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无损检测工艺规程范本,无损,检测,工艺,规程,范本
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HTULTRASONIC EXAMINATION PROCEDUREHTA0502-99Revision: oPage 12 of 12 CONTENTS1.Scope2.Qualification of NDE Personnel3.Procedure4.Instrument and Supplies5.Surface Preparation6.Calibration of Instrument7.Examination8.Evaluation9.Reexamination for Repaired Area and Nonconformity Control10.Post Cleaning11.ReportULTRASONIC EXAMINATION INSTRUCTIONULTRASONIC EXAMINATION REPORT EVALUATION SHEET FOR ULTRASONIC EXAMINATION FOR BUTT-WELDSCALIBRATION SHEET FOR ULTRASONIC EXAMINATION (HALF V PATH)CALIBRATION SHEET FOR ULTRASONIC EXAMINATION (FULL V PATH)1.Scope1.1 This procedure is applied to ultrasonic angle beam examination technique using pulse-echo type ultrasonic instrument.1.2 This procedure is applied to butt-welds of ASME Code vessels fabricated according to ASME Code Section Division 12.Qualification of NDE Personnel Personnel performing ultrasonic examination shall be qualified and certified in accordance with the requirements of HTs Written Practice for NDE Personnel Training, Examination, Qualification and Certification based on the requirements of “SNT-TC-1A”(Current Code accepted edition).3.Procedure This procedure shall be supplemented by the ULTRASONIC EXAMINATION INSTRUCTION which shall be issued to every product and in which more detail parameters shall be specified. The Instruction shall be prepared by Level and approved by Level NDE examiner.4.Instrument and Supplies4.1 Instrument4.1.1 A pulse-echo type of ultrasonic instrument shall be used. The instrument shall be equipped with a stepped gain control calibrated in units of 2.0 dB or less, and have a capability of generating frequencies over the range of at least 1 to 5 MHz (see Table 1). Table 1ManufacturerTypeGain ControlFrequency, MHzShantou Ultra.InstrumentResearch Insti.CTS-26 0.5db 1-5CTS-21 2dB 1-54.1.2 Screen Height Linearity The ultrasonic instrument shall provide linear vertical presentation within 5% of the full screen height for 20% to 80% of the calibrated screen height (base line to maximum calibrate screen point).The screen height linearity shall be qualified in accordance with “ULTRASONIC INSTRUMENT CALIBRATION PROCEDURE”.The calibration shall be performed at the beginning of each period of extended use or every 3 months, whichever is less.4.1.3 Amplitude Control LinearityThe ultrasonic instrument shall utilize an amplitude control accurate over its useful range to 20%(2db) of the nominal amplitude ratio, to allow measurement of indications beyond the linear range of the vertical display on the screen. The amplitude control linearity shall be qualified in accordance with “ULTRASONIC INSTRUMENT CALIBRATION PROCEDURE”.The calibration shall be performed at the beginning of each period of extendeduse or every 3 months, whichever is less.4.2 Search Units (single) One of search units listed in Table 2 shall be used. Table 2Type Nominal AngleFrequency MHzSize, in (mm)Thickness Range In. (mm)2.5PK2.51016 68 2.50.390.63(1016)1(25)2.5PK21313 63.4 2.50.510.51(1313)1-4(25-100)2.5PK11313 45 2.50.510.51(1313)1-4(25-100)4.3 Basic Calibration Block4.3.1 Material of Basic Calibration Block The material from which the block is fabricated shall be of the same product form, and material specification or equivalent P-Number grouping as one of the materials being examined, P-Numbers 1,3,4 and 5 materials are considered equivalent, For calibration block for dissimilar metal welds, the material selection shall be based on the material on the side of the weld from which the examination will be conducted; if the examination will be conducted from both sides, calibration reflectors shall be provided in both materials. Where two or more base material thickness are involved, the calibration block thickness shall be determined by the average thickness of the weld. The calibration block in which any weld is not contained shall be used. It shall received heat treatment as same as the material being examined and shall be taken from the material to be examined.4.3.2 Surface Finish The finish on the surfaces of the calibration block shall be representative of the surface finishes on the components.4.3.3 Block Quality The calibration block material shall be completely examined with a straight beam search unit. Areas that contain an indication exceeding the remaining back reflection shall be excluded from the beam paths required to reach the various calibration reflectors.4.3.4 Block Thickness The thickness shall be determined (see Fig.1) in accordance with the thickness of the part to be examined.4.3.5 Calibration Reflectors Side drilled holes, as calibration reflectors shall be used for setting the instrument sensitivity and generating DAC curve. The sizes and locations of the calibration reflectors are shown in Fig.1. Additional reflector (notch) is provided a reference for determining the surface defects as required.4.3.6 Calibration Block Configuration (1) For examination in materials where the examination surface diameter is greater than 20in.a block of essentially the same curvature, or alternatively, a flat basic calibration block, shall be used. (2) The basic calibration block shall be curved for materials with diameters 20in. and less. A single curved basic calibration block may be used to calibrate the examination on surfaces in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter. The curvature range from 0.94 in. to 20 in. (24 to 508mm) diameter requires 6 block curvatures as indicated in Fig.2 for any thickness range. 4.4 Couplant Couplant having good wetting characteristics such as SAE NO. 20 or NO.30 motor oil, or glycerin shall be used in this examination, The same couplant shall be used for calibration and examination.5.Surface Preparation5.1 Base Metal The surface of base metal on each side of the weld shall be free of weld spatter , surface irregularities, or foreign matter that might interfere with the search unit moving and coupling. If necessary, the surface shall be ground so that the metal luster shall be seen. In general, the width of preparation on the each side of the weld shall not less than distance of search unit moving.5.2 Weld Metal Where the weld surface interferes with the examination, the weld shall be prepared as needed to permit examination.6. Calibration of Instrument6.1 Frequency In general, the nominal frequency shall be 2 MHz to 2.5 MHz, 2.5 MHz or 5 MHz shall be recommended for the part thickness less than 5/8 in. (16mm).6.2 Beam Angle An angle shall be selected as appropriate for the thickness and configuration of the part being examined as described in Table 2 of para.4.2. 6.3 Sweep Range Calibration6.3.1 For a Half V Path (1) Position the search unit for the maximum first indication from the 1/4 T side drilled hole. Adjust the left edge of this indication to line 2 on the screen with delay control. (2) Position the search unit for the maximum indication from the 3/4 T side drilled hole. Adjust the left edge of this indication to line 6 on the screen with the range control. (3) Repeat delay and range control adjustments until the 1/4 T and 3/4 T hole reflections start at sweep lines 2 and 6. (4) Position the search unit for maximum response from the square notch on the square surface. The indication will appear near sweep line 8. (5) Two divisions on the sweep equal 1/4 T. Basic calibration HoleWeld thickness t Block Thickness T Diameter Notch Size1in. Or less 3/4in. Or t 3/32in. Width=1/8in. To 1/4in.Over 1in. Through 2in. 1-1/2in. Or t 1/8in.Over 2in. Through 4in. 3in or t 3/16in. Depth=2% t or 0.04 inOver 4in. Through 6in. 5in or t 1/4in. Whichever is greater.Over 6in. Through 8in 7in or t 5/16in. Into the base metalOver 8in. Through 10in. 9in or t 3/8in.Over 10in. t1in. Note (d) Length=2in.minNOTE: (a) Holes shall be drilled and reamed a minimum of 1.5in. deep essentially parallel to the examination surface (b) For curved surface, two curved blocks, one for each representative curvature: or two sets of calibration reflectors oriented 90 degree from each other shall be used (c) The tolerance for hole diameter shall be 1/32 in. The tolerance on notch depth shall be +10% and 20%. The tolerance on hole location through the thickness shall be 1/8 in. (d) For each increase in weld thickness of 2 in. or fraction thereof over 10 in., the whole diameter shall increase 1/16 in. Fig.1 Basic Calibration BlockNote: (a) Plot examination surface of basic calibration block on diagonal (45 degree) line (b) Draw horizontal line through that point from the 9/10 to the 3/2 in. limit line. (c) The ends of this line read on the horizontal scale give the range of examination surface diameters which may be examined with a Calibrated on this block. (d) Thickness range requirements shall also be satisfied. Fig.2 Ratio Limits for Curved Surfaces6.3.2 For a Full V Path (1) Position the search unit for the maximum first indication from 3/4 T side drilled hole. Adjust the left edge of this indication to line 3 on the screen with the delay control. (2) Position the search unit for the maximum indication from 1/4 T side drilled holes (7/8 full V path). Adjust the left edge of this indication to line 7 on the screen with the range control. (3) Repeat delay and range control adjustments until the 3/4 T (3/8 full V path) and 1/4 T (7/8 full V path) hole reflection start at sweep line 3 and 7. (4) Position the search unit for the maximum response from the square notch on the same surface (8/8 full V path). The indication will appear near sweep line 8. (5) One division on the sweep equal T/4.6.4 Position Calibration6.4.1 For a Half V Path (Fig.3) (1) Position the search unit for maximum response from the T/4 side drilled hole. Place one end of the indexing strip against the front of the search unit, the other end extending in the direction of the beam, Mark the number 2 on the indexing strip at the scribe line which is directly above the hole (If the search unit covers the scribe line, the marks may made on the side of the search unit.) (2) Position the search unit for the maximum indications from T/2 and 3T/4 holes. Keep the same end of the indexing strip against the front of the search unit. Mark the numbers 4 and 6 on the indexing strip at the scribe line. (3) If possible, position the search unit so that the beam bounces from the opposite surface to the 3T/4 T hole. Mark the number 10 on indexing at the scribe line. (4) Position the search unit for the maximum opposite surface notch indication. Mark the number 8 on the indexing strip at the scribe line. (5) The calibration numbers on the indexing strip indicate the position directly over the reflector in sixteenths of the V path. (6) The depth from the examination surface to the reflector is T at 8, 3T/4 at 6 and 10, T/2 at 4, T/4 at 2, and 0 at 0. Interpolation is possible for smaller increments of depth. The radius of hole may correct the measurement if the radius is considered significant to the accuracy of reflectors location.6.4.2 For a Full V Path (Fig.4) (1) Position the search unit for maximum response from the T/4 side drilled hole. Place one end of the indexing strip against the front of the search unit, the other end extending in the direction of the beam. Mark the number 1, 7 and 9 on the indexing strip at the scribe line which is directly above the hole (If the search unit covers the scribe line, the marks were made on the side of the search unit). (2) Position the search unit for maximum indications from the 3T/4 holes. Keep the same end of indexing strip against the front of the search unit. Mark the number 3 and 5 on the indexing strip at the scribe line. (3) The depth from the examination surface to the reflectors is 3T/4 at 3 and 5,T/4 at 1,7 and 9. Interpolation is possible for smaller increments of depth. The radius of the hole may correct the measurement if the radius is considered significant to the accuracy of reflector location. 6.5 Marking a DAC Curve (Primary Reference Level) (Fig.5) (1) Position the search unit for maximum response from the hole, which gives the highest amplitude. (2) Adjust the sensitivity control to provide an 80% (5% of full screen height) of full screen indication from the hole. Mark the peak of the indication on the screen. (3) Keeping the sensitivity control, position the search unit for maximum response from another whole indication. (4) Mark the peak of the indication on the screen. (5) Keeping the sensitivity control, position the search unit for maximum response from the third hole indication and mark the peak on the screen. (6) So on as this, and then, connect the screen marks to provide the distanceamplitude curve. Record the peaks of the indication on the screen for notches to provide reference as evaluation surface defects.7.Examination Level NDE examiner shall perform the specific ultrasonic examination in accordance with the requirements of the Instruction, and shall record examination data on the ULTRASONIC EXAMINATION REPORT.7.1 Examination Coverage The volume shall be examined by moving the unit over the examination surface so as to scan the entire examination volume. Each pass of the search unit shall overlap a minimum of 10% of the transducer (piezo-electric element) dimension perpendicular to the direction of the scan.7.2 Rate of Search Unit Movements The rate of search unit movements for examination shall not exceed 6 in./sec (150mm/s) unless calibration is verified at scanning speed.7.3 Setting up the Sensitivity7.3.1 Sensitivity for Straight Beam The sensitivity shall set up the reference back reflection from the opposite side of a sound area of the base metal at 80% of the full screen height.7.3.2 Sensitivity for Angle Beam The sensitivity shall be used as specified in para. Scanning The scanning including straight beam and angle beam shall be performed at a gain setting at least two times the primary reference level (increase 6 dB). Evaluation shall be performed with respect to the primary reference level.7.4.1 Straight Beam Scanning The straight beam scanning of the adjacent base metal shall be performed to detect reflectors that might affect interpretation of angle beam results, and is not to be used as an acceptance rejection examination. Locations and areas of such reflectors shall be recorded,7.4.2 Angle Beam Scanning for Reflectors Oriented Parallel to the Weld The search unit shall be placed on the base material near weld. The angle beam shall be directed at approximate right angles to the weld axis from two directions where possible. The search unit shall be manipulated so that the ultrasonic energy passes through the required volume of weld metal and heat affected zone.7.4.3 Angle Beam Scanning for Reflectors Oriented Transverse to the Weld The angle beam shall be directed at an angles(45)to the weld axis from two sides of the weld where possible. The search unit shall be manipulated so that the ultrasonic energy passes through the required volume of the weld metal and heat affected zone. The search unit shall be rotated 180 degree and the examination repeated. If weld reinforcements have been ground, the search unit shall be placed on the weld to scan.7.5 System Calibration7.5.1 General Requirements (1) Calibration shall include complete ultrasonic examination system.The original calibration must be performed on the basic calibration block. (2) Checks shall be made to verify the sweep range calibration and distance-amplitude correction. Checks shall include the entire examination system. (3) In all calibration, it is important that maximum indications be obtained with the sound beam oriented perpendicular to the axis of the side drilled holes and notches, the center line of the search unit shall be at least 3/2in,from the nearest side of the block (rotation of the beam into the concern formed by the hole and the side of the block may produce a higher amplitude at a longer beam path; this beam path shall not be used for calibration). For contact examination and basic calibration block surfaces shall be with 25(14).7.5.2 Calibration Measurements Each calibration shall be performed form the surface corresponding to the surface of the component from which the examination will be performed.7.5.3 Calibration Check on Calibration Block (1) When any part of the examination system in changed, a Calibration check shall be made on the basic calibration block to verify that T/4, T/2 and 3T/4 points on the sweep and distance amplitude correction values recorded satisfy the requirements of para.7.5.4. (2) A calibration check on at least one of the basic reflectors in the basic calibration block shall be made at the finish of each examination or series of similar examination. every 4 hours during the examination personnel are changed. The sweep and distance-amplitude correction values recorded shall satisfy the requirements of para..5.4 Calibration Confirmation Calibration shall be performed prior to use of the calibration system in the thickness range under examination. A calibration check shall certify the sweep range calibration and distance-amplitude correction as required below: Sweep Range Calibration If a point on the DAC curve has moved on the sweep line more than 10% of the sweep reading or 5% of full sweep, whichever is greater, correct the sweep range calibration and note the correction in the examination record. If reflectors are recorded on the data sheets, those data sheets shall be voided and a new calibration shall be recorded. All recorded indication since the last valid calibration or calibration check shall be reexamined with the corrected calibration and their values shall be changed on the data sheets. DAC Curve Correction If a point on the DAC curve has decreased 20% or 2db of its amplitude, all data sheets since the last calibration or calibration check shall be marked void. A new calibration shall be made and recorded, and area covered by the voided data shall be reexamined. If any point of the DAC curve has increased more than 20% or 2db of its amplitude, all recorded indications since the last valid calibration or calibration check shall be reexamine with the corrected calibration and their values shall be changed on the data sheets.8.Evaluation Level or NDE examiner shall evaluate indications in accordance with the acceptance standards of ASME Code, and record evaluated result on the EVLUATION SHEET FOR ULTRASONIC EXMINATION FOR BUTT-WELDS.8.1 Evaluation sensitivity shall be defi
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