球罐无损检测相关制度作业指导书程序

球罐制作安装工程无损检测相关制度

射线检测作业指导书RToperationguide

1总则General1.1适用范围Scope适用于XX球罐现场组焊对接焊缝X和γ射线检测施工。ApplytoX/GAMMAraytestoperationforsphericaltankweldsinXXXXPetrochemicalProject.1.2编制依据Reference1.2.1XX球罐设计图纸及设计变更单DesignDrawingAndModificationForXXSphericalTankInXXXX1.2.2质技监局锅发[1999]154号《压力容器安全技术监察规程》NO.[1999]154<supervisionandinspectioncodesforpressurevessel>issuedbyQualityAndTechnologySupervisionBureau.1.2.3JB4730-94《压力容器无损检测》JB4730-94<NDEForPressureVessel>1.2.4GB150-1998《钢制压力容器》GB150-1998<SteelPressureVessel>1.2.5GB4792-1994《放射卫生防护基本标准》GB4792-1994<fundamentalstandardforRTsanitaryprotection>《放射性同位素与射线装置放射防护条例》<TheRadioactiveIsotopes&DevicesInstallationRegulation>1.2.7SY4055-93《球形储罐γ射线全景曝光技术标准》SY4055-93<GAMMARayExposureTechnologyStandardForSphericalTank>1.2.8GB12337-1998《钢制球型储罐》GB12337-1998<SteelPressureVessel>1.2.9GB50094-1998《球型储罐施工及验收规范》GB50094-1998<constructionandacceptancestandardforsphericaltank>2人员要求RequirementsOfTheOperators2.1该工程射线检测工作由持有技术监督局核发的射线检测Ⅰ级及以上资质且持有卫生监督部门核发的放射工作人员证的人员进行操作，Ⅱ级及以上人员进行评片、出具报告和审核。其中RT-Ⅱ级持证至少两人。TheRToperationshallonlybeexecutedbythespecialpersonnelwithlevelⅠqualificationcertificateissuedbyQuality&TechnologysupervisionBureau,Operatingcertificateissuedbysanitarysupervisionauthority;thepersonnelwithatleastlevelⅡshallinspectthefilms,carryoutreportandapproval.2.2评片人员校正视力不得低于1.0，能读出距离400mm高为0.5mm、间距为0.5mm的一组印刷体英文字母。ThevisionofRTobservershallnotlessthan1.0,canreadprintedletters(400mminterval,0.5mmheight0.5mdistance).2.3所有检测人员必须身体健康，责任心强，不弄虚作假，玩忽职守。AlltheRTpersonnelshallbeofhealthycondition,strongsenseofresponsibility,nofalsificationandmalpractice.3检测时机、检测任务量及方法occasion,taskandmethodsfor.RT3.1检测时RToccasion进行形状尺寸和外观检查合格且焊接结束36小时后进行射线检测。WeimplementRT36hoursuponthecompletionofvisualcheck.3.2检测任务量RTtask球壳板所有对接焊缝，符合JB4730-94标准Ⅱ级合格。AlltheweldsoftheshellplateshallbeexecutedRTincompliancewithJB4730-94levelⅡ.3.3检测方法RTmethod采用Ir192γ源进行全景曝光，全景曝光死角区及返修片、补片可使用3005型X射线机进行检测，也可使用Ir192γ源进行检测。TheRTapplyIr192GAMMAsourceexposuretechnology,thedeadangle,repairfilmapplyEX300GH-3Xrayinstrument(orIr192GAMMAsource)4检测设备及材料RTequipmentsandmaterials4.1检测设备RTequipmentsDL-VA型γ射线探伤机2台，300KVX射线机2台，观光灯2台，黑度计1台，使用状况应良好，并符合有关标准的规定，所有计量器具应在检定有效期内使用。2setsDL-VAGAMMA-raymachine;2sets300KVX-raymachine;1setconstanttemperatureexposuremachine;1setfilmdrier,2setsprofessionallight;1setdarknessmeasurementmachine,alltheequipmentsshallbeofsound,workableconditionincompliancewithrelatingstandard.4.2材料RTmaterials该工程全部采用AGFA利维那T7型胶片；γ射线检测使用300X100X0.1mm增感屏，X射线使用300X100X0.03mm增感屏；使用自动洗片机时选用AGFA公司生产的与利维那胶片配套使用的专用冲洗套药，手洗时选用天津Ⅲ套药。TheprojectapplyAGFALivanatypeT7film;Gammasourceadopt300X100X0.1mmscreen;Xrayapply300X100X0.03mmscreen;AutomaticexposuremachineapplyfilmkitexposurematerialmadebyAGFAcompany,detergentshallbeofTianjinⅢ.5透照布置及出源次数IlluminationDistributionAndRadiographyTimes.5.1依照现场情况，选择中心全景曝光和单壁单影透照方式，X、γ射线单壁单影单张透照时透照焦距选用700mm；γ源全景曝光时透照焦距为球罐半径+母材厚度+焊缝余高。Accordingtothesituationinjobsite,weusecentralexposuretechnologyandmonolayer-singleimage-technology,thefocusofX、Gamma-rayformonolayer-singleimage-technologyshallbe700mm;ExposurefocusofGammasourceshallfollowtheformula:focuslength=sphericalradius+shellplatethickness+complementaryheightofwelds.5.2一次透照长度250mm。onetimeexposurelength:250mm5.3搭接长度两端不宜小于15mm。misalignmentshallnotbelessthan15mm.5.4球罐容积小于2000m3，宜采用一次出源进行全景曝光，球罐容积大于或等于2000m3，可采用二次出源进行全景曝光。Thesphericaltank(whosecubagelessthan2000m3)shallapplyonetimeexposuretechnology;morethan2000m3mayadopttwotimesexposuretechnology.6像质计及放置位置positionofImageQualityIdentification6.1选用Fe6/12Ⅱ号像质计。UsingFe6/12ⅡIQI(Imagequalityidentification)6.2球罐外壁的赤道带上每隔90O放置一个像质计，上下极带环焊缝方向每隔90O放置一个像质计，下极板内壁部位至少应放置二个像质计，并在此位置做对比实验。WeshalllocateoneIQI(imagequalityidentification)every90Oonequatorplate,oneIQIinhorizontalweldsdirectiononupper/lowercrown/ringplate,atleasttwoIQIinsidethelowercrown/ringplate,thencarryoutexperimentforalltheIQIlocated.6.3像质计应置于被检焊缝上，且钢丝被检焊缝垂直，放置位置宜在胶片长度的1/4处，细丝朝外，当像质计处于球罐外壁时，在其最粗丝右下角或左下角放置F标记。AlltheIQIshallbelocatedverticallytotheweldsmentionedabovein1/4filmposition.ThethinnerpartofIQIshallbeplacedoutwardly,iftheIQIlocatedontheexternalshellplate,thelowerrightangle/upperleftangleshallbemarked“F”.7定位标记、识别标记和布片locationandidentificationofthesigns,filmdistribution7.1定位标记：locationsigns透照时焊缝透照部位应有搭接标记，和中心标记，搭接标记起确定有效评定长度的作用。中心全景曝光时，定位标记置于射线源内外均可。单壁单影单张透照时，定位标记应置于射线源侧。Thepositionofexposureshallbemarked&duringapplicationofcentralexposure,welocatethesigninner/outerthesource.Signsofmonolayer–singleimageexposureshallbelocatedbesidethesource.7.2识别标记：identificationsigns为了使每张射线底片与工件被检部位始终可以对照，在透照过程中应将铅质识别标记和定位标记与被检区域同时透照在底片上。识别标记必须有工程（产品）编号、焊缝编号、底片号、球罐厚度、搭接标记和中心标记、年月日等标记，铅字距离焊缝边缘至少5mm。（识别标记见下图：）Forthecomparisonbetweenthefilmandtestedparts,weshallexposetheleadIQI,locatingsignandtestedzoneonthefilminthesametime.Alltheidentificationsignsshallbewithengineeringnumber,weldsnumber,film,numberandtankthickness,misalignmentsign,centralsignalsomarkedyear/month/date,thelettershallbeatleast5mmfromthewelds.Showninthefollowingsketch.工程（产品）编号engineeringnumber焊缝编号、底片编号weldsNO,filmNO说明：由于是中心全景曝光，底片之间均有搭接，每道焊缝上的底片只要有一张标识是完整的，就能保证整道焊缝的信息识别，所以要求每条焊缝的第一张底片的标识是完整的，其它底片可以没有年月日及中心标识。但补片及返修片搭接标识必须齐全。Interpretation:Duetothecentralexposuretechnologyapplyallthefilmsoverlayprocedure,sojustonefilmontheweldsfullymarked,otherfilmshallbenoneedforthedatesignandcentralsign.thisdoesnotapplytothere-exposuresign&repairsign.7.3布片filmdistribution焊缝进行射线检测前，按图样和焊缝排版图对受检部位标记，并画布片示意图。纵焊缝的底片顺序号宜从上至下为1、2、3……，环焊缝的底片顺序号宜从0º90º180º270º0º为1、2、3……。胶片在曝光间应在受检区域上固定稳妥，必要时另外附加磁铁固定。球罐全景曝光检测前应到气象部门咨询气候情况，如遇阴雨天气必须进行检测时，暗盒外面套塑料袋进行保护，上下方向布片时，暗盒的帽盖开口部位朝下。（该工程采用带磁铁的标记带）beforeRT,wedrawthedistributionsketchaccordingtothesamplemapandweldsdrawing.SequenceNo.forthefilmsofverticalweldsshallbe“1、2、3……”SequenceNo.forthefilmsofhorizontalweldsshallbe0º90º180º270ºDuringtheexposureperiod,thefilmshallbesecuredothetestedzone(magnetfornecessarycondition).BeforetheRT,weshallconsultedtheweatherbureau,ifRTmustbeimplementedeveninunfavorableweathercondition,weshallwrapthedarknessboxwithplasticbag.注：球壳板组装前，内外两侧应进行划线，标出布片位置，以防止返修、复拍时出现错位。Interpretation:beforetheshellplateassembly,weshalllineandmarkthepositionsoastopreventmisalignmentduringrepairandre-exposure.8曝光参数的选择及无用射线的屏蔽choosetheexposureparameterandscreentheuselessray.8.1曝光参数的选择choosetheexposureparameterγ射线检测时曝光时间使用专用曝光尺（A2）或计算公式（160F2e0.05T/A）确定，因影响γ射线检曝光时间的因素较多，以上仅作估算，在罐体某一部位放上双片，曝光至计算值90%时收回源，取下单片，在规定条件下冲洗，湿片测黑度，当黑度不足时继续曝光，直到母材处试验片黑度均在3.0为止；X射线检测根据焦距透照厚度及曝光曲线确定，且管电压不应超过射线机额定电压的90%，曝光量不应低于15mA.min。DuringtheGammaraydetection,weconfirmtheexposuretimebyprofessionalexposuretapeandrelatingformula160F2e0.05T/A,formanyfactorswillaffecttheexposuretime,wejustestimateit.Weplacedoublefilmsoncertainpartofthetank,withdrawthesourceat90%exposuredesigned,andexposethefilm.Tosomedampfilm,wetestthedarknessdegree,incaseofunsatisfactoryoutcome(referstodefectexposure),wecontinueexposingtothe3.0filmdarknessdegree.WeconfirmtheparameterofXraydetectionbyfocusexposurethicknessandexposurecurve,meanwhilethecubevoltageshallnotexceed90%ratingvoltageofRTmachine.Theexposureshallnotlessthan15mA.min.8.2散射线的屏蔽screenthedispersionray一般情况下，球罐周围的反射体距离球罐较远，不需采用特殊防护措施进行散屏蔽。为防万一，胶片暗盒背面放置1.6mm厚铅字B，曝光后，如在底片上出现B标记的较淡影像，则表明对背面散射线防护不足，需采取补充预防措施。Generally,wedonotapplyspecialprecautionsduetolongdistancebetweenthetankanditsreflectingobjectsaround.Forabarepossibility,weplace1.6mmthicknessleadletter“B”onthebackofthedarkbox,ifwefindthe“B”imageonthefilm,itmeansthebackofboxisunsafe,precautionisneeded.8.3进出源时射线的防护precautionforwithdrawing/sendingradiographysource,γ源送出、收回时，会对部分胶片造成曝光影响，为减轻这一影响，采取以下措施：出源、收源的速度要快，缩短进出源时间；尽可能减小输源管在球罐外暴露的长度，能全部放在球罐内最好；当输源管在球罐外暴露较长，必要时可将暴露在球罐外面的输源管用2mm厚弧形铅板将输源管罩住。Duetowithdrawing/sendingradiographysourcewillaffectfilmquality,soweapplytheprecautionasfollow:quickwithdrawing/sendingradiographysource,decreasetheexposurelengthofsourcetransmittingpipe,itwillbethebestchoicethatwholepipehideinsidethetankunderpossiblecondition.Ifmostpartofthepipeexposedoutsidethetank,weshalluseleadboardtocovertheexposedportionofthepipe.9暗室处理darkroomprocedure严格按《暗室作业指导书》进行。Strictlycomplywiththe<darkroomoperationguide>10焊接接头返工及复探refusal/re-exposureoftheweldjoints.10.1不合格的底片由评片人员下达“焊接接头返工通知单”，一式三份，连同返工底片复制件交焊接技术员，由焊接技术员协助探伤人员确定返工部位。（必要时使用超声波探伤仪进行定位）Thefilmobservershallcarryout“weldjointsrefusalbill”fordefectjoints,oneoriginaltwocopies,andsendthemwiththefilmtoweldingtechnicianwhowillassisttheRTpersonnelconfirmthere-weldingposition.10.2焊接接头返工后由焊接技术员回置返工通知单作为委托，由焊接检查员外观检查确认后且返工完成36小时后方可进行复探。Afterre-doingthejoints,theweldingtechnicianshallimplementvisualcheck,andconfirmsatisfactoryatconsignerstance,uponthe36hoursaftertheconfirmation,re-exposurewillbeimplemented.10.3返工片按返工次数分别在焊缝编号后加R1，R2，以示区别。FilmrefusedshallbemarkedR1，R2behindtheweldingnumberforidentificationaccordingtoitsrefusaltimes.10.4当返修、补片量比较大时，宜使用γ源全景曝光技术，当数量比较少时且位置处于球罐下半球时，可使用普通X射线机单壁单影透照。Inconditionofmorere-weldingandre-exposure,weapplyGamma–exposuretechnology,forlessre-weldingandre-exposure,weadoptcommonx-raymonolayer-singleimageexposuretechnology.11底片的质量要求filmqualityrequirement11.1底片黑度控制在1.8-3.5范围内。Filmdarknessdegreeshallbecontrolledwithintherangedesigned(1.8-3.5.)11.2像质指数达到标准要求，摆放位置正确，在焊缝影像上如能清晰地看到长度不小于10mm的像质计金属丝影像，就认为是可识别的。Theimagequalityparametershallreachedthestandardrequirementandproperlyplaced.iftheshadowofIQIwireappearsontheweldsimageclearlyinatleast10mmlength,itwillbeacceptable.11.3各种标记齐全，摆放整齐，位置正确，且不掩盖被检焊缝影象。Allthesignsmustbeallreadyandshouldnotcovertheweldingseamsimage.11.4在较黑背影下无“B”的较淡影象。Couldnotfindthe“B”imageundertherelativedarkshadow.11.5底片有效评定区域内不得有因胶片处理不当引起的缺陷或其它妨碍底片评定的缺陷。Allthedefectscausedbyfilmmishandlingshallnotappearintheeffectivezoneforfilmobservation.11.6凡不符合上述要求之一的底片均应重照。Thefilmwithanyincompliancewiththestipulationmentionedaboveshallbere-exposed.12底片观察filmobservation12.1评片室内光线应暗淡，室内照明不应在底片上产生反射。Theobservingroomshallbedarkwithoutcausingreflectiononthefilm.12.2观片灯应能观察最高黑度为3.5以上，且亮度可调。Observinglightshallidentifyatleast3.5degreedarknessandhandadjustable.13底片的初评与审核primaryviewandauditforfilm13.1按JB4730-94标准Ⅱ级合格进行评定。WeshallcomplywithJB4730-94standardlevelⅡ.13.2评片过程中应具备该产品排版图，现场透照记录，暗室记录和射线检测委托单，布片图等。Duringtheobservationweshallholdtheproductmakeupketch,siteexposurerecord,darkroomrecord,RTconsigningbillandfilmdistributionsketch.13.3在评片过程中，发现异议应及时去现场了解被检件情况，与复评员，无损检测责任工程师汇评。Duringthefilmobservation,weshallgotositeandobservethefilmwithre-observerandNDEengineerforanyunusualconditiondetected.14检测报告与底片存档RTreportandfilmfiling14.1产品经射线检测合格后，先发出产品合格通知单，而后填发检测报告，并将底片与原始记录整理好一起存档。UponthepassofRT,weshallissueproductcertificateandworkouttheRTreportthenfileupthefilmandoriginalrecord.14.2报告、原始记录与底片在公司档案室保存七年，七年后可转交用户或自行销毁。AlltheRTreportsandoriginalrecordsshallbestoredwithrelatingfilmsfor7years,thensendthemtotheclientordestroyed.15安全防护safetyprecaution15.1作业人员熟悉探伤工安全操作规程，进入现场前应接受施工安全教育，严格遵守安全规章制度。AlltheRToperatorsshallbefamiliarwithsafetyoperationandinstructedHSEregulationpriortositeentryandstrictlyincompliancewithitsrequirements.15.2进入现场应穿戴好劳动防护用品；进行射线操作时，须穿防护服。NDEpersonnelshallbewellequippedwithPPEpriortositeentry;duringtheradiographicinspectionprocessradio-proofclothesshallbedressed.15.3夜间工作时球罐内外应有充足的照明条件，罐内照明用电使用安全电压；进入球罐内工作时应有专人监护。Duringnightoperationinsidethetank,sufficientilluminationwithsafetyvoltageshallbeneededunderthesupervisionofspecialpersonnel.15.4探伤人员设备空中作业时，应谨慎操作，系好安全带。NDEpersonnelworkingatheightshouldwearsafetyharnessatalltime15.5射线探伤时，应先清理现场，确认无人后，划定控制区和管理区，设置警戒标志，并派专人警戒。安全距离应先根据公式进行计算，同时进行现场测量，有出入时，以现场实测为准。计算公式：WhiletheRToperation,weshallevacuateunauthorizedperson,lineoutcontrolandmanagementzone,alarmsignandsafetyguardareneeded.thecalculationofsafetydistancefollowtheformulabelowmeanwhilewecarryoutsitemeasurement,iftheoutcomeisinconsistentwepreferthesitemeasurement.formulashownasbelow:Akr1Rx=（——×——）1/2Nx2δ/Th15.6γ源应放在专用储藏室内，派专人保管，运输时，也应采取必要的安全措施。Gammasourceshallbeonlykeepinprofessionalhouseandwatchedbyappointedpersonnel,incaseoftransportation,weshalladoptnecessaryprecautionmeasures.15.7γ源在出源收源时应使用剂量检测仪进行监测，一旦发生意外事故，应及时保护现场并报告有关主管部门。DuringthesendingandwithdrawingofGammasource,weadoptdosageinspectionequipmenttomonitorthesource,anyunusualconditionshallbepromptlyreporttorelatingresponsibledepartment.15.8严禁在射线工作场所进食、吸烟或储存食品。Noeating,smokingandfoodstorageinRToperationzone.15.9其它未尽事宜严格执行《射线安全程序》、《放射源安全管理制度》Otherdetailsnotmentionedaboveshallstrictlycomplywith<temporarystipulationforGammaradiographymanagement><temporarystipulationofsafetymanagement>

超声波检测作业指导书UToperationguide

1总则General1.1适用范围Scope适用于XX球罐现场钢板及对接焊缝超声波检测施工。TheguideonlyapplytoUTforthesteelboardanditsweldsinXXPetrochemicalspheretankProject.1.2编制依据reference1.2.1XX球罐设计图纸及设计变更单DesignDrawingAndModificationForXXSphericalTankInXXXX1.2.2XX市XX检验公司《质量手册》及《质量控制程序文件》。<QualityManual>And<QualityControlProcedure>inXXcompany.1.2.3质技监局锅发[1999]154号《压力容器安全技术监察规程》NO.[1999]154<supervisionandinspectionregulationforpressurevessel>issuedbyQualityAndTechnologySupervisionBureau.1.2.4JB4730-94《压力容器无损检测》JB4730-94<NDEForPressureVessel>1.2.5GB150-1998《钢制压力容器》GB150-1998<SteelPressureVessel>1.2.6GB50094-1998《球型储罐施工及验收规范》GB50094-1998<constructionandacceptancestandardforsphericaltank>2人员要求RequirementsOfTheOperators2.1该工程所有超声波检测工作由持有技术监督局颁发的Ⅱ级及以上资格证书人员进行检测。TheUToperationshallonlybeexecutedbythespecialpersonnelwithlevelⅡqualificationcertificateoraboveissuedbyQuality&TechnologySupervisionBureau.2.2从事焊缝检测的操作者，应具备一些焊缝超声波探伤经验，并掌握一定的材料、焊接基本知识，能分析缺陷产生的部位，根据荧光屏上的反射波形来综合判断。AlltherelatingoperatorsshallhaveexperienceonweldsUT,befamiliarwiththeweldingmaterialsconsumablesandgeneralknowledge,becapableofanalysethedefectpositionbyreflectingwaveonthefluorescentscreen.2.3所有检测人员必须身体健康，责任心强，不弄虚作假，玩忽职守。AlltheRTpersonnelshallbeofhealthycondition,strongsenseofresponsibility,nofalsificationandmalpractice3检测时机、检测任务量及要求occasionandtaskforUT.3.1检测时机UToccasion钢板及周边超声波抽查随委托在组装前进行检测，球壳板所有对接焊缝在全部射线检测合格后进行UTTheperipheralzoneoftheshellplatesshallbeimplementedUTbyrandombeforeshellassembly;AllthebuttjointsoftheshellplatesshallbeimplementedUTafterapprovedRT.3.2检测任务量UTtask3.2.1原材料复验re-examtherawmaterials球壳板进行不少于20%超声波复验，且每带不少于2块，上下极不少于1块，若发现超标缺陷，应加倍抽查，若仍有超标缺陷，则应100%检查，结果应符合JB4730-94的Ⅲ级要求；球壳板周边100mm范围内应做全面积超声波抽查，结果应符合JB4730-94的Ⅲ级要求.Theshellplateshallbeimplementedatleast20%UT(thatistosaythatthetestedplatesshallbenotlessthan2equatorplates,1upperand1lowerpolarplates),theoutcomecomplywithJB4730-94standardlevelⅢ,Theperipheralzone(100mmtoitsbevel)oftheshellplatesshallbeimplementedUTperJB4730-94standardlevelⅢ.3.2.2对接焊缝复验re-examthewelds所有对接焊缝在合格后进行100%超声波复验，结果应符合JB4730-94的Ⅰ级要求Alltheweldsshallbeimplemented100%UTupontheRTinspection&acceptanceperJB4730-94standardlevelⅠ.3.3检测方法UTmethod钢板原材料复验采用纵波直探头进行检测；使用测厚仪进行测厚；使用横波斜探头对焊缝进行检测。Re-examinationoftheshellplatematerialapplyverticalwavedetectortechnology;theweldsapplyhorizontalwavedetector.4探伤仪、探头及系统性能UTmachine,detectorandsystemcapability4.1探伤仪UTmachine汉威数字超声波、CTS-22A型超声波各1台，设备必须经计量鉴定合格。1setHANWEIdigitalultrasonicmachine;1setCTS-26typeultrasonicmachine4.2探头detector钢板原材料复验选用2.5P20D直探头，20个20pieces2.5P20Ddetectorsforplatematerialsre-examination.焊缝复验选用2.5P13X13K2斜探头，20个20pieces2.5P13X13K2detectorsforweldsre-examination.4.3系统综合性能systemcapability符合JB4730-94标准要求。StrictlycomplywithJB4730-94standard.5试块testingtemplate5.1钢板原材料复验选用1～5号平底孔试块。ApplyNo.1～5flatbuttontemplateforshellplate.5.2焊缝检测时，选用CSK-1A，CSK-ⅢA试块。ApplyCSK-1A，CSK-ⅢAtemplateforwelds.6耦合剂couplingmaterial使用洗洁精做耦合剂,检测焊缝应采用相同的耦合剂。Weapplydetergentascouplingmaterialforplate/weldstest.7钢板的超声波检测UTforshellplates7.1采用5次波法进行检测，按1：20/T（T钢板厚度）调节扫描比例。Weshalltesttheplateby5-time-wavetechnologyandadjustthescanscaleaccordingto1：20/T(T=platethickness)principle.7.2检测灵敏度：应计入灵敏度试块与被探钢板之间的表面耦合声能的损失（dB），一般取，也可以实测为准。Testthesensitivity:werecordthelossofcouplingultrasonicenergy（dB）onthesurfacebetweenthesensitivitytemplateandtestedplate,wechoose4dBasgeneralprinciplepriortothepracticalmeasurement.7.3探头扫查方式：探头沿垂直于钢板压延方向，间距为100mm的平行线扫查，在钢板剖口预定线两侧各,内应作扫查100%。Detectorscanningtype:thedetectorshallbemovedonparallellineswith100mmintervalandverticaltotheplate.100%scanningwillbeneededwithinthe50mmrangefrombothsidesofscheduledlinesonplatesection.7.4钢板超声波检测时缺陷的测定identifythedefectsforplateUT7.4.1在检测过程中，发现下列情况之一者，即作为缺陷。Anyofthefollowingsshallberegardedasdefects.A、缺陷第一反射波（F1）波高大于或等于满刻度的50%，即F1≥50%者。F1≥50%fullgraduation(F1referstheheightoffirstreflectingwave)B、当缺陷第一次反射波（F1）波高与底面第一次反射波（B1）波高之比大于或等于满刻度的50%，即B1＜100%，而F1/B1≥50%者。B1＜100%fullgraduation&F1/B1≥50%fullgraduation(B1=heightoffirstreflectingwaveofbottom)C、当底面第一次反射波（B1）波高于满刻度的50%，即B1＜50%者。B1＜50%fullgraduation7.4.2检出缺陷后，应在它周围继续进行检测，当探头移动到缺陷波第一次反射波高与地面第一次反射波高之比为50%，此时探头中心移动距离即为缺陷的指示长度，探头中心点即为缺陷的边界点。Upontheidentificationofdefects,wecontinuescanningaroundthedefectsuntilF1/B1≥50%fullgraduation,thedistanceofdetectormovementwillbedefectlength;Centralpointofthedetectorwillbethedefectcenter.8焊缝的超声波检测UTforwelds8.1利用CSK-IA试块按深度1：1调节扫描比例。WeuseCSK-IAtemplateforweldsandadjustthescanscaleby1：1.8.2测定入射角，确定前沿距离，在标准中的试块上进行K值的测定，并应在2N以外进行。（N为近场长度）identifytheangleofincidenceanddistance;carryoutK-valuetestontemplateoutsideof2Nrange(N=distanceofultrasonicfield)8.3利用CSK-ⅢA试块制作距离-波幅曲线图或在荧光屏上直接绘出。WeuseCSK-ⅢAtemplatetoworkoutinterval-amplitudecurveorshownthecurveonfluorescentscreen.8.4检测时，应对表面声能损失与材料衰减时进行修正，修正量必须计入距离-波幅曲线，一般取4dB，也可实测；探伤灵敏度不得低于最大声程处的评定线灵敏度。Weshallreviselossofcouplingultrasonicenergyanditsattenuation,andwritedowntherevisioninthecurve.wechoose4dBasgeneralprinciplepriortothepracticalmeasurement.TheUTsensitivityshallnotexceedthemaximumsensitivityfigureofassessmentline.8.5探伤面和移动区UTsurfaceandmovementrangeofdetector8.5.1探头移动区应小于1.25PThemovementrangeofdetectorshallnotexceed1.25PP=2TK:P-跨距(span)，mmT-母材厚度(platethickness)，mmK-探头K值(Kvalueofdetector)8.5.2采用直射法检测时，探头移动区应不小于0.75P。Duringapplicationofdirect-sendingsonicwave8.6灵敏度校验verificationofsensitivity现场探伤前应对距离-波幅曲线在CSK-ⅢA上校验，校验不少于两点，其误差小于2dB，否则应重新确定检测灵敏度。Weshallverifytheinterval-waveamplitudecurveonCSK-ⅢAtemplate(atlest2checkingpoints),andcontroltheerrorwithin2dB.8.7探头移动方式movingtypeofdetector8.8.1锯齿型扫查：探伤过程中，每次前进齿距不得超过探头晶片直径，在保持探头与焊缝中心垂直中心线的同时，做大致10～150的摆动。Sawtoothscan:eachcurveofadvancingSawtoothshallnotexceedthedetectordiameter,keepthedetectorverticaltotheweldsandswingitinrangeof10～1508.8.2斜平行扫查：在焊缝边缘使探头与焊缝中心线成一定夹角（10～200），作斜平行扫查。Parallelscan:wescantheweldsinparallellinesbyangle(10～200.)fromtheaparallelscanninglinetothecentralweldsline.8.8.3为了确定缺陷的位置方向或区分缺陷波与假信号可采用前后，左右，转角，环绕，转动等四种探头移动方向来判定。Weswingthedetectorinforth-back,left-rightandhorizontaldirectiontoconfirmthedefectlocationandidentifythedefectorfalsewave.8.9焊缝超声波检测过程中缺陷的测定identifythedefectinUT8.9.1缺陷定量：波幅位于定量线和定量线以上的缺陷其缺陷指示长度可采用半波高度法（6dB）和端点半波高度法进行测量。Quantifythedefects:weapplythehalf-heighttechnology6dBforthedefectsexceedingorequaltothelinedesigned.8.9.2确定缺陷位置：测定缺陷在整条焊缝上的位置和焊缝断面上的位置及埋藏深度。Confirmthedefectlocation:confirmthedefectslocationinthewholeweldsanditssection.9缺陷的评定，返工，复探，扩探assessment,refusal,re-testandtestextendingforthedefects9.1钢板缺陷的评定，返工，复探，扩探assessment,refusal,re-testandtestextendingforthedefectsofsteelboard.9.1.1JB4730-94Ⅲ级合格JB4730-94standardlevelⅢisacceptable.9.1.2评定后，若要求被检件局部修补，应将超标缺陷填写在返工通知单上，一式三份，反馈给材料责任工程师。Ifthetestedpartsneedrepairafterassessment,weshallfillexcessofsetstandardinthetriplicateformandsendtheformstomaterialengineerasfeedback.9.1.3修补后，由材料责任工程师用返工通知单作委托进行复探，复探时仍按原检测条件进行。Aftertherepair,thematerialengineerwillinformthecompanytore-testthelocationundersameUTstandard.9.1.4若发现超标缺陷，应加倍抽查.Weshallincreasetherandomcheckfordefectforexcessofsetstandard,9.2焊缝缺陷的评定、返工、复探。Assessment,refusal,re-testforweldsdefects9.2.1被探焊缝的评定应按委托单的委托级别进行评定，对于超标缺陷均应进行返工，并填写返工通知单一式三份，反馈给焊接技术员。Alltheassessmentforweldsdefectsshallonlyfollowtheconsigningstandard,anydefectsforexcessofsetstandard(withtriplicateform)willbesendedtoweldingtechnicianforrepair.9.2.2返工后，由焊接技术员用返工通知单作委托进行复探，复探时仍按原检测条件进行。IftheUTisrefused,theweldingtechnicianshallinformtheconsignedcompanybyrefusalbilltore-testtheweldsbythesamestandard.9.2.3在检测时，当发现不能准确判断的波形时，应辅以其他检测方法进行综合判断。Duringtest10报告与存档。Reportandfileup10.1无损检测合格的产品由操作者按原始记录整理填写报告书，并由无损检测工程师复审签字，盖公章后生效。AlltheproductwhichpassNDEwillbereportedinwrittenform(whichwillbesignedbyNDEengineerforreview)accordingtoitsoriginalrecord10.2报告、原始记录应在公司档案室保存七年，七年后可转交用户或自行销毁。AlltheUTreportandoriginalrecordshallbefiledupbyNDEcompanyfor7years.11安全管理safetymanagement11.1作业人员熟悉探伤工安全操作规程，进入现场前应接受施工安全教育，严格遵守安全规章制度。AlltheUToperatorsshallbefamiliarwithsafetyoperationregulation,instructedHSEregulationpriortositeentryandstrictlyincompliancewithitsrequirements.11.2进入现场应穿戴好劳动防护用品NDEpersonnelshallbewellequippedwithPPEpriortositeentry;duringtheradiographicinspectionprocessradio-proofclothesshallbedressed.11.3夜间工作时球罐内外应有充足的照明条件，罐内照明用电使用安全电压；进入球罐内工作时应有专人监护。Duringnightoperationinsidethetank,sufficientilluminationwithsafetyvoltageshallbeneededunderthesupervisionofspecialpersonnel.11.4探伤人员、设备空中作业时，应谨慎操作，系好安全带。NDEpersonnelworkingatheightshouldwearsafetyharnessatalltime

表面检测作业指导书operationguideforsurfacetest

1总则General1.1适用范围Scope适用于xx球罐现场采用磁粉、渗透等方法的检测施工。TheguideonlyapplytoMT,PTinXXPetrochemicalspheretankProject.1.2编制依据reference1.2.1xx球罐设计图纸及设计变更单DesignDrawingAndModificationForXXSphericalTankInXXDAYABay1.2.2xx检验公司《质量手册》及《质量控制程序文件》。<QualityManual>And<QualityControlProcedure>inXXXXcompany.1.2.3质技监局锅发[1999]154号《压力容器安全技术监察规程》NO.[1999]154<supervisionandinspectionregulationforpressurevessel>issuedbyQualityAndTechnologySupervisionBureau.1.2.4JB4730-94《压力容器无损检测》JB4730-94<NDEForPressureVessel>1.2.5GB150-1998《钢制压力容器》GB150-1998<SteelPressureVessel>1.2.6GB50094-1998《球型储罐施工及验收规范》GB50094-1998<constructionandacceptancestandardforsphericaltank>2人员要求RequirementsOfTheOperators2.1该工程所有表面检测工作由持有技术监督局颁发的Ⅰ级及以上资格证书人员进行。TheUToperationshallonlybeexecutedbythespecialpersonnelwithlevelⅠqualificationcertificateissuedbyQuality&TechnologyBureau.2.2检测人员必须身体健康，无色盲，校正视力不得低于1.0。ThevisionofRToperatorshallnotlessthan1.0.2.3责任心强，不弄虚作假，玩忽职守。Allthepersonnelshallbeofhealthycondition,strongsenseofresponsibility,nofalsificationandmalpractice.3检测时机、检测任务量及要求occasionandtaskforMT,PT.3.1检测时机occasionforPT,MT坡口表面检测在安装、焊接前，跟随委托随时进行；焊接过程中清根焊缝按委托随时进行；球壳组焊后，钢板对接焊缝及与钢板焊接的所有焊缝内、外表面，焊接工卡具清除后的焊迹及热影响区，热处理前、水压实验前后分别进行。Beveltestshallbeimplementedinaccordancewithconsigningbillbeforetankassemblyandwelding;duringtheweldingprocesswegaugetheweldsaccordingtoconsigningbill;afterweldingweimplementUT,PTforallthewelds,weldsscarsandheat-affectedzoneafterhydraulictestpriortoPWHT.3.2检测任务量及要求taskandrequirementofPT,MT3.1原材料复验rawmaterialre-check球壳板坡口表面应进行磁粉检测或渗透检测抽查，抽查数量不小于球壳板数量20%，若发现有不允许的缺陷，应加倍抽查，若仍有超标缺陷，结果应符合JB4730-94的I级要求。AllthebevelssurfaceofthetankshallbeimplementedMT,PTbyrandomcheck(notexceed20%oftotal).WeshallincreaserandomcheckforidentifieddefectperstandardJB4730-94levelI.3.2焊接过程中无损检测NDEforweldingprocess球壳板对接焊缝单面焊完，背面清根打磨后，应进行100%磁粉检测，特殊情况下可做100%渗透检测；工夹具拆除后焊疤修磨处进行100%磁粉检测；当修磨深度超过3mm时，应进行射线检测；磁粉检测无法进行的部位应100%渗透。结果应符合JB4730-94的I级要求。Uponthecompletionofsinglesidewelding,gougingthebackside,then100%PT;Uponthedismantlingofkeyplates,specialjigsetc.grindingthescarsthen100%PTor100%MagneticParticleTest(MT).;RTwillbeimplementedifthegrindingdepthexceeding3mm;iftheplacewhereisnotsuitableforMTshallbeimplemented100%PTincompliancewithstandardJB4730-94levelI.3.3焊后无损检测post-weldNDE球壳组焊后，钢板对接焊板焊接的所有焊缝内、外表面，焊接工卡具清除后的焊迹及热影响区，热处理前、水压实验前后分别进行100%MT检测，结果应符合JB4730-94的I级要求。Afterthetankassembly,weshallimplement100%MTforallthewelds,weldingscar,andheat-affectedzone,post/prePWHTetc.,perstandardJB4730-94levelI.3.4球罐内表面推荐采用荧光磁粉进行检测。WecommendfluorescentMTforinternaltank.4表面检测前的准备surfacepreparation4.1受检区域及附近小于25mm宽度范围内应清洁，干燥，无油脂、涂料、铁锈、氧化皮及其他妨碍缺陷显示的各种覆盖物。Thereshallbecleananddrywithoutgrease,paint,rust,oxidepeeledandotherdefectsetc.,4.2表面处理以钢丝刷、砂轮、有机溶剂清洗为宜。We`applysteelbrash,abrasivewheel,organicsolventforsurfacepreparation.5渗透检测（PT）5.1根据实际情况，推荐选用着色法溶剂去除型渗透剂和快干式显像剂进行检查。（VC-S），WecommendcolorantpenetrantandquickvolatiledeveloperforPT.5.2采用喷罐式着色剂，且渗透剂、显像剂必须是同一厂家的产品，不得混用。该工程选用DPT-5型渗透剂系列。Weapplythetank-sprayingcolorant;PTliquidanddevelopermustbemanufacturedinthesamefactory.5.3检测前，必须在相同的环境下，使用镀铬试块作灵敏度实验,灵敏度试块选用法定厂家生产的镀铬裂纹试块。Beforetest,weusingchromeplate(legallyprovided)tomakeasensitivityexperiment.5.4检测程序procedure5.4.1预清洗pre–washing在喷涂渗透剂之前，用丙酮或清洗剂将受检表面洗净，然后烘干