菲律宾无损检测方案(中英文对照).doc

菲律宾ANGAT水利用和管道改造工程ANGAT Water Utilization and Aqueduct Improvement Project (AWUAIP)无损检测方案Non-destructive testing scheme编制单位（Enterprise）： 编 制 人 （Compiler）：审 核 人 （Verifier）：批 准 人 （Approver）：编制日期年 月 日Compile Date y m d 印 号（Printed Number）:版本：第一版 发布日期： 年 月 日Edition：First published Release Date: y m d大马尼拉供水项目钢管制作工程无损检测方案Angat Water Utilization and Aqueduct Improvement Project (AWUAIP) Steel Pipe Manufacture Project Non-destructive testing scheme1 概述 1 General该工程管道规格为D3300mm16mm和D3500mm6mm，材质为：A283C ,要求所有对接焊缝进行超声波检测，其他焊缝进行磁粉检测或液体渗透检测，超声波检测应符合ASME第8部分第1条附件U的要求，磁粉检测应符合ASME E109 的要求。Specifications of pipe in this project are D3300mm16mm and D3500mm6mm, material quality is: A283C, requiring ultrasonic testing (UT) for all butt weld, magnetic particle testing (MT) or liquid penetrant testing (PT) for other weld, ultrasonic testing (UT) shall conform to requirements in Clause 1 Section 8 of Annex U, magnetic particle testing (MT) shall conform to requirements of ASME E109. 2 超声波检测工艺2 Ultrasonic Testing Technics2.1 本方法采用A型脉冲反射式数字超声探伤仪对承压部位的所有对接焊接接头进行超声波检测。2.1 Butt weld joint for compression position shall be ultrasonic tested by A-mode digital ultrasonic flaw detector using pulse echo technique during this technique2.2对具体的产品需要制定详细的检测方案，按程序要求进行审批和实施。2.2 Inspection scheme in detail shall be drawn up for specific product, approved and executed according to the requirements of procedure. 2.3 检测工艺卡由超声波检测级人员按合同要求编制。2.3 Inspection technics card shall be drawn up by ultrasonic testing II class personnel according to contract requirements.2.4 检测人员2.4 Inspector2.4.1 检测人员必须经过培训，取得国家有关部门颁布的，符合SNT-TC-1A标准要求，并与其工作相适应的资格证书。2.4.1 Inspectors must be trained, acquiring qualification certificate which is corresponding to their operations and conforms to requirements of SNT-TC-1A standard issued by related departments.2.4.2 检测人员每年检查一次身体，其矫正视力不低于1.0。2.4.2 Health of inspectors shall be checked whose corrected visual acuity should be not less than 1.0. 2.5 仪器、探头和试块2.5 Instrument, probe and test block 2.5.1使用仪器为PFUT2400型或其他型号的数字超声波探伤仪。2.5.1 Instrument shall be used Digital ultrasonic flaw detector as PFUT2400 or other type.2.5.2仪器和探头的组合灵敏度：在达到所检工件最大声程时，其有效灵敏度余量应10dB。2.5.2 Combination sensitivity of instrument and probe: when it comes up to maximum Beam path of inspected work piece whose effective sensitivity shall be 10dB.2.5.3仪器和探头的组合频率与公称频率误差不得大于10%。2.5.3 Error of combination frequency and nominal frequency between instrument and probe shall be not more than 10%.2.5.4超声波探伤仪的工作频率范围为0.510MHZ，仪器至少在荧光屏满刻度的80%范围内呈线性显示。水平线性误差不大于1%，垂直线性误差不大于5%。2.5.4 Operation Frequency Range of ultrasonic fault detector shall be 0.510MHZ, instrument shall be linear indication at least including 80% of full-scale fluorescent screen. Error of horizontal linearity is not more than 1%, and vertical linearity is not more than 5%。2.5.5壁厚为6mm的对接焊缝选用频率为5 MHZ，折射角为70和折射角为60的2个聚焦斜探头分别进行检测。2.5.5 Butt weld with 6mm wall thickness selects 5 MHZ frequency, shall be inspected by two focusing angle probe with 70and 60refracted angle.2.5.6壁厚为16mm的对接焊缝选用频率为2.5 MHZ，折射角为60和折射角为45的2个单晶斜探头分别进行检测。2.5.6 Butt weld with 16mm wall thickness selects 2.5 MHZ frequency, shall be inspected by two monocrystal angle probe with 70and 60probe refracted angle.2.5.7对比试块应采用与被检工件相同声学性能的材料制成。2.5.7 Material of contrast test block shall be identical to acoustical property of inspected work piece.2.5.8对比试块的其它制造要求应符合ASME第8部分第1条附件U的要求。也可采用合同规定的其他型号对比试块。2.5.8 Other manufacture requirements of contrast test block shall be according with requirements in Clause 1 Section 8 of Annex U. Other type contracted contrast test block shall be used.2.6检测的一般方法2.6 General technique of inspection2.6.1检测复盖率:检测时探头的每次扫查复盖应大于探头直径的15%。2.6.1 Inspection coverage rate: scanning coverage of probe when inspect shall be more than 15% of probe diameter each time.2.6.2 探头的移动速度:探头的扫查速度不得超过150 mm/S。2.6.2 Travelling speed of probe: scanning speed of probe shall be not more than 150 mm/s.2.6.3采用机油、浆糊、甘油和水等透声性好，且不损伤检测表面的耦合剂。2.6.3Engine oil, paste, glycerol and water etc. shall be well permeability to ultrasound and couplant shall not damage inspected surface. 2.6.4检测面的确定,应保证工件被检部分均能得到充分检查。2.6.4 Inspected work piece shall be inspected in sufficient during determine of inspection surface. 2.6.5检测面应经外观检查合格，所有影响超声检测的锈蚀、飞溅、污物都应予以清除，其表面粗糙度应符合检测要求。2.6.5 Inspection surface shall be qualified by appearance inspection, rust corrosion and dirt should be cleared away to make surface roughness corresponding to requirements of inspection.2.7 校准2.7 Calibration2.7.1校准应在标准试块上进行，校准中应使超声主声束垂直对准反射体的反射面，以获得稳定的和最大的反射信号。2.7.1 Standard test block shall be calibrated, reflecting surface of reflector which ultrasonic main beam vertically aims at, to obtain stable and maximum reflected signals. 2.7.2每隔三个月至少应对仪器的水平和垂直线进行一次测定。2.7.2 Instrumental horizontal and vertical line shall be determined one time at least every three months.2.7.3仪器和探头系统的复核2.7.3 Recheck instrument and probe遇到下述情况应对系统进行复核：In case of following conditions, system shall be rechecked: (1) 校准后的探头、耦合剂和仪器调节旋钮发生改变时；When adjusting knob of probe, couplant and instrument shall be changed after calibration;(2) 检测者怀疑扫描量程和扫查灵敏度有变化时；When inspector doubts that scanning range and scanning sensitivity has changed;(3)连续工作4小时以上时；When continuous working hours are more than 4 hours;(4)工作结束时。End of job.2.8 超声波检测要求2.8 Ultrasonic testing requirements2.8.1一般用两种K值探头采用直射波法和一次反射波法在焊接接头的单面双侧进行检测。2.8.1 Generally signal side and bilateral of welding joint shall be inspected using straight beam technique and primary reflected wave technique with two kinds of K value probe. 2.8.2应进行横向缺陷的检测。检测时将探头放在焊缝及热影响区的两侧作两个方向的平行扫查。 2.8.2 Inspection of lateral defect. When inspecting probe shall be located at two sides of weld and heat affected zone, to do parallel scan of two directions.2.8.3 扫查灵敏度：不低于最大声程处的参考反射体波高。检测横向缺陷时，要将灵敏度提高6dB。2.8.3 Scanning sensitivity: no less than reference reflected body wave height at maximum Beam path. When inspected lateral defect, sensitivity shall increase to 6dB.2.8.4 表面补偿：以实测为准，不得低于4 dB。2.8.4 Surface compensation: based on actual measurement, no less than 4dB.a.为检测纵向缺陷，斜探头应垂直于焊缝中心线放置在检测面上，作锯齿型扫查。探头前后移动的范围应保证扫查到全部焊缝截面。在保持探头垂直焊缝作前后移动的同时，还应作1015的左右转动。a. For inspecting longitudinal defect, angle probe shall be vertical to weld center line, locating on the inspection surface, to scan as saw tooth. Range of probe moving back and forth shall ensure to scan the entire weld cross profile. While keep probe moving back and forth vertical to weld, turn about 1015.b.为检测焊缝及热影响区的横向缺陷应进行平行和斜平行扫查。检测时，可在焊缝两侧边缘使探头与焊缝中心线成1020作斜平行扫查。焊缝余高磨平时，可将探头放在焊缝及热影响区上作两个方向的平行扫查。b. Lateral scan and lateral scan with oblique angle in order to inspect weld and landscape flaw of weld and heat affected zone. When testing, lateral scan with oblique angle at 1020angle between probe and weld center line on weld two sides edge. When grinding weld reinforcement, probe shall locate at two directions of weld and heat affected zone to lateral scan. c.为确定缺陷的位置、方向和形状，观察缺陷动态波形和区分缺陷信号或伪缺陷信号，可采用前后、左右、转角、环绕等四种探头基本扫查方式。c. In order to determine position, direction and shape of flaw, observe flaw dynamic wave from and distinguish flaw signal or fake flaw signal, four kinds of basic scanning methods for probe are back & forth, right and left, move at an angle, and encircle etc.2.9 缺陷评定2.9 Assessment of defect2.9.1超过参考反射体的信号应注意其是否具有裂纹等危害性缺陷特征，如有怀疑时，应采取改变探头折射角、观察动态波型并结合焊接工艺作综合分析。2.9.1 Exceed signal of reference reflector, notice if there is hazard flaw characteristic such as flaw, if in doubt, conduct comprehensive analysis with changing refracted angle of probe, observing dynamic wave from and combined with weld technics.2.9.2 单个点状缺陷指示长度按mm计。2.9.2 Indicating length shall be 5mm for single point defect.2.9.3 相邻两缺陷在一直线上其间距小于其中较小的缺陷长度时，应作为一条缺陷处理，以两缺陷长度之和作为其指示长度（不考虑间距）。2.9.3 When gap distance between adjacent two defects in a straight line shall be less than smaller defect length, it shall be as one defect, and made sum of two defect length as its indicating length (without regard to gap).2.9.4 当检测人员认为缺陷为裂纹时，或缺陷长度和缺陷信号大小超过合同规定的拒收范围时，该缺陷必须拒收，并及时进行返修，返修后需采用原来的超声波检测工艺进行检测。2.9.4 When inspector considers it as flaw, or flaw length and flaw signal level exceed contracted rejection scope, this defect must be rejected, and repaired in time, after repaired it shall be inspected with primary ultrasonic testing technics. 3磁粉检测工艺3 Magnetic Particle Inspection3.1本工艺适用于铁磁性材料焊缝表面及近表面的磁粉检测。3.1 The magnetic particle inspection shall be applicable for flaw detection of welds and the adjacent surface of the ferromagnetic materials. 3.2 检测工艺卡由磁粉检测级人员按合同要求编制。3.2 The inspection procedure sheets shall be prepared by persons with Grade qualifications for magnetic particle inspection.3.3 检测人员3.3 Inspector(s)3.3.1 检测人员必须经过培训取得国家有关部门颁布的，符合SNT-TC-1A标准要求，并与其工作相适应的资格证书。3.3.1 The inspector(s) shall be trained and have related qualification certificates that shall be issued by authorities and in compliance with specifications SNT-TC-1A.3.3.2 检测人员每年应检查一次身体，其矫正视力不低于1.0,不得有色盲。3.3.2 The inspector(s) for the test shall have his or their eyes examined at least for one time every year, whose vision after correction shall not be less than 1.0. Person(s) who has or have color blindness shall not be allowed for the inspection work.3.4 设备、工具和材料3.4 Equipment, Tools and Materials3.4.1 磁化设备3.4.1 Magnetic Equipment采用便携式磁轭磁化探伤机Portable magnetic yoke detector shall be used for the test.3.4.2 灵敏度试片3.4.2 Test Piece for Sensitivity 选用CX-230或CX-430薄试片，灵敏度试片用于被检工件表面有效磁场强度和方向、有效检测区以及磁化方法是否正确的测定。磁化电流应能使试片上显示清晰的磁痕。A thin test piece CX-230 or CX-430 shall be used for determining if the efficient intensity and direction of magnetic field, the efficient inspection zone and the magnetization method on the part surface subject to inspection is in compliance with requirements. The magnetization current shall have magnetic particle clearly indicated on the test piece. 3.4.3磁场指示器3.4.3 Indicator of Magnetic Field磁场指示器是一种用于表示被检工件表面磁场方向、有效检测区以及磁化方法是否正确的一种粗略的校验工具，但不能作为磁场强度及其分布的定量指示。The indicator of magnetic field is a rough calibration tool to determine if the direction of magnetic field, the efficient inspection zone and the magnetization method is correct, but shall not be referred to as a quantitative indicator of the intensity and the distribution of magnetic field.3.5 灵敏度试片的使用3.5 Usage of Test Piece for Sensitivity3.5.1将薄试片无人工缺陷的面朝外，使试片与被检面接触良好，可用透明胶带将其整体贴在被检面上，但人工缺陷处不得贴覆。试验时边磁化边洒磁悬液，以人工缺陷清晰显示来确定磁化规范。3.5.1 One side of the test piece without artificial defects shall face outward and the other side shall have full contact with the surface subject to inspection, which shall be pressed to the surface with a scotch tape except the artificial defects, if required. During the test the magnetization and the spraying of magnetic suspending liquid shall be carried out at the same time. As a result, the indications of the artificial defects shall determine whether the inspected surface is in compliance with specifications or not.3.5.2磁场指示器：应在用连续法对工件磁化的同时，将其平放在被检面上，并对其表面施加磁悬液，以是否出现 “*”形磁痕来判定工件磁化适当与否。3.5.2 Indicator of magnetic field: During the continuous magnetization of the part the indicator of magnetic field shall be put on the part surface subject to inspection and applied with magnetic suspending liquid to see if a star-shape magnetic indication occurs, which helps to judge whether the part is properly magnetized or not.3.5.3试片的摆放位置：应将灵敏度试片摆放在有效检测区域边界处。3.5.3 Location of Test Piece: The test piece for sensitivity shall be put at the edge of the efficient inspection area. 3.6磁粉及磁悬液3.6 Magnetic Particle & Magnetic Suspending Liquid3.6.1 磁粉：采用灵敏度符合要求的磁粉。3.6.1 Magnetic Particle: Magnetic particle with the sensitivity as required shall be applied.3.6.2 磁悬液：一般采用水作为分散媒介，新配制的磁粉沉淀浓度要适当，并要进行反复试验。3.6.2 Magnetic Suspending Liquid: With water as the dispersing medium, the magnetic particle sedimentation density of the newly prepared liquid shall be in compliance with the related requirement, which shall be tested for several times.3.6.3 施加磁悬液：使用磁悬液喷液器或其它有效方法进行喷洒。3.6.3 Application of Magnetic Suspending Liquid: A sprayer or other practical spraying method(s) shall be applied for the spraying of magnetic suspending liquid.3.7被检表面的准备3.7 Preparation of Surface Subject to Inspection3.7.1 若被检表面凹凸不平，以致可能遮盖缺陷显示时，应进行表面打磨处理。3.72. If the surface subject to inspection is uneven that may cover the defect indications, the surface shall be polished and ground.3.7.2 被检工件表面不得有油脂或其它粘附磁粉的物质。3.7.2 No oil, grease or other adhesive substances shall be allowed on the surface subject to inspection.3.7.3 被检工件上的孔隙在检测后难于清除磁粉时，则应在检测前用无害物质堵塞。3.7.3 Holes on the part subject to inspection, which may have difficulty to remove the residual of the magnetic particle, shall be plugged by proper materials.3.7.4 若被检面为焊缝，其两侧100mm范围内不得有松散的锈蚀、氧化皮、飞溅、油污或其它妨碍检测的外来物。3.7.4 For the welds subject to inspection, there shall be no loose rust, oxide-scale, spatter, oil, grease or other foreign matters that may obstruct the inspection on the surface within a range of 100mm at both sides.3.8 检测时机：焊缝的磁粉检测应安排在焊接工序完成之后进行。对于有延迟裂纹倾向的材料，磁粉检测应安排在焊后24小时进行。3.8 Time for Inspection: The magnetic inspection for welds shall be carried out after the welding. For those materials that may have possible delayed cracks, the inspection shall be carried out 24 hours after the welding. 3.9采用连续磁化方法，在通电磁化的同时，施加水磁悬液，持续磁化时间为13S。为保证磁化效果至少反复磁化二次，停施磁悬液至少1S 后才可停止磁化。交叉磁轭磁化时。不可停止行进磁化，要一边行进一边施加磁悬液。3.9 For the continuous magnetization, water-blended magnetic suspending liquid shall be applied at electric magnetization, which shall be kept for one to three seconds. To guarantee the effects, the magnetization shall be repeated for one time at least. The magnetization shall not be stopped within one second after the application of the magnetic suspending liquid, but the alternating yoke magnetization shall be accompanied with application of magnetic suspending liquid for the whole time. 3.10 磁化方向3.10 Direction of Magnetization磁轭磁化，被检工件的每一被检区至少进行两次独立的检测，两次检测的磁力线方向应大致相互垂直；For the yoke magnetization, two independent tests shall be carried out for every inspection station of the part subject to inspection, of which the magnetic lines shall be approximately vertical.3.11 磁轭磁化的间距应控制在75200mm 范围内，检测的有效区域为两极中心连线两侧各50mm 的范围内，磁化区域每次应有15mm 重叠；交叉磁轭法的有效磁化区域，用灵敏度试片确定；3.11 The space for yoke magnetization shall be controlled within a range of 75mm to 200mm and the efficient inspection area shall be within a range of 50mm at both sides of the central connection lines between two polarities. There is an overlap of 15mm between magnetized areas for every time. For the alternating yoke magnetization, a test piece for sensitivity shall be used to determine the efficient magnetic areas.3.12 磁痕的评定3.12 Magnetic indication assessment3.12.1 除能确认磁痕是由于工件材料局部磁性不均或操作不当造成的之外，其它一切磁痕显示均作为缺陷磁痕处理。3.12.1 Magnetic indications except those caused by local non-uniform magnetism on the part subject to inspection or improper operation shall be classified as magnetic defect indications.3.12.2 长宽比大于3 的缺陷磁痕，按线性缺陷处理；长宽比小于等于3 的缺陷磁痕，按圆形缺陷处理。3.12.2 For the magnetic defect indications with a ratio of length and width exceeding 3, they shall be classified as linear defects; otherwise they shall be classified as circular defects.3.12.3 缺陷磁痕的长轴方向与工件轴线或焊缝中心线的夹角大于等于30时，作为横向缺陷处理，其它按纵向缺陷处理。3.12.3 For the magnetic defect indications with an angle formed between the longitudinal axis of the indication and the axis of the part or the central line of the weld equivalent to 30 or exceeding 30, they shall be classified as transverse defects otherwise classified as longitudinal defects.3.12.4 两条或两条以上缺陷磁痕在同一直线上且间距小于等于2mm 时，按一条缺陷处理，其长度为两缺陷长度之和加间距。3.12.4 If two or more magnetic defect indications occur on the same line with a space between them equivalent to 2mm or less than 2 mm, they shall be treated as one defect indication, of which length shall be the total length of the defect indications plus the space between them.3.12.5 磁粉检测时，磁痕的评定应在可见光下进行，工件被检面处可见光照度应不小于1000Lx；3.12.5 For the magnetic particle inspection, the determination of magnetic indications shall be carried out under visible light irradiation, while the intensity of illumination on the surface subject to inspection shall not be less than 1000Lx.3.12.6 当辨认细小磁痕时可用210 倍放大镜进行观察。3.12.6 2X to 10X magnifying glass shall be used for determination of slight magnetic indications. 3.13 复验:当出现下列情况之一时，应进行复验：3.13 Re-inspection: The inspection shall be repeated, where the followings occur:3.13.1 检测结束时，用灵敏度试片验证检测灵敏度不符合要求；3.13.1 Where the sensitivity proves to be not in compliance with the related requirements by a test with a test piece at completion of the inspection;3.13.2发现检测过程中操作方法有误；3.1.3.2 Where operation method(s) is or are found to be not in compliance with the related requirements during the inspection; 3.13.3供需双方有争议或认为有其它需要时；3.13.3 Where disputes arise between the vender and the purchaser or there are other requirements;3.13.4经返修后的部位。3.13.4 Where repair work has been executed.3.14 下列缺陷拒收：3.14 The following defects shall be rejected:3.14.1 任何裂纹；3.14.1 Cracks, if any;3.14.2 任何线性磁痕，任何外径大于1.5mm的圆形缺陷；3.14.2 Any linear magnetic indications or circular defects with a outside diameter larger than 1.5mm.4 液体渗透检测4 Penetration Test4.1 适用表面开口缺陷的液体渗透检验方法。4.1 The liquid penetration test is applicable for detection of crack defects on the surface.4.2 检验人员必须经过培训取得国家有关部门颁布的，符合SNT-TC-1A标准要求，并与其工作相适应的资格证书。 4.2 The inspector(s) shall be trained and have related qualification certificates that shall be issued by authorities and in compliance with specifications SNT-TC-1A. 4.3渗透检验人员的视力应每年检查一次