检验程序Testprocedure
9.1检测方法的选用原则Selectionthetestmethod
(a)渗透检测方法的选用可根据被检工件表面粗糙度,检测灵敏度、检测批量大小和检测现场的水源、电源等条件来决定。
Selectionofthetestmethodshallbebasedonthesurfaceroughnessoftestobject,testsensitivity,quantityoftestobjectandtheconditionofwaterandpowersupplyintestcite.
(b)对于表面光洁且检测灵敏度要求高的工件宜采用后乳化型着色。
Forthecleansurfaceandhightestsensitivityoftestobject,thepost-emulsificationdyeingshallbeapplied.
(c)对于表面粗糙且检测灵敏度低的工件宜采用水洗型着色法。
Fortheroughsurfaceandlowtestsensitivityoftestobject,thehydrophilicdyeingshallbeapplied.
(d)对于现场无水源、电源的检测宜采用溶剂去除型着色法。
Fortheconditionofnowater,powersupplyattestsite,thenthesolventremovaldyeingshallbeapplied.
(e)对于批量大的工件检测,宜采用水洗型着色法。
Forthelargequantityoftestobject,thewaterwashabledyeingshallbeapplied.
(f)对于大工件的局部检测,宜采用溶剂去除型着色法。
Forthepartialtestoflargescaletestobject,thesolventremovaldyeingshallbeapplied.
9.2操作过程Testoperation
9.2.1预清洗Pre-cleaning
检测部位的表面状况在很大程度上影响着渗透检测的检测质量。
因此,在进行过表面清理之后还要进行一次预清洗,以去除检测表面的污垢。
清洗时,可用溶剂、洗涤剂等进行。
Toagreatextent,theconditionoftestingsurfacewillaffectthequalityofpenetrantinspection.So,afterfinishingthecleaningjobofsurface,onemoretaskofpre-cleaningwillbedemandedtoclearawaythedirtyfromsurface.Thecleaningshallbecarriedoutbysolventcleaning,steamcleaning,paintremover,alkalinedetergent,acidcleaning,etc.,consideringthekindandextentofadheringmatter,andthequalityoftestobject.
干燥过程:
自然干燥和风吹方式
Dryprocedure:
natureandblowmethod.
9.2.2施加渗透剂Penetrationtreatment
(a)渗透剂施加方法penetrationtreatmentmethod
施加方法应根据零件大小、形状、数量和检测部位来选择。
所选方法应保证被检部位完全被渗透剂覆盖,并在整个渗透时间内保持湿润状态。
Thepenetrantshallbeappliedbydipping,spraying,brushingorthelike,accordingtothequantity,dimensionsandshapeofthetestobjectaswellasthekindofpenetrant,andthesurfacetobetestedshallbewettedwithpenetrantforthetimerequiredforpenetration.
(b)渗透时间及温度penetrationtimeandtemperature
在(10~52)℃的条件下,渗透剂的渗透时间一般不少于5min。
当温度低于10℃时内要适当增加渗透时间,当温度在大于4℃并小于10℃或高于52℃时,用对比试块进行比较,并在检验报告中必须加以说明。
Thepenetrationtimeshallbedeterminedconsideringthekindofpenetrant,qualityofthetestobject,kindandsizeofflawanticipated,andthetemperatureofthetestobjectandpenetrant.Generally,intherangeof(10~52)℃,thetimeshallnotlessthan5min.Forthetemperaturesareabove52℃orbelow10℃butnotlessthan4℃,thencomparativereferencepanelwillbeusedforcomparisonandmustbestatedintheinspectionreport.
9.2.4清洗多余的渗透剂Rinseandsolventwipingremoval
(a)在清除工件被检表面多余的渗透剂时,应注意防止过度清洗而使检测质量下降,同时也应注意防止清除不足而造成对缺陷显示识别困难。
Rinseandsolventwipingremovalshallbesocarriedoutthatonlytheexcesspenetrantadheringonthesurfaceisremoved.Overrinsethatmightdrainoutthepenetrantpenetratedintoflawsshallnotbecarriedoutandinsufficientrinsemightalsocausethetroubletorevealtheflaws.
(b)水洗型和后乳化性渗透剂均可用水清洗。
冲洗时,水射束与被检面以30°
为宜;
在无冲洗装置时,可采用干净不脱毛的抹布蘸水依次擦洗。
采用冲水方法时,如无特殊规定,冲洗装置喷嘴处的水压应不超过0.34Mpa。
Bothwater-washabilityandpost-emulsifiablepenetrantscanbecleanedwithwater.Whencleaning,itispreferablethat30°
betweenwaterspraybeamandtestobjectsurface.Incaseofnowashingdeviceused,penetrantshallberemovedbyclean,un-detersilerag.Incaseofusingaspraynozzle,thewaterpressureshallbe0.34Mpaorunder,unlessotherwisespecified.
(c)溶剂去除型渗透剂用清洗剂清洗。
除特别难于清洗的地方外,一般应先用干净不脱毛的布依次擦拭,直至大部分多余渗透剂被清洗后,再用蘸有清洗剂的干净不脱毛的布或纸进行擦拭,直至将被检面上的多余渗透剂全部擦净。
但必须注意,不得往复擦拭,不得用清洗剂直接在被检面冲洗。
Solvent-removablepenetrantsshallberemovedbysolventcleaner.Exceptincasethattheremovalisdifficult,thepenetrantshallbasicallybewipedoffbycleanragwithsolventcleaner,howeverdippingofthetestobjectintosolventcleanerortheuseofexcessivequantityofsolventcleanershallnotbeapplied.
9.2.5干燥处理Drying
(a)施加快干式显像剂之前或施加湿式显像剂之后,检测面须经干燥处理。
一般可用热风进行干燥或进行自然干燥。
干燥时,被检面的温度不得大于52℃。
Incaseofusingquicklydrieddeveloper,dryingshallbecarr