磁粉检测工艺规程.doc

XXXXQC Procedures程序文件Doc. No. 文件号：QCD-08-045Edition版 本：2011Shop Construction Pressure Vessels and parts to ASME Boiler and Pressure Vessel Code Section VIII Division 1按ASME规范第卷第1分册建造压力容器Revision修订号：0Magnetic Particle Examination Procedure磁粉检验工艺规程Page页码：14 of 14Magnetic Particle Examination Procedure磁粉检验工艺规程Prepared By编制: Date日期: Reviewed By审核: Date日期: Approved By批准: Date日期: CERTIFICATION演示证实声明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.本规程已按ASME规范第卷T150的要求，在带缺陷试板上进行了演示。演示结果得到了AI的认可。Certified by Date级证明人： 日期：Witnessed by Date授权检验师： 日期：1 Scope范围1.1 This procedure is applied to the magnetic particle examination of ferromagnetic materials and welds for ASME Code items.本规程适用于ASME规范产品铁磁性材料和焊缝的磁粉检验。1.2 The magnetic particle examination method is suitable for detecting cracks and other discontinuities on or near the surface in ferromagnetic materials.磁粉探伤方法适用于检测铁磁性材料表面或近表面裂纹及其它不连续性。1.3 This procedure is applied to wet continuous magnetization by Yoke. 本规程适用于磁轭湿粉连续磁化法。1.4 This procedure shall be demonstrated to the satisfaction of the AI prior to implementation. When construction 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 specified 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.本规程应按照ASME规范第卷T-150的要求向AI做演示证明。当规定了规程鉴定时，附录中重要变素规定值的变更引起所要求的变化，本规定应重新鉴定。对于非重要变素规定值或数值范围的变更引起的要求变化，本规定不需要重新鉴定。所有重要变素或非重要变素数值或数值范围的改变，应修订增补进本规程。2 Personnel人员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 Examination (NDE) Personnel based on the requirements of SNT-TC-1A (2006) and ASME Code Section I, VIII Division 1.从事磁粉检验的NDE人员应按本公司按照SNT-TC1A（2006）及ASME规范第卷、第-1卷编制的无损检测人员培训考评及认证实施细则进行培训、考试、资格鉴定和认证。3 Description of Method方法描述3.1 In principle, the magnetic particle examination method involves magnetizing 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 detected.磁粉检验法的原理，是使被检验区域磁化，并将铁磁性粉末（检验介质）施加到此区域的表面上，此时表面上有裂缝及其他不连续性的地方因使正常磁场产生畸变而使磁粉构成一定的图形，这些图形通常是以所探测的不连续性类型为特征的。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, this method can only be used for detecting the discontinuities on or near the surface of the material or parts to be tested.此方法对表面不连续性最灵敏，而随表面以下的近表面不连续性埋藏深度的增大，其灵敏度迅速降低。因此，此方法仅适用于探测材料或零件近表面的不连续性。4 Magnetization Equipment and Calibration磁化设备及校验4.1 The MT equipment to be used shall be selected from the following Table.磁化设备应在下表中选取。Table 1 MT Equipment表1 磁化设备制造商Manufacturer型号Type电流限制Current Limitation备注Note射阳县强达探伤设备制造厂SHEYANG QIANGDA FLAW DETECTION EQUIPMENT FACDTORYCJE-215A-4.2 Calibration of Magnetizing Equipment磁化设备的校验4.2.1 Frequency of calibration: Each Magnetizing Equipment shall be calibrated 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.校验周期：磁化设备至少每年用安培表校准一次，或当设备进行重要电气修理、周期大修或损坏时，必须进行校准。如果设备停止使用一年或更长时间，则应在其第一次使用前应进行校准。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 reading shall not deviate by more than 10% of full scale, relative to the actual current value as shown by the test meter.磁化设备仪表：磁化设备仪表应使用可溯源至国家标准的设备每年进行一次校验。必须以有效范围内三次输出电平的最低值比较读数。仪表读数偏差应不大于测试仪表显示的实际电流值相关的整个刻度的10%。4.2.3 Calibration for lifting power of the Yoke: The lifting power will be 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. 磁轭提升力的校验：提升力用标准重块提升法来校验。当使用磁轭最大间距时，每个交流磁轭至少应有10lb.（4.5kg）的提升力。4.3 Calibration of Light Meter光度计的校验4.3.1 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.光度计应每年或修理后校验一次。如果光度计有一年或一年以上没有使用，使用前应对其进行校验。5 Examination Medium检验介质5.1 The examination medium shall be the 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.检验介质应为具有高导磁率和低顽磁性的细铁磁粉，其尺寸和形状必须易于形成磁痕。5.2 The black or red color wet magnetic particles as listed in Table 2 are used according to the workpiece to be tested.表2 所列黑色或红色湿磁粉按照检测工件选用。Table 2 Magnetic Particles- Wet Magnetic Particle (Non-fluorescent)表2 磁粉湿磁粉（非荧光）Manufacturer制造商Type型号Color颜色 上海新美达探伤有限公司SHANGHAI XINMEIDA FLAW DETECTION MATERIAL CO., LTD / 黑磁膏BLACK5.3 The fluid medium for the magnetic suspension 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).磁悬液的液体介质必须是变压器油、无味煤油或水。磁悬液的温度和工件表面温度均不得超过135 (57 0C)。5.4 Concentration of Wet Magnetic Particle Suspensions湿磁粉悬浮液的浓度5.4.1 The initial 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 greatly.磁悬液浓度应按制造厂推荐，用沉淀量值验证，务使日常浓度一定。浓度不当，会大大影响探伤结果。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.除制造厂另有规定外，非荧光磁粉悬浮液浓度应为每100ml 1.2-2.4ml的水平。5.4.3 Bath concentration is 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 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 concentration 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.槽中磁悬浮液浓度通常是用ASTM的梨形离心管测定其沉淀值来确定的，对非荧光磁粉悬液为1.5ml芯柱（0.1ml刻度）的沉淀柱；在取样以前，将悬浮液在再循环系统中至少流动30分钟，以保证所有磁粉的完全混合，否则磁粉可能在油盘滤网和沿槽的壁或底沉淀下来，从软管或管嘴取100ml悬浮液并使它沉淀大约30分钟，大管底沉淀的体积是槽底磁粉浓度指示值；假如磁悬浮中磁粉浓度太低，加足够量的磁粉以获得所需浓度；假如磁悬浮液中磁粉浓度太高，则加足够液体介质以获得所需浓度。5.4.4 If the settled particles appear to be loose agglomerates rather than a solid layer, take a second sample. If still agglomerated, the particles may have become magnetized, replace the suspension.假如沉淀磁粉表现为松散的团块，而不是紧密的敷层，则应作第二次取样试验，如果还是团块，说明磁粉可能已被磁化，这里需更换悬浮液。6 Magnetization Procedure磁化过程6.1 Yoke Technique磁轭法6.1.1 The alternating current electromagnetic yokes shall be used for localized magnetization to form a longitudinal magnetic field.可采用交流的电磁轭来磁化一个局部区域，形成一个纵向磁场。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 in that area.磁化方向：每一区域应至少进行两次分别检验。在第二次检验中，磁通线的方向应大致与第一次检验区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.受检区域应限制在两磁极连线的双侧，相当于1/4最大磁极间距的范围内，磁极间距每次至少有1in.（25mm）的搭接。7 Magnetic Field Strength磁场强度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 copper plate side of the field indicator, it indicates that adequate field strength is obtained.使用专用的碳钢/铜板磁场指示器来校验零件表面的磁场强度和方向是否满足要求。如果铜板边有清晰的磁粉线条，则表明磁场强度是足够的。8 Examination Requirements检验要求8.1 Surface Preparation表面制备8.1.1 Satisfactory results are usually obtained in the as-welded, as-rolled, as-cast, or as-forged conditions. However, surface preparation by grinding or machining may be necessary where surface irregularities could mask indications due to discontinuities.经焊接、轧制、铸造、锻造等加工的零件，一般会取得满意的效果。然而，表面不平（不均匀）会掩饰缺陷的显示，这些地方则需要通过打磨或机加工进行表面制备。8.1.2 Prior to magnetic particle examination, the surface 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.在磁粉检验之前，被检验的表面及其附近至少1 in.（25mm）的区域内应是干燥的，并且没有任何污垢、纤维屑、锈皮、焊剂和焊接飞溅、油污或其他会妨碍检验的外来物。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.可使用去污剂、有机溶剂、除锈剂、除锈液、去漆剂、蒸汽除油、喷吵或超声波清洗等方法达到清洁的目的。8.1.4 Unless specified on the drawings or other technical documentation, the magnetic particle examination shall be carried out on the parts with finished surface condition, or finished-machined condition and final heat treatment condition.除非图纸或其他技术文件中另有规定，任何零件均应在完工的表面状态，或最终机加工状态，或最终热处理状态下进行磁粉探伤。8.1.5 The small opening, slots or holes in the parts can be blocked to prevent the magnetic particle from getting into.零件上的小开口、槽或孔，应检验前堵塞好以防磁粉进入。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 examination medium is being removed.磁粉的施加采用喷淋的方法。检验采用连续法，在施加磁化电流时施加湿磁粉，同时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.检验时应有足够的重叠（至少10%），保证受检零件在规定的灵敏度下能得到100%的覆盖。8.4 The repaired area shall be reexamined according to the original examination procedure.受检工件上经返修的区域，应按原来的检验程序重新检验。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 be used as a light source and the distance from the bulb to the surface to be examined shall not exceed 400 mm.受检工件表面的观察亮度必须至少为100fc（1000lx）。为保证得到最低光强度，使用6V15W的灯泡KM 8209手电筒作为光源，光源至受检表面的距离应不超过400mm。9 Evaluation of indications and acceptance standards显示评定及合格标准9.1 Evaluation of indications磁粉显现评定Indications 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.磁粉保留一段时间回显示出磁线，并不是所有显示出来的都是缺陷，因受检表面粗燥（如在热影响区边缘），导磁发生变化等原因，会产生类似于缺陷的显示。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.只有被确认为机械缺陷的显示，且显示的尺寸大于1/16英寸（1.6mm）时才被认为有效显示；a. A linear indication is one having a length greater than three times the width.线形显示是指其长度超过宽度3倍的显示。b. A rounded indication is one of circular or elliptical shape with a length equal to or less than three times the width.圆形显示是指一个圆形和椭圆的长度或等于宽度的3倍的显示。c. Any questionable or doubtful indications shall be reexamined to determine whether or not they are relevant.可疑的、有争议的显示均应重新检验以决定它们是否为有效显示。d. Broad areas of particle accumulation which might mask indications from discontinuities are prohibited, and such areas shall be cleaned and reexamined.主要区域被积聚的不连续的磁粉遮盖是不允许的，对这些区域应重新检验。9.2 Acceptance standards (per A-260 of Section I and Appendix 6 of Section VIII Div.1)合格标准（根据第卷A-260及第卷第一分册附录6）All surfaces to be examined shall be free of:所有受检表面不允许有如下缺陷显示。a. relevant linear indications;有效的线形显示；b. relevant rounded indications greater than 3/16 in. (4.8mm);尺寸大于3/16英寸(4.8mm)有效的面形显示；c. four or more relevant rounded indications in a line separated by 1/16 in. (1.6mm) or less, edge to edge;一条直线上边缘间隔等于或小于1/16in.(1.6mm)的4个或更多的有效的面形显示。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.缺陷显示可能大于缺陷本身，但是以显示尺寸作为合格评价的基础。10 Demagnetization退磁When residual magnetism in the part could interfere with subsequent processing or usage, the part shall be demagnetized any time after completion of the examination.当剩磁对零件附加工或使用有影响时，该零件在磁粉检验后应及时进行退磁。11 Cleaning清洁Post-test cleaning is necessary where magnetic particle material could interfere with subsequent processing or usage.磁粉材料会妨碍后继加工或使用时，检验后应进行清理。12 Records and report记录和报告12.1 The examination details and results shall be recorded by the operator. For each examination, the following information shall recorded:操作员应记录检验详情和结果。对于每次检验，应记录以下信息：a) Procedure identification and revision;规程的名称和修改版本；b) Magnetic particle equipment and type of current;磁粉检验装置和电流类型；c) Magnetic particles (visible or fluorescent, wet or dry);磁粉（目视或荧光、干或湿）；d) Examination personnel identity and if required by referencing Code Section, qualification level;检验人员的身份，资格等级，如果相关卷要求的话；e) M