GOST R 56663-2015

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  ГОСТ Р 56663-2015

GOST R 56663−2015 nondestructive testing. Quality control of engineering products by residual magnetization formed in the manufacturing process. General requirements

GOST R 56663−2015
Group Т59

NATIONAL STANDARD OF THE RUSSIAN FEDERATION

Nondestructive testing

QUALITY CONTROL OF ENGINEERING PRODUCTS BY RESIDUAL MAGNETIZATION FORMED IN THE MANUFACTURING PROCESS

General requirements

Non-destructive testing. Quality control of engineering products by residual magnetization formed during their manufacture. General requirements

OKS 77.040.10

Date of introduction 2016−07−01

Preface

1 was DEVELOPED by limited liability company «Energodiagnostika (LLC «Energodiagnostika»), Open joint stock company «Scientific-research center of control and diagnostics of technical systems» (JSC «NIC KD»)

2 SUBMITTED by the Technical Committee for standardization TC 132 «Technical diagnostics"

3 APPROVED AND put INTO EFFECT by the Federal Agency for technical regulation and Metrology, dated 22 Oct 2015 N 1614-St

4 INTRODUCED FOR THE FIRST TIME


Application rules of this standard are established in GOST R 1.0−2012 (section 8). Information about the changes to this standard is published in the annual (as of January 1 of the current year) reference index «National standards» and the official text changes and amendments — in monthly information index «National standards». In case of revision (replacement) or cancellation of this standard a notification will be published in the upcoming issue of the monthly information index «National standards». Relevant information, notification and lyrics are also posted in the information system of General use — on the official website of the Federal Agency for technical regulation and Metrology on the Internet (www.gost.ru)

Introduction

It is known that the main sources of damage in the operation of engineering products are the local stress concentration zones, which are formed under the action of workloads, primarily in the areas of defects of metallurgical and technological origin.

Internal casting defects, various types of heterogeneity structure, as well as process manufacturing defects (defects of welding, rolling, bending, heat treatment, etc.) due to the lack in most factories 100% quality control products, as well as due to imperfection of applied methods of non-destructive control remain unidentified. However, the rules of rejection of methods of nondestructive control at the manufacturing plants of articles aimed at identifying defects with dimensions many times greater than the size of metallurgical defects.

Metallurgical and process manufacturing defects create local zones of products with a high level of residual stresses, control of which is often carried out selectively. This controls the average level of residual stresses and their local area usually are not controlled and are ignored. In addition, it is unknown where these local zones are located, and how they can be detected.

Thus, the lack of control of residual stresses to determine their concentration in areas of structural defects of the products in manufacturing plants is the missing link in the NDT, which considerably reduces the reliability and safety of equipment and structures.

The method of metal magnetic memory [1]-[3] allows to define the zones of concentration of residual stresses, due to the complex influence of technological factors, the design features of the node and workloads.

This standard is aimed at creating a methodological framework for the use of the method of magnetic memory of metal to evaluate the quality of engineering products according to the criteria of residual stresses in the zones of defects of metallurgical and technological origin.

1 Scope

This standard applies to engineering products, pipelines, vessels and structures for various purposes and their elements, including the weld joint of any design, made of steel and alloys, cast iron and other structural materials without restriction sizes and thicknesses.

This standard establishes the General provisions and guidelines for quality control of engineering products by residual magnetization formed in the manufacturing process. This standard applies to products made of ferromagnetic and paramagnetic materials.

2 Normative references

This standard uses the regulatory references to the following standards:

GOST 12.1.004−91 System safety standards. Fire safety. General requirements

GOST 12.1.019−79 System of standards of occupational safety. Electrical safety. General requirements and nomenclature of types of protection

GOST 12.1.038−82 standards System of labor safety. Electrical safety. The maximum permissible values of the touch voltage and currents

GOST 12.2.003−91 System safety standards. Equipment production. General safety requirements

GOST 12.3.002−75 System safety standards. The process of production. General safety requirements

GOST 27.002−89 reliability of the technique. Basic concepts. Terms and definitions

GOST 30489−97* Qualification and certification of personnel in nondestructive testing. General requirements
________________
* Access to international and foreign documents referred to here and hereinafter, can be obtained by clicking on the link to the site shop.cntd.ru. — Note the manufacturer’s database.

GOST R ISO 9712−2009 nondestructive testing. Certification and personnel certification.

GOST R ISO 24497−1-2009 nondestructive testing. The method of metal magnetic memory. Part 1. Terms and definitions

GOST R ISO 24497−2-2009 nondestructive testing. The method of metal magnetic memory. Part 2. General requirements

GOST R ISO 24497−3-2009 nondestructive testing. The method of metal magnetic memory. Part 3. Weld inspection

GOST R 52330−2005 non-destructive Control. Control of the stress-strain state of objects of industry and transport. General requirements

Note — When using this standard appropriate to test the effect of reference standards in the information system of General use — on the official website of the Federal Agency for technical regulation and Metrology on the Internet or in the annual information index «National standards» published as on January 1 of the current year, and the editions of the monthly information index «National standards» for the current year. If replaced with a reference standard, which was given an undated reference, then it is recommended to use the current version of this standard, taking into account all enabled in this version modifications. If replaced with a reference standard, which is given a dated reference, it is recommended to use the version of this standard referred to above by year of approval (acceptance). If after approval of this standard in the reference standard, which is given a dated reference, a change affecting a provision to which reference, the provision is recommended to be applied without taking into account this change. If the reference standard is cancelled without replacement, the position in which reference is made to him, recommended to be used in part not affecting this link.

3 Terms, definitions and abbreviations

3.1 this standard applies the terminology according to GOST R ISO 24497−1 and GOST 27.002.

3.2 this standard applies the following abbreviations:

OK — the object of control;

IPRA — stress concentration zone;

MPM — magnetic memory metal;

NDT — non-destructive testing;

Tmms — magnetic field scattering;

SK is a means of control.

4 General provisions

4.1 In the development of technical regulations, national standards and enterprise standards, design and other normative and technical documentation for engineering products it is recommended to provide the NDT methods and metallurgical defects of technological origin.

4.2 To solve the problem specified in 4.1, the possible application of the method of metal magnetic memory based on the use of natural magnetization of the products formed during their manufacture.

4.3 To apply the MPM in the quality control of engineering products needs to be provided with certain conditions and to formulate General methodological recommendations.

4.4 the manufacturer of products should have a manufacturing instructions for performing the NDT of articles using the method MPM. The statement must include qualitative and quantitative criteria for the rejection of the products by metallurgical and technological defects of origin.

5 safety Requirements

5.1 To allow inspection of persons trained in the method of MPM with certification for qualification levels I and II.

To confirm the qualifications of the personnel conducting the certification in accordance with the requirements of GOST R ISO 9712 and GOST 30489.

5.2 Persons involved in magnetic control, should observe the safety regulations established for workers of this industry.

5.3 Under the control of the operator should be guided by GOST 12.2.003, GOST 12.3.002 and safety regulations in the operation of electrical 12.1.019 according to GOST and GOST 12.1.038.

5.4 Measurement is carried out in accordance with the safety requirements specified in the operating instructions of the equipment that is included in the used IC.

5.5 Facilities for measurements shall meet the requirements [4] and [5].

5.6 In the organization of control must be complied with fire safety requirements according to GOST 12.1.004.

5.7 Prior to admission to the testing of MPM of all persons involved in the work must pass the appropriate instruction and safety training with registration in a special register.

5.8 At each change of conditions of works to carry out instructions. Responsible for conducting the instruction and training of operators must have the engineering level (level III).

5.9 in carrying out the control in a specific industrial environment use personal protective equipment.

5.10 During the inspection on high-rise structures used scaffoldings, ladders or cradles that meet the standards, norms and safety regulations.

6 Requirements for control devices

6.1 control of equipment using the MPM used specialized magnetometric devices with appropriate certificates. In the description of these devices should be standard methods of determining the IPRA.

6.2 Principle of operation of these devices should be based on the fixation of current pulses in the winding of the transducer when inserting it in tmms of the near-surface space of the test object. As sensors to measure the intensity of tmms can be used fluxgate or other magnetically sensitive transducers: polimery or gradiometers.

6.3 Devices must have a screen for graphical representations of control settings, the registered device based on a microprocessor, the memory and the scanning device in the form of specialized sensors. Must be capable of transmitting information from the device to the computer and print on the printer. Included with the device shall be supplied software for processing control results on the computer.

6.4 complete with instrument sensors. Sensor type is determined by method and object of control. The sensor should be at least two measuring channels, one of which is measuring and the other is used for the detuning of the external magnetic field of the Earth.

The sensor housing must have an electronic unit increase of the measured field and the sensor for measuring the length of the controlled area.

6.5 Permissible error of measurement of the magnetic field is indicated in the methods depending on the object of control.

6.6 the Instrument shall have the following metrological characteristics:

— the main relative error of the measured magnetic field for each measurement channel must not exceed ±5%;

— the relative error of the measured length should not exceed ±5%;

— the range of the measurement instrument should be at least ±1000 A/m;

the minimum scanning step (distance between two adjacent control points) must be 1 mm;

— the level of electronic noise due to processor and chipset, should not exceed ±5 A/m.

6.7 the equipment must have a passport with an instruction manual.

7 Requirements for building control

7.1 When using the MPM equipment and design of control both in working condition (under load) and when they stop (after removing the workload).

7.2 cleaning and surface preparation are required. Insulation is recommended to be removed. In some cases, Pets OK non-magnetic insulation. Maximum insulation layer thickness is determined by experiment.

7.3 the Range of thickness of metal in control areas indicated in the methods on this OK.

7.4 limiting factors To the application of the method of MPM include:

— artificial magnetization of the metal;

— extraneous ferromagnetic product is OK;

— availability of close proximity (closer than 1 m) OK source of an external magnetic field and fields from electric.

7.5 Acoustic noise and mechanical vibration OK have no effect on the results of the inspection.

8 the Procedure for preparation of the control

8.1 Preparation for control consists of the following main stages:

— analysis of technical documentation on OK and the mapping (of the form) OK.

— the choice of types of sensors and control devices;

— configure and calibrate devices and sensors in accordance with the instructions specified in the passport of the device;

— conditional division of object of control on the parts and components that have design features and marking them in the form OK.

8.2 Analysis of technical documentation on the test object includes:

— identification of grades and sizes of nodes;

— analysis of modes OK and causes of failure (damage);

— identify the structural features of nodes, locations of welded joints.

9 General guidance on the application of the method of metal magnetic memory under the control of the quality of engineering products

9.1 For the development of production instructions for quality control of products using the method of MPM, it is recommended to use the General provisions of vhost R ISO 24497−2, GOST R ISO 24497−3 and GOST R 52330.

9.2 When performing quality control of products using the MPM, the product must have the same size, made of the same material and the same technology.

9.3 In the development of production instructions that specify quantitative criteria for the rejection of the products by the method of MPM, it is recommended to conduct experimental studies for each type of product with confirmation of the criteria of the other methods of destructive and non-destructive testing (the study of the structure of metals, hardness measurement, mechanical testing, etc.).

9.4 monitoring Devices for the measurement of residual magnetization of products must comply with the requirements of IC specified in GOST R ISO 24497−2. Devices must have a certificate of Rosstandart and the certificate of verification in Metrological service.

9.5 in the implementation of control methods MPM products should not have artificial magnetization. Sweep the surface of products is not required.

Bibliography

The electronic text of the document
prepared by JSC «Code» and checked by:
the official publication of the
M.: STANDARTINFORM, 2016