无损探伤通用技术规范(中英文).doc

东方电机股份有限公司dongfang electrical machinery co., ltd.rev: 0东方电机股份有限公司dongfang electrical machinery co., ltd无损探伤通用技术规范ndt general technology procedure东方电机股份有限公司dongfang electrical machinery co., ltd.rev: 0 编 制issued by刘文高、王麟校 核checked by邓伟勇审 定approved by吴天茂2003年9月18日无损探伤通用技术规范ndt general technology procedurerev: 0 目 录index1锻件超声波探伤规范1ultrasonic inspection procedure for forging 12焊缝超声波探伤规范5ultrasonic inspection procedure for welds 53磁粉探伤规范15magnetic particle inspection procedure154液体渗透探伤规范26liquid penetrant inspection procedure 265射线探伤规范34radiographic inspection procedure 34锻件超声波探伤规范ultrasonic inspection procedure for forgingpage: 4 of 481. 锻件超声波探伤规范ultrasonic inspection procedure for forging1.1 适用范围 scope本规范适用于jb4730-94压力容器无损检测标准第二篇或astm a388规定的钢锻件超声波探伤。this procedure covers ultrasonic inspection for the iron forged products in accordance with the jb4730-94nondestructive testing of pressure vesselssection or astm a388.1.2 设备和人员 apparatus and presonnel1.2.1 设备 apparatus超声波探伤仪采用a388 4.1条规定的a型超声波探伤仪。探头晶片直径1429mm，最大有效面积为635mm2，探头频率采用25mhz，必要时也可采用1或1.25mhz。an ultrasonic pulsed reflection type a of instrument shall be required in accordance with part 4.1 of astm a388. the probe shall have a maximum active area of 635mm2 with the diameter of 1429mm max and the probe frequency shall be 2 to 5mhz. if necessary, a frequency of 1mhz or 1.25mhz may be employed, and the areas to be inspected shall be defined on the test report.1.2.2 超声波探伤仪应根据astm e317作垂直、水平和线性的校验，其周期应不超过一年。ultrasonic examination equipment shall be calibrated in accordance with astm e317 for screen height, horizontal and amplitude linearity. the calibrations shall be at a frequency not to exceed one year.1.2.3 人员 personnel所有从事超声波探伤的人员都应按照gb9445-88无损检测人员资格鉴定通则或snt-tc-1a推荐的方法进行培训和资格鉴定。all personal performing ultrasonic examination shall be trained and qualification according to the gb9445-88rules for qualification and certification of ndt personnel or snt-tc-1a recommended method.1.3 检测时机 testing stage超声波检测应在锻件最终热处理之后，粗加工状态下进行。the ultrasonic examination for iron forged products shall be performed in final heat treatment and rough machined condition.1.4 表面制备 surface preparation1.4.1 所有探伤表面应加工到ra6.3m，锻件被检表面应无任何污物。the roughness of all surfaces to be examined shall not exceed 6.3 micrometer. the surface of the forging to be tested shall free and form extraneous dirt.1.5 耦合剂 couplant甘油、ultragel高温耦合剂、金属专用浆糊、机油、水或相当的物质可作为检查用耦合剂。校正与检验应使用相同的耦合剂。glycerin, ultragel, metal paste, oil, water or equivalent, shall be used as couplant for these inspection. the same couplant shall be used for calibration and testing.1.6 扫查技术 scanning technique1.6.1使超声波传入工件应涂刷适量的耦合剂。探头应紧贴探伤面移动。sufficient proper couplant shall be used to permit for sound wave transmission into the material being examined. the search unit shall be moved in intimate contact with examination surface.1.6.2 扫查速度不超过150mm/s。相邻两次扫查之间应有一定的重叠，重叠宽度至少为探头晶片尺寸的15%。the rates of scanning not exceed 150mm/s. each pass of the search unit shall overlap the previous pass by a minimum of 15% of the transducer element dimension perpendicular to the direction of scanning.1.7 仪器校准 calibration of equipment1.7.1纵波探伤采用底面反射法校准仪器，第一次底波调至屏高和屏宽的75%。to perform the longitudinal technique examination ultrasonic equipment calibration on the back reflection. adjust the first response to 75% of full screen height (fsh) and full screen width (fsw).1.7.2 仪器在下列时间应重新根据校正标准。equipment shall be calibrated checked against a calibration standard for proper functioning and gain setting at the following intervals：每次检查的开始和结束；at the beginning and end of each examination.每四个小时；every four hours探伤更换人员时；when examination personnel are changed.怀疑仪器出现故障时；at any time when an equipment malfunction is suspected.当断面厚度或直径有较大改变时；when the section thickness or diameter are changed.探头、耦合剂、仪器调整或者扫查速度有变化时。when the search unit, couplant, setting of equipment or the rate of scanning are changed.1.8 验收 acceptance除非在产品图纸上另有说明，否则应按下述验收。unless otherwise noted on a product drawing, the following acceptance criteria shall apply.1.8.1 用直探头检查 examination with normal bundle存在任何下列情况的不连续将拒收：the discontinuities will be refused in any of the following situation:任何类型的线性缺陷；every kind of the linear discontinuities;底波衰减超过95%；loss of depth echo superior to 95%;波幅超过4mm当量的任何显示。（两个显示范围之间的距离小于一个单独缺陷的大小）；any indication with an amplitude higher than the obtained of a bore with 4mm of the diameter (if the distance between the limits of two indications were lower than a unique indication).波幅超过80%参考线且引起底波衰减大于30%的密集缺陷。accumulation of the indications with amplitudes superior to 80% of the level of the reference and causing a reduction of the depth echo superior to 30%.密集缺陷的定义是在任意100cm22cm体积内缺陷的数量超过6个。accumulation of the indications is defined as any area of the 100cm2, that shows a quantity superior to 6 indications in each depth of 2cm.波幅超过50%参考线的允许缺陷必须记录并提交dfem认可。the indications permissible, which amplitudes were superior to 50% of the reference level, must be registered and submitted to the approbation of the dfem ltd.1.8.2 用斜探头检测 examination with angle bundle下列情况的缺陷将被拒收。the discontinuities will be refused on the following situation:波幅超过asme标准第v卷第5章所限定直径的圆柱孔的任何显示。（孔径是锻件厚度的函数）any indication with an amplitude higher than the obtained of the one cylinder bore with diameter determined by the standard asme v. article 5(in function of the thickness of the forged).波幅超过50%参考线的容许缺陷，必须记录并提交dfem批准。the indications permissible, which amplitudes were superior to 50% of the reference level, must be registered and submitted to the approbation of the dfem ltd.1.9 探伤报告 report探伤报告至少应包括下列内容：a report of the examination shall be prepared containing the following information as a minimum:工 作 号job no.图 号dwg. no.委托单位applicant零件数量quantity委托编号dep. no.零件尺寸size材 料material零件名称part name炉 号heat no.探伤标准spec. no.材料状态conditions探伤区域exam. area探伤方法method探头规格probe灵 敏 度sensitivity所用规程procedure used.扫 查 面surface scanned.耦 合 剂couplant使用的超声仪ultrasonic equipment used.校准试块编号calibration block number.dac曲线说明description of dac curve.探头频率probe frequency.探伤员姓名和资格证等级inspectors name and level of qualification.探伤日期date of the inspection.焊缝超声波探伤规范ultrasonic inspection procedure for weldspage: 15 of 482 焊缝超声波探伤规范ultrasonic inspection procedure for welds2.1 适用范围 scope本规范适用于jb4730-94标准压力容器无损检测第二篇或asme第五章和第八章规定的焊缝超声波探伤。this procedure covers ultrasonic inspection of welds in accordance with the jb4730-94nondestructive testing of pressure vesselssection or the asme code sections , and section .2.2 参考标准 applicable documentsjb4730-94标准压力容器无损检测第二篇jb4730-94nondestructive testing of pressure vesselssection ;asme标准第五章和第八章“锅炉和压力容器规程”；asme boiler & pressure vessel code sections v and ;astm 标准中的e317；astm e 317;gb9445-88无损检测人员技术资格鉴定通则或asnt，snt-tc-1a标准中推荐的关于无损探伤人员资格的考核办法。gb9445-88rules for qualification and certification of ndt personnel or asnt, snt-tc-1a. recommended practice for qualification of nondestructive testing personnel.2.3 人员资格 qualifications所有从事超声波探伤的人员都应按照gb9445-88无损检测人员资格鉴定通则或snt-tc-1a推荐的方法进行培训和资格鉴定。all personal performing ultrasonic examination shall be trained and qualification according to the gb9445-88rules for qualification and certification of ndt personnel or snt-tc-1a recommended method.2.4 形状和尺寸 shape and dimensions被检工件形状和尺寸符合工件表中制造图纸的说明。shape and dimensions according to manufacturing drawings mentioned in the job sheets.2.5 探伤和扫查要求 requirement of examination and scanning2.5.1 扫查 scanning为了检查整个被检件，采用接触法通过手工操作使探头在探伤面上移动来完成检测。scanning shall be performed manually via the contract method by moving the search unit over the examination surface so as to scan the entire volume to be examined.相邻两次扫查之间应有一定的重叠，重叠宽度至少为探头晶片尺寸的15%。each pass of the search unit shall overlap the previous pass by a minimum of 15% of the transducer element dimension perpendicular to the direction of scanning.扫查速度不超过150mm/s。the rates of scanning not exceed 150mm/s.2.5.2 探伤 examination 声波传播进入被检材料，应通过观察超声波的正常噪声或正常的背反射来进行校验。sound transmission into the material being examined shall be verified by observing normal ultrasonic noise and/or normal back reflection.用于产品检验的仪器的扫查增益量至少应是仪器校准增益量的2倍。但是当超声噪声超过校正水平的25%时，扫查增益量低于2倍校准增益量时的仪器也是可以使用的。扫查方向应垂直于焊缝方向。the instrument gain for production scanning shall be at least twice the calibration gain setting; however, when ultrasonic noise exceeds 25% of the calibration level, a gain setting less than 2x may be used. the direction of scanning shall be perpendicular to the weld direction.2.6 表面条件 surface conditons焊缝的超声波探伤应在最终热处理后进行。ultrasonic inspection of welds shall be performed the final heat treatment condition.探伤面和反射面应无妨碍探头移动与耦合的焊接飞溅、轨制鳞皮、凹凸不平或波浪度。通常，被检表面光洁度最小应是iso1302的ra12.5m（n10）。当使用双晶探头时，表面光洁度应不大于ra6.3m。the surface shall be free of weld spatter, mill scale, and/or any roughness or waviness that will interfere with the movement or coupling of the search unit. they shall be blasted or ground. in general a surface finish corresponding to reference a minimum from ra 12.5m (n10) as per iso1302 is acceptable. in case a separate transmitter receiver probe is used, the surface finish shouldnt be greater than ra6.3m.2.7 耦合剂 couplant甘油、ultragel高温耦合剂、金属专用浆糊、机油、水或相当的物质可作检查用耦合剂。校正与检验应使用相同的耦合剂。glycerin, ultragel, metal paste, oil, water, or equivalent, shall be used as couplant for these inspection. the same couplant shall be used for calibration and testing.2.8 距离和折射角校验 distance calibration and check of angle of refraction2.8.1 应根据astm e317校验仪器的垂直、水平和波幅线性。校验周期不超过一年。equipment shall be calibrated in accordance with astm e317 for screen height, horizontal and amplitude linearity. the calibrations shall be at a frequency not to exceed one year.2.8.2 在以下的工作时间内应使用参考试块校验仪器和增益：equipment shall be calibrated checked against a calibration standard (reference block) for proper functioning and gain setting at the following intervals:每次检查的开始和结束；at the beginning and end of each examination.每四个小时；every four hours;探伤更换人员时；when examination personnel are changed;怀疑仪器出现故障时。at any time when an equipment malfunction is suspected.2.8.3 校验时，若确定仪器发生故障，应重做全部检查。if during any check, it is determined that the equipment is malfunctioning, all the testing that has been completed since the last valid equipment check shall be retested.2.9 校正试块 calibration block校正试块应采用与被检材料相同的工艺、相同的声特性或等效的材料制成。the calibration block shall be made of a material that is the same product form as the material being examined and the same or equivalent p-number grouping as the materials being examined.校正试块表面光洁度应能代表被检件的表面光洁度。the surface finish on the calibration blocks shall be representative of the surface finish on the component being examined.常用的校正试块结构尺寸如图2-1所示。a typical calibration block configuration is shown in figure 2-1.表2-1中规定了常用的探伤校正反射体（除另有规定）calibration reflectors to be used for the inspection are specified in table 2-1 below (unless otherwise specified):图2-1 角度探头校准试块fig.2- 1 basic calibration block for angle beam examinationl=使用角度探头和v型扫查轨迹确定的试块长度；t=试块厚度（见表1）；d=横孔深度38mm；d=横孔直径（见表1）；t=材料标称厚度。l=length of block determined by the angle of search unit and the v-path used.t=thickness of basic calibration block (see table 2-1)d=depth of side-drilled hole 38mmd=diameter of side-drilled hole (see table 2-1)t=nominal production material thickness.表2-1 角度声束检查用校正试块table 2-1 dimensions of calibration blocks for angle beam examination焊缝厚度weld thickness（t）（mm）校正试块厚度calibration blockblock thickness（mm）孔径hole diameter（mm）深度depth（mm）2525 or “t”2.44025 t5050 or “t”3.24050 t100100 or “t”4.840100 t150150 or “t”6.440150 t200200 or “t”7.940200250t（见注1）(see note 1)40注：1.焊缝厚度每增加50mm，孔径增加1.6mm。2.孔径公差0.8mm。note: 1. for each increase in thickness of 50mm or fraction thereof, the hole diameter shall increase 1.6mm.2. the tolerance for hole diameter shall be 0.8mm.2.10 探伤仪器的校正 examination calibration为了全厚度探伤，一条距离波幅校正曲线（dac）应当使用1/4t，1/2t，和3/4t不同距离的校准点加以核定，需要时，也可根据工件厚度校正（t为被检查材料厚度）。for these examinations, a distance amplitude correction curve (dac) should be used with 1/4t, 1/2t, and 3/4t calibration points, as required, based on the part thickness (where t equals the thickness of the material under examination).当材料厚度超过50mm时，最少用两个dac校准点。a minimum of two dac points should be used for material thickness over 50mm.从校正孔获取最大的信号幅度，调节增益使波幅达到屏高的70%80%。the gain shall be adjusted to provide an indication 70% to 80% of full screen height (fsh) from the calibration hole which provides the greatest signal.使用该增益设置，找出其它校正孔的最大反射波幅点，将其标在示波屏上，两个相邻校正点的最大波幅用直线连接，通过连接这些点制成dac曲线。using this gain setting, the maximum indication height for the other calibration holes shall be marked on the screen and the dac curve shall be formed by connecting these points with a straight line between adjacent calibration points.把从最大声程距离校正孔上得到的回波至少调节到屏宽的75%处。the response from the calibration hole at the greatest sound path distance shall be set at least 75% of full screen width (fsw).不应使用“抑制”。reject shall not be used.校正试块和被检查材料的声阻抗应相近。声阻抗应在2db内。被检查材料和校正试块之间的声阻抗差值应增加到扫查增益的调节上。the calibration block and material shall be examined for compatible acoustic impedance. the acoustic impedance should be within 2db. the difference between the material to be examined and the calibration block shall be added to the scanning gain setting.dac曲线校准-如果dac曲线上的任意点幅值变化大于20%，探伤应重新进行。dac correction-if any point on the dac curve has changed in amplitude more than 20%, the inspection shall be repeated.扫描范围校准-如果dac曲线上的任意点在扫描线上水平移动量大于10%，则探伤应重新进行。sweep range correction-if any point on the dac curve has moved on the sweep line more than 10%, the inspection shall be repeated.2.11 基体母材金属检查 base material examination实施横波检查前，横波通过母材的部分应进行纵波技术探伤。before shear wave examination performed, the base material through which the sound will pass shall be inspected by the longitudinal technique.实施纵波探伤采用底面反射校正。调节底波至屏高的80%to perform this examination, calibration on the back reflection. adjust the response to 80% of fsh. 任何引起底波降低50%（或更大）的区域应在探伤工件上打上标识记号并记录在试验报告上，任何引起底波下降100%衰减的区域应由dfem的级无损探伤人员或其委派人员评判。any areas producing a 50%(or greater) reduction in the back reflection shall be marked on the part being inspected and noted on the test report. any area producing a 100% loss of back reflection shall be evaluated by dfem level or designee.2.12 探伤方法 examination method所有焊缝应按表2-2检查（除非另有说明）。all welds shall be examined by the method shown in table 2-2 (unless otherwise instructed).表2-2table 2-2焊缝类型weld type焊缝厚度weld throat thickness（mm）小于12less than 1212到3812 to 3838到6338 to 6363到12763 to 127127到203127 to 203首选primary最大1/4top1/4首选primary最大1/4top1/4首选primary最大1/4top1/4首选primary最大1/4top 1/4首选primary最大1/4top 1/4对接焊缝推荐角度butt recommended angel707070or6045or 6070or60or 4545or 6060or 4545or 6060or 4545技术technique2222222222t字焊缝面atee face a recommended angel7070or8070or 60or 4560or4545技术technique33333面bface b7070or 6070or 60or 4560or 4545技术technique33333面cface c0, 700(70or 45)0, 450, 450, 45技术technique33333角焊缝面a推荐角度corner face a7070or 807060, 4560or 4545技术technique44444面bface b7070or 807060, 4560or 4545技术technique44444面cface c00000技术technique44444双角焊缝面a推荐角度double fillet face b conner weld face a4545454545技术technique55555面b推荐角度face b4545454545技术technique55555区域1到焊缝平台的螺旋框面bzone 1spiral case to deck weld face b707070n/an/a技术technique666n/an/a区域2推荐角度zone 27, 45, 07, 45, 07, 45, 0n/an/a技术technique666n/an/a区域3推荐角度zone 370or 6070or 6070or 60n/an/a技术technique666n/an/a图2-2 技术2 图2-3 技术3figure 2-2 technique 2 figure 2-3 technique 3 图2-4 技术4 图2-5 技术5 figure 2-4 technique 4 figure 2-5 technique 5图2-6 技术6figure 2-6 technique 62.13 评判 evaluation反射波幅度超过20%dac曲线的缺陷显示应对其可能的最大尺寸进行分析并用文本所述的验收标准加以评判。any imperfection that produces an indication in excess of 20% of dac shall be investigated to the maximum extent possible and evaluated to the acceptance standard contained herein.反射波幅度超过100%dac曲线的任何显示应按下述方法测定其大小：imperfections that produces an indication in excess of 100% of dac shall be sized as follows:调节最大的显示至屏高的80%；maximize indication and set at 80% full screen height.移动探头使缺陷信号从最高点降至屏高的40%；move off maximum point until indications are at 40% fsh.标记下探头的中心。注：必须从所有方向测定其显示的大小。mark the center of the pro