1、无损检测施工技术方案1、总则 Ge neral上海赛科90万吨/年乙烯工程属中外合资的大型项目，由于工期要求紧， 参战单位多，现场安全、质量要求严格，为保证工程安全、高效、高质量交工特 编制此无损检测施工技术方案。 Shanghai SECCO 900ktay ethylene project is alarge joi nt ven ture project with a short con struct ion period and lot of con structi on institutes as well as the strict requirements of site saf
2、ety and quality. We make this Method Statement for NDT with intention to ensure the turn over in terms of safety, high efficie ncy and high quality.1. 1编制依据 Basis压力容器无损检测 (JB4730 94)( JB4730 94)无损探伤和检测实施管理办法 (SECCO)vlmpleme ntatio n & Man ageme nt Method of NDT (SECCO)辐射安全 (SECCO) (SECCO)射线检测安全防护管理制
3、度 (SECCO) (SECCO)压力容器无损检测工艺规程 (中石化十公司) (Compa ny No.10 of SINOPEC)压力管道无损检测工艺规范 (中石化十公司) (Compa ny No.10 of SINOPEC)压力容器质保手册 压力管道质保手册 (中石化十公司) (Compa ny No.10 of SINOPEC)1.2 无损检测人员要求 Requirements for NDT Crew无损检测人员应按照锅炉压力容器无损检测人员资格考核规则进行考核， 取得资格证书，方能承担与资格证书的种类和技术等级相适应的无损检测工作， 现场检测必须由I级或I级以上人员担任， 无证人员
4、不得上岗，检验报告填写与签发必须由U级或U级以上人员担任。NDT crew could assume the corresp onding NDT job only after they have bee n assessedand issued the certificates according to and only the grade I or above persons can shoulder the site in specti on which un authorized pers ons are forbidde n. The test report shall be fil
5、led and issued only by persons who are grade or above.射线检测工作人员必须取得射线工作人员证方能上岗，检测作业时严禁 个人单独上岗，射线检测工作人员在作业时必须穿戴防护用品和随身携带个人剂 量仪。The ray test personnel could start his work only after he was certificated and wear PPE with his in dividual meter is a must. Work by himself is forbidde n.1. 3无损检测质量控制程序 NDT
6、Quality Control procedure无损检测质量控制程序见表1NDT Quality Control Procedure: See figure1*RT拍片RT FilmUT调整仪器UT AdjustIn strume ntati on底片不符 合标准要 求、影响 评定或有 疑问重拍Refilm if the film doesnc- omply with the sta ndard and affects the assessmer or exists some questi ons暗室处理DarkroomTreatme nt初评PrimaryAssessme nt校准灵敏度S
7、ta ndardSen sitivity初探Primary Test实施磁探Apply MTI复探Resume Test观察分析Observe &An alyze复评ResumeAssessme ntPT预清洗PTPre-clea n施渗透液ApplyPen etra nt清洗Clean显象Fluorex准备工作Preparatio nMT配磁悬液MT Mag neticLiquid观察痕迹Observe the Mark1. 4无损检测设备 NDT Equipment射线检验采用理学 2505、3005,丹东2505、3005,东芝2705型X光机。超声波检验采用QKS- 958型超声波探伤
8、仪，磁粉检验采用 CJE-2A型磁粉探伤仪，渗透检验采用DPT 5型渗透探伤剂。LIXUE2505、3005QANDONG2505、 3005 and TOSHIBA 2705 X-ray machine shall be used for RT , QKS 958 ultrasonic inspection unit for UT, CJE 2A magnetic inspection unit for MT and DPT 5 pen etrate in spect ion unit for PT.2、无损检测工艺NDT Process2. 1渗透检测工艺PT Process2.1.1渗透
9、探伤采用溶剂去除型着色法探伤，使用溶剂去除型渗透液。渗透剂、 显象剂、清洗剂型号采用 DPT 5。对比试块为镀铬试块。PT adopts dye ing test method with dissolve nt pen etra nt wip ing the solve nt off and the type of penetrant, developer and cleaner is DPT 5 with the chrome-plating test block as the con trast test block.2.1.2渗透探伤前需应对表面及附近 25mm范围内进行打磨处理，不得有
10、污垢、 铁锈、锈蚀、焊渣、氧化皮、毛刺及保护层等妨碍显示的杂物。Polish the surface as well as the area ranged in 25mm before PT till there is no sun dries disturb ing visibility in terms of dirt, rust, weldi ng slag, oxside skin, burr and protective layers etc rema in ed.2.1.3渗透探伤前应对受检表面进行预清洗。Pre-clea n the tested surface before P
11、T2.1.4喷洒渗透剂时喷嘴距离受检表面宜为 300-400mm,渗透剂要完全润湿被检表面，在15 50 C的温度下，渗透时间不得少于10分钟，并在整个渗透过程中 始终保持润湿。 The suitable dista nee betwee n the no zzle and the tested surface should be 300-400mm whe n spay inq pen etra nt also the tested fur nace should be wetted completely. Under 15-50 C environment ,the penetrating
12、 time should no less than 10 minu tes and keep moist duri ng the whole pen etrati ng period .2.1.5去除多余渗透液时，应先用不脱毛的布擦掉多余渗透液，然后再用蘸有清 洗剂的布向同一方向擦拭，直到把多余渗透液全部去出，但应注意不要清洗过度， 同时也应防止清洗不足，清洗时不得用清洗剂直接喷洒在被检工件表面。 Thesuperabundancepenetrant should be wiped off with a cloth no depilation before removed, the n cle
13、a n along the same direct ion with a cloth dippi ng clea ner till all the superab undance pen etra nt is removed off. Avoid the excess of clea ning as well as the lack and forbid spay ing the clea ner directly onto the surface of tested work piece.2.1.6施加显象剂前应充分摇动显象剂，喷洒显象剂时，喷嘴距离被检表面宜为300- 400mm，喷洒方向
14、与被检表面夹角为 30-40度，显象剂喷洒应薄而均匀。结果的观察应在被检表面光照度大于 500lx的条件下进行。观察结束后应清除剩余显象剂以防腐蚀工件。 Shake the developer sufficiently before apply and thesuitable distance between the tested surface and the nozzle is 300-400mm, the angle of the spay ing direct ion and the tested surface is 30-40 degree also the developer s
15、hould be spayed thin and eve nly. Observatio n should be done un der the con diti ons of tested surface illumination more than 500lx and the developer should be removed immediately after that lest the work piece erode.2.1.7被检工件不允许有任何裂纹、白点、任何横向缺陷、任何长度大于 1.5mm的线性缺陷、单个尺寸大于或等于 4mm的圆形缺陷显示，在35mm x 100mm范
16、围内缺陷累积长度小于0.5mm,如发现超标缺陷时应做好记录，并清除缺陷，用 上述方法进行复验。 There should not be any default remained on the work piece in terms of flaw, point defaults, transverse defaults, linear defaults more than 1.5mm in len gth, circular defaults with the sin gle size = 4mm and the accumulated defaults length ranged in 35
17、mm x 100mm should less than 0.5mm .Any excess of the defaults should be recorded, clea ned and retested in terms of above men ti on ed.2.1.8验收标准JB4730- 94 I级合格。Acceptanee Standard JB473 94 Grade I Qualified2.1.9操作时要严禁火种和采取必要的通风措施，渗透探伤的材料应防止日晒、烘烤。Prohibit the kindling and adopt necessary ventilating
18、measure and the materials for PT should be kept away from sun shining and firing.2.2磁粉检测工艺 MT Process2.2.1一般要求 Genaral磁粉探伤仪和磁粉材料性质、质量应符合 JB4730- 94标准要求，被检工件表面应清洁、干燥、没有油污、铁锈、泥沙、氧化皮、棉纤维、涂层、焊剂和焊 接飞溅物。The property and quality of MT instrument and magnetic materials should up to the standard of JB4730 94
19、 also the tested work piece surface should be clean and out of smear, rust, mud & sand, oxide skin, cotton fibre,coat,solder as well the welding slag etc.2.2.2磁悬液配制 Confect Magnetism Liquid磁悬液由黑磁膏、水、分散剂配制，每挤出 100mm长磁膏加入1000ml水，磁悬液浓度为1020g/1，并加入一定数量的分散剂，若悬浮液薄层是连续并复 盖试件的全部，则认为存在足够的分散剂，否则应继续加入分散剂。 TheM
20、agnetism liquid shall be confected from the black magnetism paste, water and dispersant with each 100mm paste in length adding 1000ml water resulting in the liquid 1020c/1 in thickness ,then add certain dispersant till the liquid lamina is continuous and cover all the work piece only this the disper
21、sant can be deemed as sufficie nt, con trarily, add more .2.2.3灵敏度要求 Sensitive Requirement应使用A型灵敏度试片在每次探伤前及探伤结束后时进行校验，必须注意测量灵敏度时试片有槽一侧应紧贴被检表面。 Checkout before and after each testwith type A sensitivity test piece and notice that the sulcate side should cling to the tested surface whe n measuri ng th
22、e sen sitivity.2.2.4操作 Operation采用交流 AC 电磁 electromagnetism轭 yoke 连续 consecutive磁化 magnetization法，探头应紧贴被检工件表面，在施加磁化电流的同时施加磁悬液， 通电时间为1 -3S,为保证磁化效果应反复磁化两次。两次磁化方向应相互垂直， 为保证检测结果的准确性，磁极间距应为 200mm,交流电磁轭的提升力要达到44N，检测区域控制在两级连线两侧各 50mm范围内，磁化区域应保证至少25mm 的重叠。结果观察应在被检工件表面的光照度不小于 500lx的条件下进行，当不能判断显示的真伪时应进行重新检验或使
23、用其它检测方法进行校验。 检测过程中若发现操作失误或灵敏度不合要求，应对原检测部位进行重新检测。 Take themethod of con secutive magn etizati on by AC electromag netism yoke and the detector should cling to the tested work piece surface ,apply the magnetism liquid whilst appl ying the magn etizati on curre nt with the electrifyi ng time is 1 3S an
24、d perform the magnetization twice in order to ensure the best result .The directions of two magn etizati ons should be vertical to each other, and the dista nee of the magn epolar is 200mm. the lifti ng stre ngth should up to 44 N and the testi ng area is in side 50mm each side with 25mm overlap at
25、least. The result observation should be done under the conditions of tested surface illumination more than 500lx and recheck or take the other checkout method if you could not tell true or false. If there is some error operation or the sensitivity is not in compliance with the requirement, recheck t
26、he orig inal part.2.2.5评定 Assessment不允许有任何裂纹、白点、任何横向缺陷、任何长度大于 1.5mm的线性缺陷、单个尺寸大于或等于4mm的圆形缺陷显示，在35mmx 100mm范围内缺陷累积 长度小于0.5mm,如发现超标缺陷时应做好记录，并清除缺陷，用上述方法进行 复验。There should not be any default remained on the work piece in terms of flaw, white point, transverse defaults, linear defaults more than 1.5mm in
27、length, circular defaults with the sin gle size = 4mm and the accumulated defaults len gth ran ged in 35mm x 100mm should less than 0.5mm .Any excess of the defaults should be recorded, clea ned and retested in terms of above men ti on ed.2. 3射线检测工艺RT Process2.3.1一般要求 Ge neral焊缝及热影响区的表面质量应经外观检查合格， 表
28、面的不规则状态在底片上的影像应不掩盖焊缝中的缺陷或与之相混淆，否则应进行修补。 The surfacequality of weld and the heat-affected area should be qualified by appeara nce test and the reflect ion on the film of irregular surface should not cover the default in weld or confound each other, otherwise, remedy.2.3.2透照方法 Transillumination Method
29、2.3.2.1 双壁单影法 Double-wall Single-shadow MethodX射线拍片时，在满足几何不清晰度的条件下，管径 D 200mm时采用X 射线机紧贴管壁垂直法拍片。 When take photos by X-ray and the con dition is up to the geometric indistinctness requirement, the X-ray machine should cling to the pipe wall and take photo vertically while the pipe diameter D 200mm.丫源
30、拍片时，在满足几何不清晰度的条件下，采用丫源紧贴管壁的方法拍片。When take photos by 丫 source and the condition is up to the geometric indistinctness requirement, they source should cling to the pipe wall to take photos. 2.322 双影双壁法 Double-shadow Double-wall MethodD 89mm管道焊缝必须采用X射线或者硒-75 丫射线双壁双影透照，每道焊 缝相隔90度拍2张片子，橢圆开口间距应控制在 3- 10mn之间；w 76管道焊口，如果因障碍限制不能实现双壁双影透照时， 可采用垂直透照，透照次数不得小于2次。但双壁双影透照法和垂直透照法焦距必须满足几何不清晰度的要求。The transillumination method taken for the D 89mm pipe weld should be Double-shadow Double-wall method using X-ray or selenium-75 丫 ray .Everyweld should be taken 2 photos for each 90 degree and the oval
