焊缝超声波检验规程.doc

* Co.,Ltd.焊缝检验规程6Rev.:0Page:1 of 9Title: ULTRASONIC EXAMINATION PROCEDUREULTRASONIC EXAMINATION PROCEDURE超 声 波 检 验 工 艺 规 程 CONTROLLED 在控本 UNCONTROLLED 非在控本 COPY NO 副本编号：PREPARED BY 编制： DATE 日期：REVIEWED BY 审核： DATE 日期：APPROVED BY 批准： DATE 日期：更多免费资料下载请进：好好学习社区* Co.,Ltd.焊缝检验规程6Rev.:0Page:2 of 9Title: ULTRASONIC EXAMINATION PROCEDUREDEMONSTRATION CERTIFICATION I hereby certify that this procedure has been demonstrated on a test specimen with known defects to the satisfaction of the Authorized Inspector according to the ASME Code Section V, T-150 as required by Section Div.1. UW-53 and Appendix 12. Test Specimen No.: Demo. Report No.: NDE Level : AI: * Co.,Ltd.焊缝检验规程6Rev.:0Page:3 of 9Title: ULTRASONIC EXAMINATION PROCEDURE1. SCOPE OF APPLICATIONThis procedure is compiled in accordance with the requirements of ASME Code Section V and Section Division 1. 1.2 In accordance with this procedure a pulse-echo type of ultrasonic instrument shall be used for Code product examination. Single probe, angle beam scanning shall be the principal method, if necessary, straight beam scanning may also be used.1.3 This procedure is applicable for ultrasonic examination of butt-welded, full penetrated joint in wrought ( rolled, drawn, forged or extruded) material with thickness equal to or greater than 5/16in.(8mm) detecting, locating and evaluating the reflectors from the weld metal, heat affected zone and base metal adjacent the weld.1.4 Ultrasonic examination of single side welded partial penetrated welds and austenitic steel welds are not considered to be within the scope of this procedure.1.5 Unless other procedure has been approved and accepted that may specify particular requirements, ultrasonic examination relating to method, evaluation, and detailed technique and requirement shall be in accordance with this procedure.2. NDE PERSONNEL2.1 NDE personnel shall be qualified and certified according to *S Written Practice QCD-011 based on SNT TC-IA (Current Code Accepted Edition).3. GENERAL EXAMINATION REQUIREMENTS3.1 Examination coverage The volume shall be examined by moving the search 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.3.2 Speed of Search Unit MovementsThe speed of search unit movement for examination shall not exceed 6 in./sec (150mm/sec.)3.3 Recording LevelAll reflections from uncorrected areas having responses that exceed 50% of reference level shall be recorded. This record shall locate each area, the response level, the dimensions, the depth below the surface, and the classification.4. ULTRASONIC INSTRUMENT, SEARCH UNIT AND PARAMETERS4.1 Ultrasonic Instrument A pulse-echo type of ultrasonic instrument shall be used. The following instruments are recommended in examination.1.适用范围1.1本规程按ASME 第V卷和第第1分册要求编制。1.2按规程对规范产品的检查用脉冲反射式超声波探伤仪。以单斜探 头扫查为主要方法，必要时可辅以直探头扫查。1.3本规程适用于板厚8mm钢制压力 容器全焊透对接焊缝的超声检查(包括焊缝金属和热影响区)。1.4本规程不适用于单面焊部分焊透焊缝的检查，也不适用于奥氏体钢焊缝的的检查。1.5除非其他程序经批准、有关具体要求经认可，UT有关方法、评定、要求应按本规程。2.无损探伤人员2.1无损探伤人员应按本公司根据SNT-TC-IA(现行版)制定的“NDE人员培训、考试、资格鉴定和认证的实施细则”进行资格鉴定和认证。3.一般探伤要求3.1探测范围 应通过探头在探测面的移动，使焊缝全体积均受超声束扫查。探头的扫查路径应至少重叠探头横向宽度的10%3.2探头移动速度 探伤时，探头移动速度应不大于150mm/s。3.3记录水平 凡波高超过50% DAC基准线而未予返修的讯号均应记录在案。4.超声仪、探头和参数4.1 超声仪 应使用下列脉冲反射式超声仪：Instrument TypeManufactured by仪器型号制造单位CTS-26Shantou, ChinaCTS 26汕头超声仪器厂更多免费资料下载请进：好好学习社区* Co.,Ltd.焊缝检验规程6Rev.:0Page:4 of 9Title: ULTRASONIC EXAMINATION PROCEDURESearch Unit typeBeam Angle()FrequencyManufactured by2.5P 8x124502.5MHzShantou, China2.5P 8x125602.5MHzShantou, China2.5P 8x126302.5MHzShantou, China2.5P 8x126802.5MHzShantou, ChinaWall Thickness (mm)Beam Angle ()K Value (tg)8-25720-6303.0-2.0>25-46680-5602.5-1.5>46630-4502.0-1.0壁厚(mm)折射角()K 值 (tg)8-25720-6303.0-2.0>25-46680-5602.5-1.5>46630-4502.0-1.0探头折射角()频率制造单位2.5P 8x124502.5MHz汕头超声仪器厂2.5P 8x125602.5MHz汕头超声仪器厂2.5P 8x126302.5MHz汕头超声仪器厂2.5P 8x126802.5MHz汕头超声仪器厂4.2 Search Unit For straight beam, the diameter of transducer shall be 14mm-25mm. For angle beam, an angle shall be selected as appropriate for the configuration being examined. The following search units are recommended to be used in examination: The range of angle is recommended as following:4.3 Frequency Generally, the frequency of 2.5MHz shall be used. For the thinner plate, 5MHz may be used.4.4 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 calibrated screen point(s). The procedure for evaluating screen height linearity is provided in Appendix of ASME Code Sect. V Sub. A Article 5 and shall be performed at the beginning of each period of extended use (or every 3 months, whichever is less).4.5 Amplitude Control Linearity The ultrasonic instrument shall utilize an amplitude control accurate over its useful range to ±20% of the nominal amplitude ratio, to allow measurement of indications beyond the linear range of the vertical display on the screen. The procedure for evaluating amplitude control linearity is given in ASME Sect V. Art .5. Appendix and shall be performed at the beginning of each period of extended use(or every 3 months, whichever is less).4.6 Checking and Calibration of EquipmentThe proper functioning of the examination equipment shall be checked and the equipment shall be calibrated by the use of the calibration standard at the beginning and end of each examination., when examination personnel are changed, and at any time that malfunctioning is suspected as a minimum. If during any check it is determined that the testing equipment is not functioning properly, all of the product that has been tested since the last valid equipment calibration shall be reexamined.5. CALIBRATION5.1 Basic Calibration Block Configuration 4.2 探头 直探头直径应为1425mm.斜探头应根据被检工件厚度适当选用(参照下表)：探头折射角与被检壁厚关系：4.3 频率 通常应频率2.5MHz，对薄板，可采用5MHz 。4.4 屏高线性 超声应提供±5%满屏高的垂直线性(在20%至80%校正屏高的范围内)。 屏高线性的测评方法按ASME 第V卷A篇第5章附录，应在每一周期开始(或每3个月，取两者中时短者)测评一次。4.5 波幅控制线性 为能测量示波屏上超出垂直线性范围的信号，超声仪应有在有用范围内可精确到标称波幅比±20%的波幅控制器。评定波幅控制线性的方法，见ASME第V卷第5章附录。此评定应在每一延长使用周期开始时进行(或每3个月进行一次，取两者中较短的时间)。4.6 设备校验对探伤设备应使用校正试块于每次检查开始和结束时进行性能校验，当探伤人员更换时，或怀疑有故障时，也要校验。校验时发现探伤设备性能不佳时，所有产品均应重新检查(自设备上次有效校验算起)。5. 校正5.1 基本校正试块* Co.,Ltd.焊缝检验规程6Rev.:0Page:5 of 9Title: ULTRASONIC EXAMINATION PROCEDUREThickness of Weld(T)焊缝厚度(T)Thickness of Block (T)试块厚度(T)Hole Diameter孔径Notch Size切槽尺寸1 (25.4)3/4(19.05) or t3/32 (2.4)width = 1/8to1/4(3.26.4)>1-2(25.4 50.8)1-1/2 (38.1)or t1/8 (3.2)>2-4 (>50.8101.6)3 (76.2)or t3/16 (4.8)Depth= 2%T or 0.04 (1.0)>4-6(101.6127)5 (127)or t1/4 (6.4)Whichever is greater.>6-8 (127203.8)7 (77.8)or t5/16 (8.0)Into the base metal.>8-10 (203.2254)9 (228.6) or t3/8 (9.5)>10 (>254)t±1 (t+25.4)Note (1)Length = 2(50.8)(min.) The basic calibration reflectors shall be used to establish a primary reference response of the equipment. The basic calibration reflectors may be located either in the component material or in a basic calibration block. GENERATE NOTES:(a) Holes shall be drilled and reamed minimum of 3/2in. deep, essentially parallel to the examination surface.(b) alternatively, the block may be constructed as shown in ASME Code Section V, Article 4, Appendix J, Fig. J-10.(c) Curved surfaces: for curved surfaces, two curved blocks, one for each representative curvature; or two sets of calibration reflectors oriented 90 deg. from each other shall be used.(d) Notches may be provided as required.(e) 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±1/8in.NOTE:(1) For each increase in weld thickness of 2in (50.8mm)or fraction thereof over 10 in,(254mm), the hole diameter shall increase 1/16in.(1.6mm)5.2 Basic Calibration Block Material 5.2.1 Block Selection. 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. For calibration blocks for dissimilar metal welds, the material selection shall be based on the material 应使用能测定设备主要基准性能的基本校正反射体。这些反射体可设定在基本校正试块或试样中。图1 基本校正试块 in. (mm)说明：(a) 应是钻孔和铰孔，深度至少为3/2(38mm)，基本平行于探测面。(b) 试块也可按ASME 第V卷，第4章附录J，图J-10制作。(c) 曲面：对曲面应有两个曲面校正试块，各自具有所代表的曲率；两组互成900的校正反射体。(d) 切槽按需设定。(e) 孔径容许公差±1/32(0.8mm),切槽深容许公差+10%、-20%，沿厚度方向孔位公差±1/8in.(3.2mm)。注：厚度10in.(254mm以上)，厚度每增加2in(50.8mm)，孔径应增加1/16in.(1.6mm)5.2 基本校正试块材料5.2.1 试块材料选择 制作试块的材料应与被检材料中的一种具有相同的产品形式、材料规范或相当的P号组。探测异种金属焊缝时，所用校正试块应按进行探伤的焊缝一侧的材料。若探伤在焊缝两侧进行，则校正反射体应设在两种材料中。被检焊缝* Co.,Ltd.焊缝检验规程6Rev.:0Page:6 of 9Title: ULTRASONIC EXAMINATION PROCEDUREon 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 thicknesses are involved, the calibration block thickness shall be determined by the average thickness of the weld. 5.2.2 Clad . Where the component material is clad, the block shall be clad by the same welding procedure as the production part. Where the automatic method is impractical, deposition of clad shall be by the manual method. It is desirable to have component materials which have been clad before the drop outs or prolongations are removed.5.2.3 Heat Treatment. The calibration block shall receive at least the minimum tempering treatment required by the material specification for the type and grade, and also a postweld heat treatment of at least 2 hr, if the calibration block contains weld(s).5.2.4 Surface Finish. The finish on the surfaces of the block shall be representative of the surface finishes on the component.5.2.5 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.5.3 Calibration Reflectors5.3.1 Basic Calibration Reflectors The calibration reflectors are specified in Fig.15.3.2 Welds in Materials with Diameters 20 in. (508mm) and less. The basic calibration block shall be curved for materials with diameters 20 in. (508mm)and less. Except where otherwise stated in this procedure 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 6. SYSTEM CALIBRATION (GENERAL) 6.1 Angle Beam Calibration(Transversal wave) as applicable the calibration shall provide the following measurements:(a) sweep range calibration;(b) distance-amplitude correction(DAC);(C) position calibration;(d) echo amplitude measurement from the transverse drilled hole in the basic calibration block.6.2 Straight Beam Calibration The calibration shall provide the following measurements:(a) sweep range calibration;(b) distance-amplitude correction(DAC). 6.3 Calibration Confirmation Calibration shall be performed prior to use of the system in the thickness range under examination. 涉及到两种以上的壁厚时，校正试块厚度应按焊缝平均厚度确定。5.2.2 堆焊层 当部件材料有堆焊层时，试块也应有堆层，其堆焊层规程应与产品零件一样。若不能采用自动焊方法，则应用手工焊方法堆焊。最好是采用切除的或延长部分未除去堆焊的部件材料。5.2.3 热处理 校正试块应按材料牌号要求，至少作最低程度的回火处理。若校正试块中含有焊缝，则还需作至少2小时的焊后热处理。5.2.4 表面粗糙度试块表面粗糙度应代表工件表面粗糙度。5.2.5 试块质量。 校正试块材料应使用直探头作全面检查。在声束到达多种校正反射体的声路中。不得有超过底波反射的信号存在。5.3 校正反射体 5.3.1 基本校正反射体 校正反射体按图1规定。5.3.2 直径20in(508mm)的材料，基本试块应为曲面。除本规程另有说明外，一个单一曲面的基本校正试块，可用来校正表面曲率范围为0.91.5倍基本校正试块直径的检验。6. 系统校验6.1 斜探头校验(横波)应作下列测定：(a) 扫查范围校正(b) 距离-波幅校正(DAC)(C) 位置校正(d) 基本校正试块中横孔回波幅度的测定。6.2 直探头校验应作下列测定 (a) 扫查范围校正： (b) 距离-波幅校正(DAC)6.3 校验确认 使用仪器前，应按被检厚度范围进行校准。更多免费资料下载请进：好好学习社区* Co.,Ltd.焊缝检验规程6Rev.:0Page:7 of 9Title: ULTRASONIC EXAMINATION PROCEDURE6.3.1 Sweep Range Correction. 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 indications 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.6.3.2 DAC Correction If a point on the distance-amplitude correction (DAC)curve has decreased 20% or 2 dB of its amplitude, all date sheets since the last calibration or calibration check shall be marked void. An area covered by the voided data shall be reexamined. If any point of the distance amlitude correction (DAC) curve has increased more than 20% or 2 dB of its amplitude, all recorded indications 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. 7. EXAMINATION 7.1 Surface preparation 7.1.1 Base Metal The base metal on each side of the weld shall be free of weld spatter, surface irregularities, or foreign matter that might interfere with the examination. 7.1.2 Weld Metal Where the weld surface interferes with the examination, the weld shall be prepared as needed to permit examination. 7.2 Couplant The couplant used in UT examination should be as same as that used in calibration. The No. 20 motor oil or glycerin or paste(C.M.C) shall be recommended to use. 7.3 Scanning Requirements7.3.1 Angle Beam Scanning 7.3.1.1 Scanning for Reflect