钢结构焊缝X射线探伤检验指导书.doc

作业指导书(一)Task Steering （第一版 1nd edition）编制：审核：批准： 执行日期：2007年10月20日1 目的Purpose1.1 为使钢结构的部件和焊缝采用X射线检测时其全过程的操作规范化，以便获得合格的透照底片，正确反映产品质量。Standardize the whole process of X-ray inspecting in order to acquire eligible negative reflecting quality of products correctly.2 适用范围Applied scope2.1 本规程适用于钢结构中板厚340mm的对接焊缝的射线透照检测。This regulations is applied to radial inspecting of butt weld of 340mm thickness steel structure plate.3 引用标准Quoted standards3.1 ANSI/AWS D1.1(2006) “Structural welding code-steel”（钢结构焊接标准）3.2 ASTM/E 747（使用金属线透度计控制射线照相检测质量的方法）3.3 ASME SEC .V3.4 ASME B31.34 实施步骤Procedure of performance4.1 人员的要求Requirements of personnel4.1.1 从事射线照相检测的人员，必须掌握射线探伤的基础技术，具有足够的部件和焊缝射线探伤经验，并掌握一定的材料，焊接基础知识。The person who inspect must know basic technology of NDT, basic knowledge of welding and material but have enough experience.4.1.2 探伤人员应由相关部门无损检测考核委员会培训和考核，并持有相关部门无损检测考核委员会认可的RT级或以上资格证书，才能从事与该等级相应的检验工作。The person who carries out flaw detecting should be trained and qualified by concerned Non-destructive testing committee and have certificate of RTor above. 4.1.3 评片员每年进行视力检查，不得有色盲和色弱，其近距离视力或近距离矫正视力不低于J1/J2. The person who assesses film will check his/her vision acuity every year. Not allowed to have color blindness and color weakness，Vision of close quarters or vision acuity of corrected should above JI/J2.4.2 表面状态Surface condition：焊缝及热影响区的表面质量（包括焊缝余高）应经外观检查合格。表面的不规则状态在底片上的图像不应掩盖焊缝中的缺陷或与之相混淆，否则应做适当的修整。The quality of welding line and heat-affected zone (include weld reinforcement) should be inspected by visual. Defects of weld shouldnt be covered up by image on negative which showing irregular state of surface, otherwise it should be adjusted in some extent.4.3 工作安全Working safety：射线探伤工作应符合所有适用的安全规程This regulation should be compliant to all suitable safety rules.。4.4 X射线设备见表1 About equipments of X-ray please see table 1 表Table 1制造厂家Manufacturer型号type管电压voltage管电流currentRigakucorporation300EG-S3 300KV5MA日本理学250EG-S2250KV5MABALTOSPOTGFK-208200KV5MA/8MA中国丹东射线仪器公司XXG-2505250KV5MA中国丹东射线仪器公司XXG-2005200KV5MA4.5 射线胶片和增感屏Intensifying screen and film of X-ray：射线胶片采用AGFA100X300，增感屏采用pb:0.03前后铅箔屏。We adopted AGFA100X300 film, pb:0.03 intensifying screen. 4.6 线型象质计Linetype IQI：象质计是用来检查透照技术和胶片处理质量的，本规程使用的线型象质计的型号和规格应符合AWS D1.1:2006第197页的规定。线型象质计的选用和要求见图A IQI is for check transilluminating technology and quality of film processing. The type and specification of linetype that used must be suit with regulation in page 197 of AWS D1.1: 2006. About choosing and requirements of IQI please see graph A 4.7 探伤工艺Workmanship of fault detection：4.7.1 X射线拍摄射线照片时，焦点应尽可能对准受检焊缝的长度和宽度中心，射线源工件距离应不少于在单一平面上曝光的底片总长度，一般采用焦距=600mm。When taken pictures by X-radial, focus should be on length &width center of weld. Ray source-generally focus=600mm, workpiece shouldnt be less than total length of exposal negative. 4.7.2 胶片应有足够长度，所放位置应使焊缝末端自由边以外，至少有13mm的胶片受到射线源的直接照射，胶片的宽度应使焊接接头所有部分均摄入照片，包括热影响区，照片上还应有足够空间容纳线型象质计和胶片识别标记而不影响焊缝及热影响区的范围。Film should have enough length, more than 13mm film is direct irradiated by ray source. It should have enough width to make sure all welding joints are taken into photo including heat-affected zone. Photos also should have enough space to contain line-type IQI and identifying marks without influencing scope of welding line and heat-affected zone. 4.7.3 为减少散射线的影响，应采用/1mm的铅板屏蔽背后散射。In order to reduce influence of scattered ray we should adopt /1mm leading to screen dispersion.4.7.4 为检查背后散射，应在暗盒背面贴附一个“B”的铅字标记（B的高度 为 13mm，厚度1.6mm），若在较黑背景上出现“B”的较淡影象，说明背后散射防护不够，应予重照。In order to check dispersion we could attach a letter B on cassettes back (Height 13mm, thickness 1.6mm), if there is B light image on dark background it means we should pay attention on dispersion.4.7.5 线型象质计应放在射线一侧的工作表面上被检焊缝区的两端（按图1或图2要求）。Wire type IQI should put both ends of inspected weld on working surface along one side of ray. (Please see graph 1&2)4.7.6 定位标记和识别标记Position mark and identifying mark：在每个拍摄位置近处的钢材上放置一个定位标记和识别标记。Place a position mark and identifying mark on steel material that near every shooting position4.7.6.1 表明焊缝透照部位的铅质定位标记包括中心标记（ ） 和搭接标记（ ）。Position mark includes center mark ( ) and lapping mark ( )4.7.6.2 识别标记Identifying Marks识别标记包括厂方缩写名称（GWS），工程编号，焊缝编号和部位编号，日期；返修透照部位还应有返修标记R1、R2（注脚1、2表示返修次数）Identifying marks includes abbreviative name of factory (GWS)，project No.，weld no. and position no.，date；On repairing part mark R1、R2（footnote 1、2means repairing times）4.7.6.3 标记位置Marking position：上述定位标记和识别标记均需在底片适当位置显示，并离焊缝边缘至少20mm。Above-mentioned position mark and identifying mark should be shown on proper position of negative and more than 20mm far from welding edge. 4.7.7 黑度Degree of blackness：选择合适的曝光条件使底片有效评定区域内的黑度满足D=2.04.0的范围。底片的灰雾度D00.3。Choose available exposal condition for dark degree which in valid assessing zone of negative satisfies D=2.04.0 zero degree D00.3。4.8 胶片处理Film processing：胶片的手工冲洗洗应采用槽浸方式，在规定的温度（200CK20）和时间（68分钟）进行显影、定影后的底片应经充分水洗和脱水处理，以防水迹的产生然后自然干燥或在干燥箱内烘干。Using grove-dipping method to develop film in stated temp.（200CK20）and time（68 minutes）. After fixation wash and dehydrate negative to avoid producing water mark and then dry it naturally or in drying box.4.9 底片质量：在底片评定区域内不应有以下妨碍底片评定的假缺陷。a) 起灰雾。b) 处理时产生的条痕、水迹或化学污迹。c) 划痕、指纹、污迹、静电痕、斑痕或撕裂。d) 由于增感屏不好造成的缺陷显示。Quality of negative：In assessing zone, shouldnt have following problems e) Photograph fog。f) wale, water trace or chemical smear。g) nick, fingerprint, dirt, static tracing, or crack 。h) Showing defects caused by intensifying screen 4.10 焊缝质量评定(并满足ASME B31.3 表341.3.2的规定)Assessing quality of weld：4.10.1 圆形和长形缺陷的定义Definition of round&oblong defects：a) 长度是其宽度的三倍或不足三倍的称为圆形缺陷，形状可以是圆形的或不规则的，也可能是有细尾的，包括气孔、点状夹渣等。Round defects is that length is equal or less than three times width. The form can be round or irregular.b) 长度超过其宽度三倍的称为长形缺陷，包括条状夹渣、条状气孔。Long defects is that length is over three times width, includes stripy slag, stripy hole.4.10.2 有下列缺陷的焊缝，不管缺陷的长度大小，都是不合格的。Welds that have following defects arent eligible whether any length they are. (1) 裂纹Crack(2) 未熔合Non-fusion4.10.3 除上述缺陷外，焊缝中的其它缺陷超过下述限度者是不合格的。（E=焊缝尺寸）Except above defects, un-qualify if excess allowance of followings （E=weld dimension）(1) 长形缺陷超过图3中的最大缺陷尺寸。Long defect excesses max. dimension of graph 3。(2) 缺陷较图3中允许的最小间距更为靠近。Min. allowed space is less compared with in graph 3.(3) 圆形缺陷单个尺寸超过焊缝尺寸E的1/3，最大限值不超过1/4 in. (6mm)。这种型式的尺寸大于或等于3/32 in. (2.5mm)的缺陷，离开可接受的长或圆形缺陷的最小间距或离交叉焊缝边缘或末端的最小间距，应是较大缺陷最大尺寸的3倍。Single dimension of round defects excesses 1/3 weld dimension E, Max. limitation not excess 1/4 in. (6mm). (4) 表现为圆形缺陷团的孤立缺陷，当它们的较大尺寸总和超过图3单个缺陷允许的最大尺寸时，它们至另一缺陷团，或另一长形或圆形缺陷，或至交叉焊缝边缘或端部的最小间距，应是所述的较大缺陷最大尺寸的3倍。Separated roundness defect mass, when its max. dimension total excesses allowed max. single dimension. The min. space from it to another defect mass should be three times of max. dimension of max. defect. (5) 在每1 in. (25mm)焊缝长度中，尺寸小于3/32 in. (2.5mm)的单个圆形缺陷的总和，不应超过2/3E或3/8 in. (10mm)，取较小值。这个要求独立于上述(1), (2), (3)。In every 1 in. (25mm) weld length, total of single roundness defect which less than 3/32 in. (2.5mm) shouldnt over 2/3E or 3/8 in. (10mm). This requirement is independent of above mentioned (1), (2), (3). (6) 当缺陷最大尺寸的总和在任何6E的长度内超过E，称为线状缺陷。如受检的焊缝长度小于6E，则允许的最大尺寸的总和按比例减小。In range of every 6E length when total dimension of defects is over E, we call it sliver defect. If dimension of inspected weld is less than 6E, then the total of allowed max. dimension should be reduced accordingly. 注：图3的合格射线图象可参考图4。Remark：Please see graph 4 for eligible ray on graph 3.5. 探伤报告（见附录A）：NDT report （See attachment A） 报告应包括以下内容：Report should include following information：(1) 委托单位，被检工件名称、编号。Inspecting companys name, members name& No.(2) 被检工件材质、母材厚度。Property of checked members and thickness of base metal(3) 检测装置的名称、型号。Name and type of inspecting sets。(4) 透照技术规范。Technical specification of transillumination。(5) 检测结果、缺陷性质评定及验收标准名称。Inspecting result, property of defect and acceptance standard。(6) 返修后检测结果。Checking after repair。(7) 检测人员和责任人员签字。Signature of inspector and person in charge。(8) 检测日期。Inspecting date。(9) 射线检测工艺卡工程名称XXXX工程编号XXXXXX检测比例按设计图纸检测部位由质检部现场指定检测标准ASME SEC.VAWS D1.1合格级别按设计图纸胶片型号AGFA铅增感屏X:0.03/0.1 底片黑度X: 2.04.0背散射线的防护背衬1mm厚铅版显影温度1822C显影时间46min定影温度1624C定影时间10min水洗时间30min脱水时间1min透照方式焦距（mm）管外径219mm的厚壁管中心透照时焦距为管外径透照厚度、像质指示器线号和设备类型的选择母材厚度mm单壁单影（射线源侧IQI）双壁双影（射线源侧IQI）双壁单影（底片侧IQI）设备类型6.45564X光机6.49.5659.512.7778612.719.08719.025.499825.438.110109拍片张数的选择外径拍片张数外径拍片张数89椭圆透照2张108426426600每张画线长度250mm注：周向曝光时拍片张数不限，只要能搭接即可。曝光时间和射线能量的选择范