超声波检测作业指导书UT operation guide

1、超声波检测作业指导书ut operation guide1 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。the guide only apply to ut for the steel board and its welds in xx petrochemical sphere tank project .1.2 编制依据reference1.2.1 xx球罐设计图纸及设计变更单design drawing and modification for xx spherical tank in xxxx1.2.2 xx市xx检验公司质量手册及质量

2、控制程序文件。and in xx company.1.2.3 质技监局锅发1999154 号压力容器安全技术监察规程no. 1999154 issued by qualityand technology supervision bureau .1.2.4 jb4730-94压力容器无损检测jb4730-941.2.5 gb150-1998钢制压力容器gb150-19981.2.6 gb50094-1998球型储罐施工及验收规范gb50094-19982 人员要求requirements of the operators2.1 该工程所有超声波检测工作由持有技术监督局颁发的级及以上资格证书人员进

3、行检测。 the ut operation shall only be executed by the special personnel with level qualification certificate or above issued by quality &technology supervision bureau.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。all the relating operators shall have experience on welds ut,

4、 be familiar with the welding materials consumables and general knowledge ,be capable of analyse the defect position by reflecting wave on the fluorescent screen.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。all the rt personnel shall be of healthy condition ,strong sense of responsibility, no falsification and

5、malpractice3 检测时机、检测任务量及要求 occasion and task for ut .3.1 检测时机ut occasion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utthe peripheral zone of the shell plates shall be implemented ut by random before shell assembly ;all the butt joints of the shell plates shall be implemented ut after approved rt .3.2

6、 检测任务量 ut task3.2.1 原材料复验 re-exam the raw materials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 的级要求.the shell plate shall be implemented at least 20%ut( that is to say that the tested plates shall be not less than 2 e

7、quator plates, 1 upper and 1 lower polar plates),the outcomecomply with jb4730-94 standard level ,the peripheral zone (100mm to its bevel )of the shell plates shall be implemented ut per jb4730-94 standard level .3.2.2 对接焊缝复验 re-exam the welds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 的级要求all the welds sh

8、all be implemented 100% ut upon the rt inspection &acceptance per jb4730-94 standard level .3.3 检测方法 ut method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-examination of the shell plate material apply vertical wave detector technology ;the welds apply horizontal wave detector .4 探伤仪、探头及系统性能 ut mac

9、hine ,detector and system capability4.1 探伤仪ut machine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。1 set hanwei digital ultrasonic machine ; 1 set cts-26 type ultrasonic machine4.2 探头 detector钢板原材料复验选用2.5p20d 直探头，20 个20 pieces 2.5p20d detectors for plate materials re-examination.焊缝复验选用2.5p13x13k2 斜探头，20 个20

10、pieces 2.5p13x13k2 detectors for welds re-examination .4.3 系统综合性能 system capability符合jb4730-94 标准要求。 strictly comply with jb4730-94 standard .5 试块testing template5.1 钢板原材料复验选用15 号平底孔试块。apply no. 15 flat button template for shell plate .5.2 焊缝检测时，选用csk-1a，csk-a 试块。apply csk-1a，csk-a template for weld

11、s.6 耦合剂 coupling material使用洗洁精做耦合剂 ,检测焊缝应采用相同的耦合剂。we apply detergent as coupling material for plate/ welds test .7 钢板的超声波检测 ut for shell plates7.1 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。we shall test the plate by 5-time-wave technology and adjust the scan scale according to 1：20/t(t =plate thickness) pri

12、nciple.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。test the sensitivity :we record the loss of coupling ultrasonic energy（db）on the surfacebetween the sensitivity template and tested plate ,we choose 4db as general principle priorto the practical measurement.7.3 探头扫查方式：探头沿垂直于钢板压延方向，间距为100mm

13、的平行线扫查，在钢板剖口预定线两侧各,内应作扫查100%。detector scanning type: the detector shall be moved on parallel lines with 100mm intervaland vertical to the plate . 100% scanning will be needed within the 50mm range from bothsides of scheduled lines on plate section .7.4 钢板超声波检测时缺陷的测定 identify the defects for plate ut

14、7.4.1 在检测过程中，发现下列情况之一者，即作为缺陷。any of the followings shall be regarded as defects.a、 缺陷第一反射波（f1）波高大于或等于满刻度的50%，即f150%者。f150% full graduation (f1 refers the height of first reflecting wave)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b1100%，而f1/b150%者。b1100% full graduation & f1/b150% full graduati

15、on (b1 = height of first reflectingwave of bottom)c、当底面第一次反射波（b1）波高于满刻度的50%，即b150%者。b150% full graduation7.4.2 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。upon the identification of defects ,we continue scanning around the defects until f1/b150%full graduatio

16、n ,the distance of detector movement will be defect length; central point ofthe detector will be the defect center.8 焊缝的超声波检测ut for welds8.1 利用csk-ia 试块按深度1：1 调节扫描比例。we use csk-ia template for welds and adjust thescan scale by 1：1.8.2 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）identify the an

17、gle of incidence and distance ;carry out k-value test on template outsideof 2n range(n =distance of ultrasonic field )8.3 利用csk-a 试块制作距离-波幅曲线图或在荧光屏上直接绘出。we use csk-a template to work out interval-amplitude curve or shown the curve onfluorescent screen.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

18、，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。we shall revise loss of coupling ultrasonic energy and its attenuation, and write down the revision in the curve. we choose 4db as general principle prior to the practical measurement.the ut sensitivity shall not exceed the maximum sensitivity figure of assessment line.8.

19、5 探伤面和移动区 ut surface and movement range of detector8.5.1 探头移动区应小于1.25p the movement range of detector shall not exceed 1.25pp=2tk :p-跨距(span)，mmt-母材厚度(plate thickness)，mmk-探头k 值(k value of detector )8.5.2 采用直射法检测时，探头移动区应不小于0.75p。during application of direct-sending sonic wave8.6 灵敏度校验 verification o

20、f sensitivity现场探伤前应对距离-波幅曲线在csk-a 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。we shall verify the interval-wave amplitude curve on csk-a template(at lest 2 checkingpoints),and control the error within 2db.8.7 探头移动方式 moving type of detector8.8.1 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10150 的摆动。saw

21、tooth scan: each curve of advancing saw tooth shall not exceed the detector diameter,keep the detector vertical to the welds and swing it in range of 101508.8.2 斜平行扫查：在焊缝边缘使探头与焊缝中心线成一定夹角（10200），作斜平行扫查。parallel scan :we scan the welds in parallel lines by angle (10200 .) from the aparallelscanning li

22、ne to the central welds line .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。we swing the detector in forth-back ,left-right and horizontal direction to confirm thedefect location and identify the defect or false wave.8.9 焊缝超声波检测过程中缺陷的测定 identify the defect in ut8.9.1 缺陷定量：波幅位于定量线和定量线以上的缺陷

23、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。quantify the defects :we apply the half-height technology 6db for the defects exceeding orequal to the line designed .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。confirm the defect location :confirm the defects location in the whole welds and its section .9 缺陷的评定，返工，复探，

24、扩探assessment ,refusal ,re-test and test extending for the defects9.1 钢板缺陷的评定，返工，复探，扩探assessment ,refusal ,re-test and test extending for the defects of steel board . 9.1.1 jb4730-94级合格 jb4730-94 standard level is acceptable .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。if the tested parts ne

25、ed repair after assessment, we shall fill excess of set standard inthe triplicate form and send the forms to material engineer as feedback.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。after the repair ,the material engineer will inform the company to re-test the location undersame ut standard .9.1.4

26、 若发现超标缺陷，应加倍抽查.we shall increase the random check for defect for excess of set standard ,9.2 焊缝缺陷的评定、返工、复探。assessment, refusal,re-test for welds defects9.2.1 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。all the assessment for welds defects shall only follow the consigning standard, any d

27、efectsfor excess of set standard ( with triplicate form )will be sended to welding technician forrepair.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。if the ut is refused ,the welding technician shall inform the consigned company by refusalbill to re-test the welds by the same standard .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。during test10 报告与存档。report and file up10.1 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。all the product which pass nde will be reported i