超声波检测作业指导书UT Operation Specification.doc

第三方NDE检测单位The Third Party Inspection OrganizationUT作业指导书UT Operation Specification目 录1.一般要求General Requirements11.1.检测范围Scope of Testing11.2.检测人员NDT personnel11.3.探伤仪、探头和系统性能Flaw detector, probe and system performance11.4.超声检测方法 Ultrasonic testing method21.5.校准Calibration31.6.报告及验收标记Reports and acceptance42.焊缝超声波检测Ultrasonic testing of welds52.1.检测范围和一般要求 Scope of testing and general requirements52.2.准备Test preparation52.3.距离-波幅曲线的绘制Plotting distance-amplitude curve82.4.检测方法Test method82.5.缺陷定量检测Quantitative test of defect92.6.缺陷评定Defect evaluation112.7.缺陷等级评定Grade evaluation of defects113.钢板超声检测Ultrasonic testing of steel plate113.1.检测范围和一般要求Scope of testing and general requirements113.2.探头选用Probe selection113.3.标准试块Standard test block113.4.检测灵敏度Test sensitivity123.5.检测方法Test method143.6.缺陷记录Defect recording153.7.缺陷的评定方法Evaluation of defects163.8.钢板缺陷条块等级评定Grade evaluation of defects of steel plate174.检测结果的发送Sent the test report175.检测报告见附件.Test report sample see the attachment.181. 一般要求General Requirements1.1. 检测范围Scope of Testing1.1.1. 依据标准JB4730承压设备无损检测。The guidelines are written in accordance with JB4730 Nondestructive Testing of Pressure Equipments.1.1.2. 超声检测系指采用A型脉冲反射式超声波探伤仪手工扫查发现内部缺陷，并对其进行等级分类的全过程。检测范围包括压力容器、压力管道以及储罐的原材料和焊缝的超声检测。Ultrasonic testing refers to the whole process that inner defects are found by scanning manually using an A-model pulse reflection ultrasonic flaw detector and then classified into grades. The scope of testing includes ultrasonic testing of raw materials and weld of pressure equipments, pressure pipes and store tanks.1.2. 检测人员NDT personnel1.2.1. 凡从事检测的人员, 都必须经过技术培训,并按照锅炉压力容器无损检测人员资格认可规则(1995)及GB9445进行考核鉴定。Personnel engaging in NDT should have received technical trainings and passed qualification tests in accordance with Rules of Certification for NDT personnel on boiler pressure equipments (1995) and GB9445 national standard.1.2.2. 取得不同无损检测方法的各技术等级人员，只能从事与该等级相应的无损检测工作，并负相应的技术责任。Technicians who have passed certain levels of NDT qualification tests should perform NDT tasks equivalent to that level and be liable to such responsibilities.1.3. 探伤仪、探头和系统性能Flaw detector, probe and system performance1.3.1. 探伤仪Flaw detector采用A型脉反射式数字式超声波探伤仪,其工作频率范围为1-5MHz，仪器至少在荧光屏满刻度的80范围内呈线性显示。探伤仪应具有0-110dB的增益范围，步进级0.1，2.0，6.0dB,其精度为任意相邻12dB误差在1dB以内，最大累计误差不超过1dB。水平线性误差不大于1，垂直线性误差不大于5。 其余指标应符合ZB Y 230的规定。For a digital ultrasonic flaw detector of A-model pulse reflection with 1-5MHz working frequency, the apparatus should display linearly in at least 80% of full scale of the fluorescent screen. The flaw detector should has a 0-110dB gain range with stepping increments of 0.1，2.0 and 6.0dB. The precision of the flaw detector is two arbitrary points that distance 12dB with error within 1dB and the maximum accumulative error not exceeding 1dB. Its horizontal linearity error is not exceeding 1% and vertical linearity error not exceeding 5%. The other criterions should meet requirements of ZB Y 230.1.3.2. 探头Probe1.1.1.1 超声检测选用探头有单直探头、单斜探头和双晶探头。Probes of UT include single straight beam probe, single angle probe and double crystal probe.1.1.1.1 晶片有效面积一般不应超过500mm2，且任一边长不应大于25mm。Generally the effective area of wafer should not exceed 500mm2, and the length of either side should not exceed 25mm.1.1.1.1 单斜探头声束轴线水平偏离角不应大于2,主声束垂直方向不应有明显的双峰。其检测方法应符合ZB Y 231的规定。For the single angle probe, the angle by which the horizontal ultrasonic beam axis deviates from the probe axis should be less than 2. Main beam at vertical direction should not produce obvious double peaks. The testing method should meet requirements of ZB Y 231.1.3.3. 超探仪和探头的系统性能System performance of the ultrasonic flaw detector and probe1.1.1.1 在达到所探工件的最大检测声程时,其有效灵敏度余量应大于等于10dB。When the detector reaches its maximum beam path length of the tested workpiece, the remaining effective sensitivity should exceed or equal to 10dB.1.1.1.1 直探头的远场分辨力应大于等于40dB,斜探头的远场分辨力应大于或等于6dB。Far-field resolution of the straight beam probe should exceed or equal to 40dB, and far-field resolution of the angle probe should exceed or equal to 6dB.1.4. 超声检测方法 Ultrasonic testing method1.4.1. 检测复盖率Percentage of scan coverage检测时，应尽量扫查到工件的整个被检区域，探头的每次扫查复盖率应大于探头直径的15。When testing，the whole area to be inspected should be scanned. Every scan of the probe should cover more than 15% of the probes diameter.1.4.2. 探头的移动速度Scan speed of the probe探头的扫查速度不应超过150mm/s。Scan speed of the probe should not exceed 150mm/s.1.4.3. 扫查灵敏度Scan sensitivity扫查灵敏度至少应比基准灵敏度高6dB。Scan sensitivity should be at least 6dB higher than norm sensitivity.1.4.4. 耦合剂Couplants应采用机油、浆糊、甘油和水等透声性好,且不损伤检测表面和耦合剂。Couplants that have good sound transparency and do not damage the surface tested should be used, such as engine oil, paste, glycerol and water, etc.1.4.5. 检测面Tested surface1.1.1.1 检测面和探测范围的确定原则上应保证检查到工件被检部分的整个体积。对于钢板,应检查到整个工件，而对熔接焊缝则应检查到整条焊缝。In principle, surface and area being tested should be guaranteed to cover the whole volume of the tested part of the workpiece. To steel plate, the whole workpiece should be inspected, while to fusion jointing weld, the whole weld should be inspected.1.1.1.1 检测面应经外观检查合格，所有影响超声波检测的锈蚀、飞溅和污物都应予以清除，其表面粗糙度应符合检测要求。The tested surface should pass appearance check. All surface rusts, splashes and contaminants that would affect UT operation should be removed. Surface roughness should meet requirements of the test.1.1.1.1 耦合补偿Coupling compensation表面粗糙度补偿Compensation because of surface roughness在检测和缺陷定量时,应对由表面粗糙度引起的能量损耗进行补偿.When testing and quantification of defects, energy waste caused by roughness of the tested surface should be compensated.1.5. 校准Calibration1.5.1. 仪器校准Calibration of instrument在仪器开始使用时，仪器需经检定合格。在使用过程中，每隔三个月至少应对仪器的水平线和垂直线性进行一次测定。Instrument should be certified for acceptance before use. During service period, horizontal and vertical linearity of the instrument should be checked at least every three months.1.5.2. 探头校准Calibration of probe在探头开始使用时，应对探头进行一次全面的性能校准。测定方法应按ZB Y231的有关规定进行。Probe should be calibrated comprehensively for performance in accordance with requirements of ZB Y231.1.1.1.1 斜探头校准Calibration of squint angle probe使用前,斜探头应至少进行前沿距离、K值、主声束偏离、灵敏度余量和分辨力等的校准。使用过程中，对前沿距离、K值和声束偏离应在每一个工作日检查一次。Squint angle probe should be, before use, at least calibrated for leading edge distance, “K” value, main beam deviation, remaining sensitivity and resolution, etc. During service period, leading edge distance, “K” value and main beam deviation should be inspected in each workday.1.1.1.1 直探头校准Calibration of straight beam probe直探头的始脉冲占宽、灵敏度余量和分辨力应在开始使用时，及每隔一个月检查一次。Before use and at every other month, the straight beam probe should be checked for occupying width of initial pulse, remaining sensitivity and resolution.1.5.3. 仪器和探头系统的复核Rechecking of the instrument and probe1.1.1.1 复核时机Rechecking occasions每次检测前均应对扫描线、灵敏度进行复核，遇有下述情况应随时对其进行重新核查:Scan line and sensitivity should be rechecked before each test. If the following circumstances occur, the system should be rechecked again at any time.a. 校准后的探头和耦合剂发生改变时；a. Changes occur to the probe and the couplant that have been calibrated;b. 开路电压波动或者检测者怀疑灵敏度有变化时；b. Voltage of open circuit fluctuates or tester doubts about its sensitivity;c. 连续工作4h以上；c. Continuous working over 4h;d. 工作结束时。d. Completion of testing.1.1.1.1 距离一波幅曲线的复核Rechecking the distance-amplitude curve复核时,曲线上任何一点幅度下降2dB，则应对上一次以来所有的检测结果进行复检；如幅度上升2dB，则应对所有的记录信号进行重新评定。In rechecking, if amplitude at any point on the curve declines by 2dB, all test results starting from last inspection should be rechecked; if amplitude rises by 2dB，all recorded signals should be reassessed .1.5.4. 注意事项Attentions校准、复核和线性检验时，任何影响仪器线性的控制器(如抑制)应处于最低水平上。In calibration, recheck and linearity test，any influence to the linearity of the equipment caused by controllers, such as suppressers, should be kept at the minimum level.1.6. 报告及验收标记Reports and acceptance1.6.1. 检测报告至少应包括以下内容:A report should at least include the following items:1.1.1.1 委托单位、报告编号；Client, report number；1.1.1.1 工件名称、编号、材质、热处理状态、检测表面的粗糙度；Workpieces name, serial number, materials, heat-treated condition and roughness of the tested surface；1.1.1.1 探伤仪、探头、试块和检测灵敏度；Flaw detector, probe, test block and test sensitivity;1.1.1.1 .超声检测区域应在草图上予以标明，如有因几何形状限制而检测不到的部位,也应加以说明；Area of UT should be marked on the draft. Parts impossible to be inspected because of limitation on geometry should be noted on the draft;1.1.1.1 缺陷的类型、尺寸、位置和分布；Type of defects, size, location and distribution1.1.1.1 检测结果及缺陷等级评定；Test results and defect grade evaluation;1.1.1.1 检测人员和责任人员签字及其技术资格；Test personnel, responsible personnel and their technical qualifications;1.1.1.1 检测日期。Test date.2. 焊缝超声波检测Ultrasonic testing of welds2.1. 检测范围和一般要求 Scope of testing and general requirements2.1.1. 本条规定了焊缝缺陷的超声检测方法。The guidelines stipulate the ultrasonic testing method of welding defects.2.1.2. 本条适用于母材厚度为8-300mm全焊透熔化焊对接焊缝的超声检测。The guidelines are applicable to the ultrasonic testing of fusion butt-jointed through welds whose thickness of base material is 8-300mm.2.1.3. 本条不适用于铸钢及奥氏体钢焊缝,外径小于159mm的钢管对接焊缝，内径小于等于200mm的管座角焊缝,也不适用于外径小于250mm或内、外径之比小于80的纵向焊缝检测。The guidelines are not applicable to the ultrasonic testing of following welds: welds of cast steels and austenite steels, welds of butt-jointed steel pipelines with outer diameter less than 159mm, fillet welds of pipe saddles with inner diameter less than or equal to 200mm, longitudinal welds with outer diameter less than 250mm or ratio of outer and inner diameters less than 80%.2.2. 准备Test preparation2.2.1. 检测面Test surface压力容器焊缝检测一般采用一种K值探头、利用一次反射法在焊缝的单面双侧对整个焊接接头进行检测。当母材厚度大于46mm时，采用双面双侧的直射波检测。对于要求比较高的焊缝，根据实际需要也可将焊缝余高磨平，直接在焊缝上进行检测。The testing of the pressure vessel welds usually adopts a “K” value probe and the entire welded joint is inspected by one reflection technique on both sides of single surface of the weld. If the thickness of the base material exceeds 46mm, the weld is tested by normal incidence on both sides of the double surfaces. For the weld with stricter requirements, the excess base metal on the welded surface may be grinded smooth if needed and be tested directly on the weld.1.1.1.1 检测区域的宽度应是焊缝本身，再加上焊缝两侧各相当于母材厚度30的一段区域，这个区域最小10mm。The width of the test area should be the weld itself plus an area at both sides of the weld that equals to 30% thickness of the base metal. Such area should be at least 10mm.1.1.1.1 探头移动区应清除焊接飞溅、铁屑、油垢及其它杂质。检测表面应平整光滑，便于探头的自由扫查，其表面粗糙度Ra应为6.3m，一般应进行打磨。Welding splashes, iron chippings, oil crusts and other impurities should be removed away from the probe movement area. The test surface should remain smooth for the probe to scan freely. Surface roughness “Ra” should be 6.3m. Usually, polishing is necessary.1.1.1.1 采用一次反射法或串列式扫查检测时,探头移动区应不小于1.25P:In reflection or tandem scanning, probe movement area should be no less than 1.25P, while: P=2TK 或 P=2Ttg式中: P-跨距,mm；which: P- skip distance, mm；T-母材厚度,mm；T-thickness of the base metal, mm；K-探头K值；K- “K” value of the probe; -探头折射角,()。- refraction angle of the probe, ()。1.1.1.1 采用直射法检测时，探头移动区应不小于0.75P。In normal incidence testing, probe movement area should be no less than 0.75P.1.1.1.1 去除余高的焊缝，应将余高打磨到与邻近母材平齐。 保留余高的焊缝，如焊缝表面有咬边、较大的隆起和凹陷等也应进行适当的修磨，并作圆滑过渡以免影响检验结果的评定Excess welding metal should be removed and grinded to the same level with adjacent base metal. Welds whose excess weld metal need to be preserved should be grinded accordingly, if undercuts, larger humps and pits exist on the welded surface. And smooth transition on the surface should be guaranteed so that these surface irregularities would not affect test results.2.2.2. 探头K值(角度) “K” value of the probe(angle)1.1.1.1 斜探头的K值(角度)选取可参照表1-1的规定。条件允许时,应尽量采用较大K值探头。Refer to Table 1-1 for the selection of “K” values (angle) of the squint angle probe. Select a probe with greater “k” value when conditions permit.表1-1 推荐应用的斜探头K值Table 1-1 Recommended “k” value of squint angle probe板 厚 T mm Plate thickness T mmK 值K8252546461201203003.02.0(7260)2.51.5(6856)2.01.0(6045)2.01.0(6045) 1.1.1.1 串列式扫查,推荐选用两个K1的探头实际折射角相差不应超过2,探头前沿长度相差应小于2mm.为便于探测厚焊缝坡口边缘未熔合缺陷,亦可选用两个不同K值的探头,但两个探头K值均应在0.71.43范围内。For tandem scan, two “k1” probes whose actual refraction angles differ no more than 2are recommended. Leading lengths of the probes should differ less than 2mm. To facilitate detection of defects caused by incomplete fusion at the edge of groove of thick weld, probes with different “k” values may be selected, but their “k” values should be among the range of 0.71.43.2.2.3. 母材的检测Testing of base materials斜探头扫查声束通过的母材区域，应先用直探头作检测，以便探测是否有影响斜探头检测结果的分层或其他种类缺陷存在。该项检测仅作记录，不属于对母材的验收检测。母材检测的规程要点如下:The base material through which sound beam transmitted using squint angle probe should be pre-tested first by straight beam probe in order to find out whether delamination or other types of defects that could affect testing results of squint angle probe exist. The pre-test is only for recording. It does not belongs to acceptance criteria of base materials. The essentials in the testing regulation of base materials are as follow:1.1.1.1 方法: 接触式脉冲反射法，采用频率25MHz的直探头，晶片直径10-25mm；Method: Contact-type pulse reflection using straight beam probe of 25MHz working frequency with wafer of 10-25mm diameter.1.1.1.1 灵敏度:将无缺陷处第二次底波调节为荧光屏满幅的100；Sensitivity: The second bottom wave at non-defect part is adjusted to 100% of the fluorescent screen. 1.1.1.1 记录:凡缺陷信号幅度超过荧光屏满幅20的部位，应在工件表面作出标记，并予以记录。Note: Any part whose amplitude of defect signal exceed 20% of full amplitude of the fluorescent screen should be marked on the weldment surface and noted down.2.3. 距离-波幅曲线的绘制Plotting distance-amplitude curve2.3.1. 距离-波幅曲线按所用探头和仪器在试块上实测的数据绘制而成，该曲线由评定线、定量线和判废线组成。评定线与定量线之间(包括评定线)为区，定量线与判废线之间(包括定量线)为区，判废线及其以上区为区。Distance-amplitude curve is plotted using data from actual measurement on the test block by some certain probe and apparatus. The curve consists of three components: evaluation line, quantification line and rejection line. The area between the evaluation line and the quantification line (including the evaluation line) isarea. The area between the quantification line and rejection line (including quantification line) isarea, while the rejection line and the area above it is area.2.3.2. 距离-波幅曲线的灵敏度选择Sensitivity selection for distance-amplitude curve1.1.1.1 壁厚为8-120mm的焊缝，其距离-波幅曲线灵敏度按表1-2的规定。To welds of 8-120mm wall thickness, sensitivities of distance-amplitude curves are set in Table 1-2.表1-2 距离-波幅曲线的灵敏度Table 1-2 Sensitivities of distance-amplitude curves试块型式Type of the test block板厚 mmPlate thicknessmm评定线Evaluation line定量线判废线Rejection lineCSK IIIA 81515464612016-12dB16- 9dB16- 6dB16-6 Quantification line dB16-3dB1616+2dB16+5dB16+10dB1.1.1.1 检测横向缺陷时,应将各线灵敏度均提高6dB。In testing of transversal defects, sensitivities of all lines should increase 6dB.1.1.1.1 工件的表面耦合损失和材质衰减应与试块相同。Surface coupling waste and decay of materials should be the same with those of the test block.1.1.1.1 扫查灵敏度不低于最大声程处的评定线灵敏度。Scan sensitivity should be less than the sensitivity of evaluation line at the maximal path length2.4. 检测方法Test method 2.4.1. 平板对接焊缝的检测Testing of flat plate butt-jointed welds1.1.1.1 为检测纵向缺陷，原则上采用一种K值探头或两种K值探头在焊缝的单面双侧进行检测。母材厚度大于46mm时，采用双面双侧检测,如受几何条件限制，也可在焊缝双面单侧采用两种K值探头进行检测，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及热影响区。在保持探头垂直焊缝前后移动的同时，还应作1015的左右移动。当壁厚大于40mm且单侧坡口角度小于5时，应采用串列式检测。In order to test longitudinal defects, a “k” probe or two “k” probes are used to test on single surface and at two sides of the weld. When the thickness of base material exceeds 46mm, test on double surfaces and at two sides of the weld is adopted. Test on double surfaces and at single side of the weld using probes of two “k” values may be adopted if restricted by geometric conditions. The squint angle probe should be placed on the tested surface perpendicularly to the centre line of the weld and scan zigzag. The back-and-fore movement of the probe should cover the whole weld section and the heat-affected zone. When the probe moves back-and-fore perpendicularly to the weld, the probe should move left-and-right 1015simultaneously. When wall thickness exceeds 40mm and groove angle at one side is less than 5, tandem scan should be used.1.1.1.1 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。焊缝母材超过100mm时，应在焊缝的两面作平行扫查或者采用两种K值探头(K1和K1.5或K1和K2并用)作单面两个方向的平行扫查；必要时亦可用两个K1探头作串列式扫查。To test transversal defects of the weld and the heat-affected zone, parallel scan and lateral scan with oblique angle should be adopted. Oblique scan can be carried out at the edges of two weld sides with the probe and the center line of weld forming an angle of 1020. When excess base metal is removed, the probe can be placed on the weld surface and heat-affected zone to scan parallel in two directions. When thickness of base metal exceeds 100mm, parallel scan should be done on two surfaces of the weld, or on one surface but at two directions using probes of two different “K” values (K1 and K1.5, or K1 and K2). If necessary, tandem scan using two K1 probes may be adopted.1.1.1.1 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信号，可采用前后、左右、转角、环绕等四种探头基本扫查方式。 In order to determine the location, direction and shape of defects, observe dynamic wave forms and identify defect signals and false signals, the following four basic scanning may be used: back-and-fore scan, left-and-right scan, rotational scan and swivel scan. 2.5. 缺陷定量检测Quantitative test of defect2.5.1. 灵敏度应调到定量线灵敏度。Sensitivity should be adjusted to the sensitivity