This article provides you with a example dye penetrant inspection procedure. This procedure contains water washable process with both visible and fluorescent systems.
1.0SCOPE
1.1此过程确定了对亚铁和非有产成分（本质上是非孔子）的渗透剂测试的一般要求，并通过可见的可见和荧光渗透物系统进行焊接，并应由NDT人员第三方进行。
2.0 PURPOSE:
2.1这些要求旨在通过解释表面适应症并根据适用的参考代码，标准或规格来评估符合PT级别的II级的认证NDT人员，从而检测出对测试表面的不连续性，并没有污染物。
2.2客户批准的特定检查/评估手册也必须严格遵循，如果可用，并且适beplay体育官网电脑用。
2.3 Any conflicts between any points of this procedure and the referenced documents or job specifications of customer shall be resolved (if given in writing) by the appointed ASNT NDT Level III or the Divisional Manager (NDT) or his authorised representative.
2.4 Where special circumstances require unique techniques of Penetrant Testing by Water Washable Process, specific technique sheets shall be attached as Annex: IV etc., with the written approval of NDT Level III.
3.0参考：
| 3.1 | ANSI/ASME B31.1 | 动力管道 |
|---|---|---|
| 3.2 | ANSI/ASME B31.3 | 化学厂和石油炼油厂 |
| 3.3 | ASME Sec.V | Boiler and Pressure Vessel Code |
| 3.4 | ASME SEC.VIII | Boiler and Pressure Vessel Code |
| 3.5 | ANSI/AWS DI.I | Structural Welding Code - Steel |
| 3.6 | API 1104 | 焊接管道和相关设施的标准 |
| 3.7 | API 620 | Dsign and Construction of Large, Welded Low Pressure Storage Tanks |
| 3.8 | API 650 | 焊接钢罐用于机油储存 |
| 3.9 | ASTM E-165 | Standard Test method for liquid penetrant test |
| 3.10 | ASTM E-1209 | Standard Test Method for Fluorescent Penetrat Examination using Water Washable Process. |
| 3.11 | ASTM E-1418 | Test Method for Visible PT using Water Washable |
| 3.12 | ANSI/ASNT-CP-189 | 人员资格和认证标准 |
| 3.13 | SNT-TC-1A of ASNT | Personnel Qualification and Certification Guidelines |
4.0测试方法和水洗渗透剂的摘要
4.1可能是可见或荧光材料的液体渗透物在被检查的表面上均匀地施加并允许进入开放性不连续性。合适的停留时间后，去除过量的表面渗透剂。将开发人员应用于从不连续性中抽出所包裹的渗透物并弄脏开发人员。然后检查测试表面以确定存在或不存在指示。
Note: Caution - Fluorescent penetrant examination shall not follow a visible penetrant examination because visible dyes may cause deterioration or quenching of fluorescent dyes.
4.2 Processing parameters, such as surface precleaning, penetration time and excess penetrant removal methods, are determined by the specific materials used, the nature of the part under examination, (that is, size, shape, surface condition, alloy) and type of discontinuities expected.
4.3 Liquid penetrant examination methods indicate the presence, location and, to a limited extent, the nature and magnitude of the detected discontinuities. Each of the various methods has been designed for specific uses such as critical service items, volume of parts, portability or localised areas of examination. The method selected will depend accordingly on the service requirements.
4.4可以在适当的渗透剂停留后，设计的水洗渗透剂被设计为可直接从测试部分的水上洗涤。由于乳化剂是“内置”的可洗涤剂渗透剂，因此在去除过量的表面渗透剂以确保防止过度冲洗时进行适当的过程控制非常重要。如果冲洗步骤太长或太剧烈，则可以从不连续性中冲洗水的渗透物。有些渗透物比其他渗透物对过度冲洗的抵抗力较低。
4.5 Post-Emulsifiable penetrants with lipophilic and hydrophilic emulsifiers are not included in this procedure.
5.0设备和材料：
5.1 This procedure is intended for use with the following consumables or their equivalent. It has to be ensured that the consumables are selected in such a way that they are compatible to the test surface and object and as per test requirements.
Dye Penetrant Inspection - Water Washable, Fluorescent Penetrant System
| Manufacturer | PENETRANT | REMOVER | 开发人员 |
|---|---|---|---|
| Sherwin | HM-440，HM-430 | 水 | D-100，D-100NF |
| Ardrox | P133D，P134D，P135D | 水 | 9D1B |
| 大弹药 | ZL-60C | 水 | SKD-LT or ZP-9F |
Dye Penetrant Inspection -水洗可见的渗透系统
| Manufacturer | PENETRANT | REMOVER | 开发人员 |
|---|---|---|---|
| Sherwin | DP-51 | 水 | D-100，D-100NF |
| Ardrox | 906/303a | 水 | 9D1B |
| 大弹药 | SKL-WP | 水 | SKD-NF，SKD-S，ZP-9B |
5.2此程序不允许从不同家族（制造商）的渗透材料（制造商）进行混合。
Manufacturer’s recommendation for compatible penetrant systems must be adhered with.
5.3染料渗透剂检查 - 污染物的beplay体育官网电脑控制
When testing nickel based alloys, austenitic stainless steels and titanium, contaminant content of penetrant materials shall be controlled. Control shall be based on the manufacturers batch certification which shall include, as a minimum, the manufacturer’s name, batch number and chemical contaminant content as determined in accordance with ASME Section V, paragraph T-625.
Only dye penetrant inspection materials having a batch number printed on the container and traceable to a valid manufacturer’s batch certification on file shall be used.
6.0PARTS TO BE EXAMINED:
This procedure shall be used for parts or welds in ferrous and non-ferrous materials in accordance with applicable code or specifications for parts or welds.
测试焊缝时，要覆盖焊缝两侧的至少一英寸的基本材料。
7.0SURFACE PREPARATION:
7.1 Prior to the test, the area to be inspected and at least one inch on either side shall be free from all contaminants (dirt, grease, lint, slag, spatter, oil, scale, water and protective coatings).
7.2In general for welds, satisfactory results may be obtained when the surface to be inspected is in as welded condition.
如果需要使用机械清洁，加工或打磨的方法，则应蚀刻表面积以去除涂抹的金属。（有关全部详细信息，ASME第v，第24条和SE-165的第24条和SE）。
After etching, suitable neutralising solutions shall be used and test surface be washed with water.
7.3 Unless otherwise recommended by the manufacturer, welded components or parts cleaned by Vapour degreasing, organic solvents or detergents, and properly protected from contamination, need not be re-cleaned with penetrant cleaner (remover) prior to application of the penetrant.
有时，钢丝刷可能有助于去除生锈，表面尺度，但仅当没有其他拆卸手段会浮出水面时才使用。如果兼容，则应用渗透清洁剂清洁。
7.4染料渗透剂检查 - 干燥：beplay体育官网电脑
Evaporation time, following precleaning, shall be 5 minutes minimum. Where indications of retained moisture exist, the evaporation time shall be increased till no evidence of moisture in the area of test can be detected.
8.0EXAMINATION:
8.1Dye Penetrant Inspection - Temperature Limitations:
The temperature of the penetrant materials and the surface of the part should be between 50°F and 100°F for fluorescent water washable penetrants and between 60°F and 125°F for visible penetrants.
8.2 Dye Penetrant Inspection -Penetrant Application:
a）浸入式（浸入），流动，喷雾或刷牙技术用于将渗透剂施加到纯净的干样品上。
b) The penetrant is applied evenly over the entire area.
c）使用压缩空气施加渗透剂时，填充剂应在空气入口的上游侧使用。
8.3Dye Penetrant Inspection - Dwell times:
a) Penetrant dwell times are critical and should be adjusted depending on temperature and other conditions and may require qualification by demonstration for specific applications.
b) Typical minimum penetration times are given in the Table-1.
c) Penetrant shall remain on the test surface for the entire dwell time period.
d) Care shall be taken to prevent drying out of the applied penetrant and additional penetrant must be applied to re-wet the surface.
Dye Penetrant Inspection - Typical Minimum Penetration Times
| 材料 | 形式 | 不连续性的类型 | 可以洗涤的渗透时间* |
|---|---|---|---|
| Aluminium | Castings | 孔隙率，冷关 | 5至15分钟 |
| Aluminium | Extrusions, Forgings | Laps | NR** |
| Aluminium | Welds | 缺乏融合，孔隙率 | 30 |
| Aluminium | All | 裂缝，疲劳裂缝 | 30, not recommended for fatigue crack |
| Magnesium | Castings | 孔隙率，冷关 | 15 |
| Magnesium | Extrusions, Forgings | Laps | not recommended |
| Magnesium | Welds | 缺乏融合，孔隙率 | 30 |
| Magnesium | All | 裂缝，疲劳裂缝 | 30, not recommended for fatigue crack |
| Steel | Castings | 孔隙率，冷关 | 30 |
| Steel | Extrusions, Forgings | Laps | not recommended |
| Steel | Welds | 缺乏融合，孔隙率 | 60 |
| Steel | All | 裂缝，疲劳裂缝 | 30, not recommended for fatigue crack |
| Brass & Bronze | Castings | 孔隙率，冷关 | 10 |
| Brass & Bronze | Extrusions, Forgings | Laps | not recommended |
| Brass & Bronze | Brazed Parts | 缺乏融合，孔隙率 | 15 |
| Brass & Bronze | All | 裂缝 | 30 |
| Brass & Bronze | |||
| Plastics | All | 裂缝 | 5 to 30 |
| Glass | All | 裂缝 | 5 to 30 |
| Carbide-tipped Tools | All | Lack of Fusion Porosity, Craks | 30 |
| 钛和高温合金 | All | not recommended | |
| 所有金属 | All | Stress or Inter-Granular Corrosion | not recommended |
8.4染料渗透剂检查 - 去除过多的beplay体育官网电脑渗透剂：
After the elapse of penetrant dwell time, the excess penetrant is removed by water spray. Water at 60°F to 110°F and a pressure not exceeding 30 psi (210 KPa) is applied with droplet type sprayer specifically designed for penetrant removal. The nozzle of sprayer is held so that water strikes the surface of the specimen at an angle of approximately 45 degrees. Care is to be taken to avoid over-washing, which causes washout of penetrantfrom discontinuities. Other methods of referenced codes or specifications could also be used if applicable for the test surface conditions.
8.5Dye Penetrant Inspection -Drying:
在应用非水或干开发商之前，必须干燥测试表面。如果使用水性湿开发商，则将其应用于渗透液清洗后立即静止潮湿的样品。过度的热量或太长的干燥时间倾向于将渗透物烘烤出不连续性。
8.6染料渗透剂检查 - 开发人员应beplay体育官网电脑用：
干燥过程完成后，该样品已准备就绪，用于应用干燥或非水湿开发商。当使用水性湿开发商时，它可以通过在去除过量渗透剂后立即将表面淹没到湿标本中。
建议在搅拌后使用气溶胶罐，通常在各种项目站点工程进行焊接检查。beplay体育官网电脑喷雾距离应距测试表面10英寸至12英寸。测试区域必须足够酷，以防止开发人员车辆过于偿还蒸发。
干开发应用于由brushi标本ng with soft brush, by use of a powder gun, or by dipping the specimen in a tank of the developer and removing excess powder with a low pressure air flow.
An even thin coat/film of developer is preferred.
Applied developer shall not be removed from test surface.
8.7染料渗透剂检查：beplay体育官网电脑
8.7.1在使用开发人员和开发时间间隔期间beplay体育官网电脑，应观察到所检查的面积。
8.7.2建议的开发时间在7到30分钟之间。
Development time begins directly after application of dry developer and as soon as wet developer coating has dried on parts-surface.
8.7.3指示在测试表面（通过开发人员的印迹作用）形成并形成，在适当的照明条件下分析（相关指示）。
8.7.4 Lighting Conditions:
a）可以在自然光或人造光中检查可见的渗透迹象。需要充分的照明，以确保检查的灵敏度损失。建议在100 fc（1000 lx）的检查部位处有最小的光强度。
b）检查黑光下黑光下的荧光渗透剂指示。可见的环境光不得超过2英尺（20 lx）。应在检查表面上的合适的摄影型可见光计中进行测量。
Black Light Level Control - Black light intensity, minimum of 1000 µW/cm2, should be measured on the surface being examined, with a suitable black light meter. The black light wavelength shall be in the range of 320 to 380 nm.
强度应每8小时至少检查一次，或者每当更改工作站时。应立即更换破裂或损坏的紫外线（UV）过滤器。在进一步使用之前，必须更换辐射紫外线的灯泡有缺陷的灯泡。由于线路电压下降会导致黑光输出降低，因此性能不一致，因此当有电压波动的证据时，应使用恒压变压器。
Caution: Certain high-intensity black light may emit unacceptable amounts of visible light, which will cause fluorescent indications to disappear. Care should be taken to use only bulbs certified by the supplier to be suitable for such examination purposes.
Note: The recommended minimum light intensity is intended for general usage. For critical examination, higher intensity levels may be required.
黑光热身 - 在使用或测量发出的紫外线强度之前，让黑光保持至少10分钟。
Visual Adaptation - The examiner should be in the darkened area for at least 5 min before examining parts to allow the eyes to adapt to the dark viewing.
Caution - Photochromic lenses shall not be worn during examination.
9.0INTERPRETATIONS AND EVALUATIONS OF INDICATIONS:
9.1所有指示应根据参考代码或规范进行评估。
9.2 Acceptance Criteria are listed for specific codes in Annex-1 of this document. Any conflicts between these documents and applicable Code section shall be resolved by the NDT Level III or Divisional Manager (NDT) .
9.3表面的机械不连续性会导致错误或无关的适应症。任何被认为是无关的迹象都应被视为不连续性，并应重新检查以验证是否存在实际缺陷。
9.4 Non relevant indications and broad areas of pigmentation which would mask indications of defects are unacceptable and require corrective action by cleaning or other suitable means of surface preparation as described herein and retest.
9.5 Make sure that surface indications are not false indications i.e. machining marks, mechanical conditions or other surface conditions which cause or produce false indications.
9.6 Interpretation of indications found and determined to be rejectable shall be based on the size of the indication. Linear indications are those having a length greater than three times the width. Rounded indications are those that are circular or elliptical shape with the length equal to or less than three time the width.
9.7 All examination shall be reported on the penetrant testing report form.
10。SAFETY:
10.1认证检查员负责for compliance with applicable safety rules in the use of liquid penetrant materials.
10。2 Liquid penetrant should not be heated or exposed to open flames.
10。3 Penetrant materials may be highly volatile, relatively toxic and the liquid may cause skin irritation. Adequate ventilation at all times shall be used.
10。4 Aerosol cans of penetrant materials should be kept out of direct sunlight or areas in excess of 130 °F. Excessive heat may cause aerosol cans to explode.
10.5避免直接注视黑色光源，因为眼球中包含的流体，如果黑光直接散发到眼睛中，则会荧光。
11.POST CLEANING:
11.1需要清洁后（除非合同中另有规定）以从渗透过程中删除任何多余的残留物。
11.2 A suitable cleaning technique such as water wash, vapours degreasing, solvent soak may be employed.
11.3 Caution should be exercised to remove all developer prior to vapour degreasing as vapour degreasing can bake the developer on parts.
11.4 Post cleaning of water washable fluorescent penetrant tests could be done by flushing surface with forced water spray or by flushing the surface with an approved solvent cleaner depending on the actual job requirements. Clean cloth and or absorbent paper towel and or dry air jet could also be used.
11.4中提到的11.5点适用于可洗水 - 可见染料。
12.人员资格和认证
12.1根据此程序进行考试的人员应根据SNT-TC-IA（1992 Edition）或CP-189（1995 Edition）的ASNT进行资格和认证。
12.2 Only individuals qualified to NDT Level I and working under the supervision of an NDT Level II or III or individuals qualified to NDT Level II shall perform the examinations in accordance with this procedure.
13.PREFERENCE FOR WATER WASHABLE PROCESS
可洗水过程应用于测试以下内容：
13.1具有粗糙表面的文章。
13.2 Articles having threads and keyways.
13.3高生产许多小文章。
13.4 Weld inspection in closed vessels or tanks.
13.5 Weld or other component inspection when solvent process is found not suitable or preferable.
13.6具有中等粗糙表面的文章（如果可以接受中等灵敏度）。
13.7 Leak detection system.
13.8焊缝，当成本控制是一个质量时的文章。
14.0可水洗荧光渗透试验的特征：
Dye Penetrant Inspection -Advantages
Dye Penetrant Inspection -缺点
染料渗透检查 - 附件 - beplay体育官网电脑我
渗透测试验收标准
The acceptance criteria given hereunder for relevant indications for various codes shall be used in general throughout of第三者. The inspector using this is cautioned that Code requirements do变更，在冲突的情况下，应将其（以书面形式）转介给指定的NDTIII级or theDivisional Manager（NDT）。
DYE PENETRANT INSPECTION -API 1104
拒绝标准
1. Liner Indications
Indications > 1/16” (1.59mm) shall be considered as Relevant Indication,Relevant indications are rejectable if:
A。Evaluated as crater cracks or star cracks and > 5/32” (3.96mm) in length.
b。Evaluated as cracks other than crater cracks or star cracks.
C。Evaluated as IF and >1” (25.4mm) in total length in a continuous 12”（304.8毫米）焊缝或焊接长度的8％> 8％。
2. Rounded Indications.
For evaluation, the maximum dimension of rounded indications shall beconsidered as it size. Indications are rejectable as defects if:
A。个人指示> 1/8“（3.17mm）
b。Distribution of scattered rounded indications exceed concentration API1104图。18或19。
C。聚集的圆形指示> 1/2英寸（12.7mm）
d。任何12英寸（304.8mm）中的聚类指示的组合长度> 1/2英寸（304.8mm）weld.
e。集群中的任何个人指示> 1/16英寸（1.59mm）。
DYE PENETRANT INSPECTION -ANSI/ASME B31.1
1. Liner indication: Any crack or liner indication.
2. Rounded indications
A。Indications is dimensions > 3/16” (5.0mm).
b。在1/16英寸（2.0mm）或更少边缘的线路中的四个或多个圆形指示。
C。Ten or more rounded indication in any 6 sq. in. (3870mm2) of surface with the major dimension of this area not to exceed 6 in. (150mm).
DYE PENETRANT INSPECTION -ANSI/ASME B31.3
1. Liner indications: Any cracks or linear indications.
2. Rounded indications
Pending verification from ANSI. Until otherwise stipulated by ANSI B31 Committee, apply B31.1 criteria for rounded indications.
DYE PENETRANT INSPECTION -ASME Section VIII Div. 1
以下迹象应被拒绝为缺陷：
1.相关线性指示> 1/16“（1.59mm）
2.相关的圆形指示> 3/16：（4.77mm）
3. Four or more rounded indications in a line separated by 1/16” (1.59mm) or less (edge to edge).
DYE PENETRANT INSPECTION -AWS D1.1
Acceptance criteria is dependent on service condition. Refer to the relevant project NDT Supervisor or Area NDT Manager.
DYE PENETRANT INSPECTION -ANNEX - II
ULTRAVIOLET LIGHT INTENSITY VERIFICATION
1. The ultraviolet light intensity shall be determined using a UV Products Mode J-221 Long Wave UV Meter or equivalent. The procedure for using the J-221 meter is as follows:
1.1 Secure the black light fixture in a stable position at a distance greater than 6 inches.
1.2检查一下黑色灯泡已打开，并被允许热身至少5分钟。
1.3确保J-221米的面是垂直的，并且仪表已为零。（应使用传感器单元格插头检查零）。当必要时，通过转动位于仪表指针正下方的螺钉时更正零。
1.4 Record the meter reading without the UPV Filter # 50107 attached to the J-221.
1.5 Attach the UPV Filter # 50107 over the sensing element of the J-221 and record the meter reading.
1.6 Subtract the reading recorded in 1.5 from the reading recorded in 1.4 and document the results.
1.7 Ensure that the value obtained in step 1.6 is a minimum of 3000 microwatt/cm2 for work in areas other than booths specifically designed for ultraviolet light work. For work in a darkened booth, a minimum value of 1000 microwatt/cm2 is required.
1.8The black light intensity shall be measured at least once every 8 hours, or whenever the work station is changed.
Note: The J-221 meter has 2 scales. The A scale reads from 0-12 and the B scale reads from 10-60. To convert the meter reading to microwatts per square cm., multiply the meter reading by 100. For example, a meter reading of 30 would be 30 x 100 = 3000 microwatts/cm2.
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