《TOFD检测（双语）》课件-23.压力容器TOFD检测

压力容器TOFD检测案例

CaseStudy:TOFDInspectionofaPressureVesselTOFD检测技术

TOFDTestingTechnology案例背景

CaseBackground1TOFD检测工艺选择

SelectionoftheTOFDInspectionProcedure2工艺参数计算与设置

CalculationandSettingofInspectionParameters3压力容器TOFD检测流程

TOFDInspectionProcessforthePressureVessel4关键控制要点

KeyControlPoints5知识目标

Knowledgeobjectives教学目标

Teachingobjectives海工某容器制造厂制造段塞流捕集器容器，筒体材质Q345R，壁厚56mm，环/纵对接焊缝需按NB/T47013.10做TOFD检测，检测等级B级，验收等级Ⅱ级，检测比例100%。

Apressure-vesselmanufacturerforanoffshoreengineeringprojectfabricatedaslugcatcherwithaQ345Rsteelshellandawallthicknessof56mm.Thecircumferentialandlongitudinalbuttweldswererequiredtoundergo100%TOFDinspectioninaccordancewithNB/T47013.10,atInspectionLevelBandAcceptanceLevelII.案例背景CaseBackground根据设计文件要求的检测标准，该容器按照NB/T47013标准进行检测，按NB/T47013标准要求，厚度超50mm，单分区声场覆盖不足，须采用非平行扫查双分区检测工艺，实现全厚度无遗漏覆盖。

Inaccordancewiththeinspectionstandardspecifiedinthedesigndocuments,thevesselwasinspectedinaccordancewithNB/T47013.Becausethewallthicknessexceeded50mmandasingleinspectionzonecouldnotprovideadequatesound-fieldcoverage,atwo-zonenonparallelscanningprocedurewasrequiredtoachievecompletethrough-thicknesscoverage.TOFD检测工艺选择SelectionoftheTOFDInspectionProcedure按照标准要求，对扫查面盲区及底面盲区进行补充检测，对扫查面进行表面磁粉检测，对焊缝横向缺陷进行超声波检测。

Asrequiredbythestandard,supplementaryinspectionswereperformedforthescanning-surfaceandback-walldeadzones.Magneticparticletestingwasperformedonthescanningsurface,andultrasonictestingwasusedtodetecttransversewelddefects.TOFD检测工艺选择SelectionoftheTOFDInspectionProcedure焊缝双分区划分

DivisionoftheWeldintoTwoInspectionZones工艺参数

InspectionParameters计算与设置

CalculationandSetting探头楔块选择

ProbeandWedgeSelection各分区聚焦深度及PCS计算

CalculationoftheBeamIntersectionDepthandPCSforEachZone各分区校准及灵敏度设置，编码器校准，-12dB扩散角测定

Calibrationandsensitivitysettingforeachzone,encodercalibration,andmeasurementofthe−12dBbeamspreadangle查面盲区及底面盲区确定

DeterminationoftheScanning-SurfaceandBack-WallDeadZones工艺参数计算与设置CalculationandSettingofInspectionParameters按照NB/T47013.10要求，对厚度56mm焊缝进行两个分区划分，厚度划分如下：

InaccordancewithNB/T47013.10,the56mmthickweldwasdividedintothefollowingtwoinspectionzones:第一分区：0~22.4mm（0~2/5T）；

Zone1:0–22.4mm,correspondingto0–2T/5;第二分区：22.4～56mm（2/5T~T）；

Zone2:22.4–56mm,correspondingto2T/5–T;1.焊缝双分区划分

DivisionoftheWeldintoTwoInspectionZones工艺参数计算与设置CalculationandSettingofInspectionParameters第一分区：采用5MHz6mm直径探头，70度楔块；

Zone1:5MHzprobeswithanelementdiameterof6mmandwedgesproducingarefractedangleof70°;第二分区：采用5MHz6mm直径探头，60度楔块；

Zone2:5MHzprobeswithanelementdiameterof6mmandwedgesproducingarefractedangleof60°;2.各分区探头楔块参数选择，依据NB/T47013标准推荐探头楔块选择如下：

SelectionofProbeandWedgeParametersforEachZone.BasedontherecommendationsofNB/T47013,thefollowingprobeandwedgeconfigurationswereselected:工艺参数计算与设置CalculationandSettingofInspectionParameters第一分区：0~22.4mm（0~2/5T），采用5MHz6mm直径探头，70度楔块；

Zone1:0–22.4mm,correspondingto0–2T/5;5MHzprobeswithanelementdiameterof6mmandwedgesproducingarefractedangleof70°areused;聚焦深度为分区厚度的2/3深度位置，即

Thebeamintersectiondepthissetattwo-thirdsofthezonethickness,namely22.4*2/3=14.9mm;PCS=2*T*tan70°=82.1mm3.各分区聚焦深度及PCS计算如下：

CalculationoftheBeamIntersectionDepthandPCSforEachZone:工艺参数计算与设置CalculationandSettingofInspectionParameters第二分区：22.4～56mm（2/5T~T），采用5MHz6mm直径探头，60度楔块；

Zone2:22.4–56mm,correspondingto2T/5–T;5MHzprobeswithanelementdiameterof6mmandwedgesproducingarefractedangleof60°areused;聚焦深度为分区厚度的2/3深度位置，即

Thebeamintersectiondepthissetattwo-thirdsofthezonethickness,namely22.4+（56-22.4）*2/3=44.8mm;

Thebeamintersectiondepthis22.4+(56−22.4)×2/3=44.8mm;PCS=2*T*tan60°=155.2mm3.各分区聚焦深度及PCS计算如下：

CalculationoftheBeamIntersectionDepthandPCSforEachZone:工艺参数计算与设置CalculationandSettingofInspectionParameters第一分区：0~22.4mm（0~2/5T），采用5MHz6mm直径探头，70度楔块；

Zone1:0–22.4mm,correspondingto0–2T/5;5MHzprobeswithanelementdiameterof6mmandwedgesproducingarefractedangleof70°areused;用TOFD校准试块、对比试块校准声速、楔块延迟、深度校准与灵敏度设置，确保直通波正常显示，第一分区可能不能正常显示底波。

UseTOFDcalibrationblocksandreferenceblockstoperformwave-velocitycalibration,wedge-delaycalibration,depthcalibration,andsensitivitysetting.Ensurethatthelateralwaveisdisplayedcorrectly.Ausableback-wallechomaynotbeavailableinZone1.4.各分区校准及灵敏度设置，编码器校准，-12dB扩散角测定：

CalibrationandSensitivitySettingforEachZone,EncoderCalibration,andMeasurementofthe−12dBBeamSpreadAngle:工艺参数计算与设置CalculationandSettingofInspectionParameters第二分区：22.4～56mm（2/5T~T），采用5MHz6mm直径探头，60度楔块；

Zone2:22.4–56mm,correspondingto2T/5–T;5MHzprobeswithanelementdiameterof6mmandwedgesproducingarefractedangleof60°areused;用TOFD校准试块、对比试块校准声速、楔块延迟、深度校准与灵敏度设置，确保底波正常显示，第二分区可能不能正常显示直通波。

UseTOFDcalibrationblocksandreferenceblockstoperformwave-velocitycalibration,wedge-delaycalibration,depthcalibration,andsensitivitysetting.Ensurethattheback-wallechoisdisplayedcorrectly.AusablelateralwavemaynotbeavailableinZone2.编码器单独进行校准，要求误差不超过1%，步进设置不大于1mm。

Calibratetheencoderseparately.Theencodererrorshallnotexceed1%,andthescanincrementshallnotexceed1mm.探头-12dB扩散角测定采用扩散角测定试块进行测量。

Measurethe−12dBbeamspreadangleoftheprobesusingabeam-spreadcalibrationblock.工艺参数计算与设置CalculationandSettingofInspectionParameters4.各分区校准及灵敏度设置，编码器校准，-12dB扩散角测定：

CalibrationandSensitivitySettingforEachZone,EncoderCalibration,andMeasurementofthe−12dBBeamSpreadAngle:扫查面盲区：采用扫查面盲区试块进行测定；盲区采用超声波检测补偿。

Scanning-surfacedeadzone:Determinethedead-zonedepthusingascanning-surfacedead-zonereferenceblock,andinspectthedeadzoneusingsupplementaryultrasonictesting.底面盲区：采用计算法确定；

Back-walldeadzone:Determinethedead-zonedepthbycalculation;5.扫查面盲区及底面盲区确定

DeterminationoftheScanning-SurfaceandBack-WallDeadZones工艺参数计算与设置CalculationandSettingofInspectionParameters容器焊缝内外焊缝表面宽度均为30mm，热影响区10mm

Theweldsurfaceis30mmwideonboththeinnerandoutersurfacesofthevessel,andtheheat-affectedzoneextends10mmfromtheweldΔh=56(1-(1-（252/(77.62+562))1/2)=1.94mm≈2mm底面盲区大于1mm，需要采用偏置扫查或超声波检测补偿，本案例采用超声波检测补偿。

Becausetheback-walldead-zonedepthexceeds1mm,offsetscanningorsupplementaryultrasonictestingisrequired.Supplementaryultrasonictestingisusedinthiscase.5.扫查面盲区及底面盲区确定

DeterminationoftheScanning-SurfaceandBack-WallDeadZones工艺参数计算与设置CalculationandSettingofInspectionParameters表面准备：T型焊缝位置余高磨平，便于探头通过，清除焊缝两侧油污、铁锈，保证耦合稳定。

SurfacePreparation:GrindtheweldreinforcementflushattheT-jointtoallowunobstructedprobemovement.Removeoil,rust,andothercontaminantsfrombothsidesoftheweldtoensurestablecoupling.压力容器TOFD检测流程TOFDInspectionProcessforthePressureVessel压力容器TOFD检测流程TOFDInspectionProcessforthePressureVessel数据扫查：

选取内表面或外表面作为TOFD扫查面，本案例选择外表面进行扫查，便于操作，采用水或化学浆糊作为耦合剂，本案例选择水泵供水，保证耦合稳定。单个数据长度不能大于2000mm，数据质量需连续观察，保证无数据丢失或灵敏度突变，保证数据采集质量。

DataAcquisition:SelecteithertheinneroroutersurfaceastheTOFDscanningsurface.Inthiscase,theoutersurfaceisselectedforeaseofoperation.Waterorasuitablegelcouplantmaybeused.Apumpedwatersupplyisusedinthiscasetomaintainstablecoupling.Thelengthofeachdatafileshallnotexceed2,000mm.Dataqualityshallbemonitoredcontinuouslytopreventdatalossorabruptchangesinsensitivityandtoensurereliabledataacquisition.缺陷识别与评定：采用TOFD评判软件对数据进行评判，对缺陷信号进行测定，包括深度、高度，长度等信息，对照标准判定等级，出具报告。

DefectIdentificationandEvaluation:UseTOFDevaluationsoftwaretoanalyzetheacquireddataandmeasuredefectparameters,includingdepth,height,andlength.Classifythedefectsinaccordancewiththeapplicablestandardandissuetheinspectionreport.压力容器TOFD检测流程TOFDInspectionProcessforthePressureVessel第一分区数据显示

DataDisplayforZone1第二分区数据显示

DataDisplayforZone2压力容器TOFD检测流程TOFDInspectionProcessforthePressureVessel扫查时应保证实际扫查路径与拟扫查路径的偏差不超过探头中心间距的10%。

Duringscanning,thedeviationoftheactualscanpathfromtheplannedscanpathshallnotexceed10%oftheprobecenterspacing.每次扫查长度不应超过2000mm；若需对焊缝在长度方向进行分段扫查，则各段扫查区的重叠范围至少为20mm；对于环焊缝，扫查停止位置应越过起始位置至少20mm，建议控制在100mm。

Thelengthofeachscanshallnotexceed2,000mm.Ifaweldisscannedinsectionsalongitslength,adjacentscannedsectionsshalloverlapbyatleast20mm.Foracircumferentialweld,thescanshallendatleast20mmbeyondthestartingposition,withanoverlapofapproximately100mmrecommended.关键控制要点KeyControlPoints扫查过程中应密切注意波幅状况，若发现直通波、底面反射波、材料晶粒噪声或波型转换波的波幅降低12dB以上或怀疑耦合不好时，应重新扫查整段区域；若发现直通波满屏或晶粒噪声波幅超过满屏高20%时，则应降低增益并重新扫查。

Signalamplitudesshallbecloselymonitoredthroughoutscanning.Iftheamplitudeofthelateralwave,back-wallecho,grainnoise,ormode-convertedwavedecreasesby12dBormore,orifpoorcouplingissuspected,theentireaffectedsectionshallberescanned.Ifthelateralwavereachesfull-screenheightorthegrain-noiseamplitudeexceeds20%offull-screenheight,reducethegainandrescanthesection.横向缺陷检测采用常规超声波按照NB/T47013.3中B级或C级的要求进行检测。

TransversewelddefectsshallbeinspectedusingconventionalultrasonictestinginaccordancewiththerequirementsforInspectionLevelBorCspecifiedinNB/T47013.3.关键控制要点KeyControlPoints01以56mm段塞流捕集器为例，学习了压力容器TOFD检测双分区检测案例，明确分区原则、参数计算、扫查流程与覆盖验证要点。

Usinga56mmthickslugcatcherasanexample,thiscasestudydemonstratestwo-zoneTOFDinspectionofapressurevesselandexplainstheprinciplesofthicknesszoning,parametercalculation,scanningprocedures,andinspection-coverageverification.0250～100