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 a large 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 safety 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)
《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)
《射线检测安全防护管理制度》(SECCO)
< Safety Preservation Ma nageme nt Rules for Ray Test> (SECCO)
《压力容器无损检测工艺规程》(中石化十公司)
《压力管道无损检测工艺规范》(中石化十公司)
《压力容器质保手册》《压力管道质保手册》(中石化十公司)
Man ual> (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 < NDT Crew Quality Assessment Rules for Boiler Pressure Vessel> 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 filled 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 1. 3无损检测质量控制程序NDT Quality Control procedure 无损检测质量控制程序见表1 NDT Quality Control Procedure: See figure1 * RT拍片RT Film UT调整仪器UT Adjust In 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 doesn'c- omply with the sta ndard and affects the assessmer or exists some questi ons 暗室处理 Darkroom Treatme nt 初评 Primary Assessme nt 校准灵敏度 Sta ndard Sen sitivity 初探 Primary Test 实施磁探 Apply MT I 复探 Resume Test 观察分析 Observe & An alyze 复评 Resume Assessme nt PT预清洗 PT Pre-clea n 施渗透液 Apply Pen etra nt 清洗 Clean 显象 Fluorex 准备工作 Preparatio n MT配磁悬液 MT Mag netic Liquid 观察痕迹 Observe the Mark 1. 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型超声波探伤仪，磁粉检验采用CJE-2A型磁粉探 4 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 Process 2. 1渗透检测工艺 PT Process 2.1.1渗透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 PT 2.1.4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 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。The superabundancepenetrant should be wiped off with a cloth no depilation before removed, the n clea 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 the suitable 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 should 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 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. 2.1.8验收标准JB4730- 94 I级合格。 Acceptanee Standard JB473—94 Grade I Qualified 2.1.9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 measure and the materials for PT should be kept away from sun shining and firing. 2. 2磁粉检测工艺MT Process 2.2.1 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 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