1、無損檢測控制程序Nondestructive testing control program1 目的和適用范圍 為了保證壓力管道焊縫無損檢測工作的順利進行，有效地控制無損檢測工作質量，保證檢測結果的準確性，達到控制焊接質量目的，特制定本程序。 本程序適用于公司的無損檢測工作。2 相關文件 產品的監視和測量管理程序 監視和測量裝置控制程序3 職責3.1 試驗室是無損檢測的實施部門，負責對工業管道焊縫無損檢測工作。4 工作程序 無損檢測質量控制程序如附圖。4.1 人員要求4.1.1 從事無損檢測的(RT、UT、MT、PT)人員，應按鍋爐壓力容器無損檢測人員資格鑒定考核規則進行考核，取得合格資格后，

2、方可擔任相應的無損檢測工作。取得不同無損檢測方法的各技術等級人員，只能從事與該等級相應的無損檢測工作，并負相應的技術責任。無損檢測人員要有良好的身體素質，其視力必須滿足要求： a)校正視力不得低于1.0，并一年檢查一次； b)從事磁粉、滲透的檢測人員，不得有色盲、色弱； c)從事射線評片人員應能辨別距離為400mm的一組高為0.5mm、間距為0.5mm的印刷字母4.2 委托受理4.2.1 無損檢測實施前，由技術員向檢測單位遞交“無損檢測委托單”，必要時，附有技術資料(包括產品結構圖或檢測部位示意圖)，作為實施無損檢測的依據。 無損檢測委托單應包括的內容： a)工程名稱，設計壓力，工作介質，母材

3、規格，材質，工程量，工作介質，坡。形式，焊接方法，探傷方法，探傷比例，探傷標準、合格級別，要求完成日期等；b)焊縫部位示意圖：應給出要求探傷的工程單線圖并標注焊縫編號及施焊焊工號(允許附頁)； c)委托人、委托日期、接收人等。4.2.2 對填寫不符合規定的探傷委托單，檢測人員有權拒絕接收，并及時向委托人反饋信息。4.2.3 委托檢測的工件應經外觀質量檢查合格。4.3 設備材料管理4.3.1 壓力管道無損檢測工作所用設備必須是在檢定周期內的完好設備。4.3.2 X射線機、超聲波探傷儀等設備每臺應有專管人員，負責儀器的維護和保養。4.3.3 無損檢測人員在檢測設備使用前，負責對設備的性能參數和使用

4、條件進行校驗，以確保檢測結果的準確性和真實性。4.3.4 無損檢測材料由無損檢測室提出計劃，無損檢測責任工程師審核，物資管理部門負責采購4.3.5 無損檢測材料驗收入庫應對所購材料規格、型號、生產日期、數量等進行核實，膠片包裝不得擠壓、破損、起直波，探頭檢驗K值是否準確。4.3.6 材料的保管應有專人負責，并設專用庫房分類擺放，應保持室內溫濕度，膠片保管應干燥、陰涼、避光、遠離射線源。4.3.7 材料的領用應建立臺帳，根據工程量大小限額領料，膠片、著色劑等不得在專用庫房外存放。4.4 檢測實施4.4.1 檢測前，檢測人員根據與客戶簽訂的合同或委托要求，編制無損檢測工藝卡，工藝卡由具有相應檢測方

5、法的級人員編制，無損檢測責任師審批。4.4.2 檢測人員應依據檢測施工方案或工藝卡，做好設備、儀器、材料、工具及防護用品的準備和輔助檢測人員的配備，并負責就現場檢測條件(如試驗試件、水源、電源、通風、照明、梯架平臺等)及工序配合與業主、施工單位等聯系，確保檢測工作順利進行。4.4.3 無損檢測操作中應注意的問題： a)正確地選用儀器、設備和材料； b)現場操作最低要由初級資格人員擔任；c)操作人員要有高度的責任心和良好的心理狀態； d)環境滿足或采取措施后滿足無損檢測要求； e)焊縫外觀檢查合格； f)檢測人員應嚴格按檢測規程標準和探傷工藝進行操作； g)嚴格按委托單要求控制現場探傷比例，應按

6、每個焊工(當天)焊口(或焊接焊縫長度)抽查。4.4.4 現場拍好的底片由現場檢測人員與暗室洗片人員交接處理。4.4.5 已射線探傷的焊縫應在實物上打上定位標記或在布位圖上標識，射線探傷底片上應有產品(工程)標記、焊縫編號、年月日等標識，如返修片時，應有返修標識(R)；如進行擴探時底片上應加有擴探標識(K)。4.4.6 經探傷的焊縫應標注在焊縫編號圖(表)上，形成射線探傷布片圖(表)4.4.7 暗室洗片人員，應嚴格按規范化進行操作，并將合格底片交評定人員。4.4.8 由具有RT級(或以上)資格的探傷人員進行底片評定。4.4.9 對透視質量不合格的底片應及時補拍4.4.10 拍片質量的控制 a)拍

7、片人員要按照工件厚度、透照方式和器材條件等合理選擇射線源的能量； b)膠片質量及膠片的裁剪、裝片應符合要求； c)準確選用象質計，象質計的擺放要正確； d)片位圖、工件上的編號與底片編號，三者必須一致； e)底片上的工件編號、焊縫編號、定位標記和透照年、月、目等標志應清晰； f)透照方式、透照幾何參數的選擇應合理，透照操作(對x光機操作、曝光條件的選定等)應正確。4.5 膠片質量控制4.5.1 暗室操作應選用技術熟練、工作細心、質量意識強的人員承擔；4.5.2 已曝光的膠片要及時沖洗，特別是高溫、高濕季節；4.5.3 顯定影配方、顯定影時間及溫度控制應按膠片說明書推薦的方法進行；4.5.4 在

8、有條件的情況下，顯，定影液應用蒸餾水配制。沖洗用水水質要潔凈，不得受化學污染。、4.6 當出現不合格底片時，應根據情況分清拍片和洗片的責任，當出現嚴重不合格底片時，應分析原因并對責任人員進行處理。4.7 復探、擴探4.7.1 經探傷評定不合格的焊縫部位，探傷人員填寫返修通知單后，通知工程委托單位，以便立即返修。4.7.2 焊縫返修后，施工單位進行復探的書面委托，探傷人員應采用同樣的探傷方法和合格級別進行復探。4.7.3 經探傷不合格的焊口，應對該焊工所焊該焊縫進行補充探傷(擴探)，其數量應符合有關施工及驗收規范規定。4.8 探傷委托單、返修通知單、檢測報告等資料在傳送過程中無損檢測室資料員和項

9、目技術人員應認真做好登記簽證手續。4.9 檢測標識4.9.1 焊縫探傷后，在離焊縫50mm-100mm，標識相應探傷字樣“RT”或“UT”。4.9.2 每道焊口片號順序以收弧處為基點，以介質流向為基準，用右手螺旋法則確定，用記號筆在焊口上標識片號。4.9.3 焊縫射線透明膠片上，標識內容：產品編號、焊縫編號、部位編號、透照日期。4.9.4 標識由無損檢測人員完成，質檢員監督檢查。4.10 檢測報告4.10.1 檢測報告應由相應檢測方法的II級(或以上)人員評定，無損檢測責任師審核。4.10.2 無損檢測報告由無損檢測責任工程師審定簽發并加蓋無損檢測專用章，檢測報告一式三份，其中兩份由資料員發至

10、委托單位，一份存檔。4.10.3 報告責任人員(拍片、評片、審核等)應嚴格履行簽字(或蓋章)手續，簽字必須由本人執行，用圖章代替簽字時，必須由本人執行，責任人員應對簽字(蓋章)的有效性負責。4.10.4 無損檢測人員須在檢測結束后根據檢測記錄和工程區域劃分情況，及時作出檢測結論和填寫“檢測報告”。4.10.5 對要求提供電子版報告的單位，按業主要求提供，電子版檢測報告應與書面檢測報告一致。4.11 檢測環境控制4.11.1 雨、雪天氣且無保護措施時，須停止無損檢測工作。4.11.2 暗室環境應符合暗室處理的有關規定和要求： a)要有適當空間，室內器具布置恰當，操作方便； b)要完全遮光，出入安

11、全，有通風設施； c)室內應保持清潔； d)應使溫度、濕度保持在一定范圍內(相對濕度50一65%)。4.12 進行RT檢測工作時，現場要設置安全警示標志，并與有關人員作好協調和安全保障工作。4.13 無損檢測工作所需的條件如：臨時電源、作業空間、作業時間等，由施工單位負責配合解決。5 無損檢測質量控制流程圖無損檢測控制系統人員控制設備控制材料控制檢驗過程控制人員培訓人員資格身體健康設備檢定設備使用設備維修保養材料檢驗材料檢驗現場檢驗測暗室處理底片質量結果評定無損檢測報告報告審核控制環節控制點附圖：無損檢測質量控制流程圖 1 purpose and scope of application In

12、 order to ensure the smooth progress of pressure piping weld NDT work, effectively control the NDT work quality, ensure the accuracy of the test results, the purpose of welding quality control, formulates this program. This procedure applies to nondestructive testing work of the company. 2 the relev

13、ant documents "Product monitoring and measurement management procedure" "The monitoring and measuring device control procedures" 3 responsibilities 3.1 laboratory is the implementation of the nondestructive testing department, responsible for industrial piping weld NDT. 4 work pr

14、ocedures Nondestructive testing quality control program such as the appended drawings. 4.1 personnel requirements 4.4.1 engaged in non-destructive testing (RT, UT, MT, PT) personnel, should press the boiler pressure vessel NDT personnel qualification assessment rules for examination, after qualified

15、, may perform NDT work accordingly. Have different NDT methods of various technical level, can only work in accordingly with the level of nondestructive testing, and corresponding technical responsible. Nondestructive testing personnel should have good physical quality, the vision must meet the requ

16、irements: A) vision correction shall be not less than 1.0, and check once a year; B) personnel engaged in magnetic powder, penetrant testing, can not have color blindness, color blindness; C) personnel engaged in X-ray evaluation sheet should be able to identify a set of high distance is 400 mm to 0

17、.5 mm, spacing of 0.5 mm of printed letters. 4.2 entrusted to accept 2 before the implementation of nondestructive testing (NDT) methods, submitted by the technician to test unit "nondestructive testing orders", when necessary, with technical data (including product structure or test parts

18、 diagram), as the basis of the implementation of nondestructive testing. The content of the nondestructive testing orders should include: A) the name of the project, design pressure, working medium, material specification, material, quantity, working medium, the slope. Form, welding method, inspecti

19、on method, inspection, inspection standard, the level of qualified, finish date, etc.; B) weld parts diagram: should give requirements engineering single line diagram and number labeling weld inspection and weld Job number (allow sheet); C) the principal, entrust the date and recipient. 4.2.2 orders

20、 to fill in is not in conformity with the provisions of the testing methods and testing personnel shall have the right to refuse to receive, and timely feedback to the client. Holdings should entrust test artifacts from the appearance quality inspection qualified. 4.3 equipment material management 4

21、.3.1 pressure pipe nondestructive testing equipment must be used in the verification cycle of sound equipment. 4.3.2 X-ray machine, ultrasonic flaw detector devices such as each shall have charge of personnel, responsible for the equipment maintenance and maintenance. 4.3.3 nondestructive testing pe

22、rsonnel is testing equipment before use, be responsible for the p4.3.4 nondestructive testing materials by nondestructive measure plans, NDT engineer audit, material management department is responsible for the procurement. 4.3.5 NDT check incoming materials to the purchased material specification,

23、type, production date, quantity, verify, film packaging shall not squeeze, breakage, direct wave, probe test K values are accurate. 4.3.6 the material custody should be the specialist is responsible, and set aside special-purpose stock rooms classification put, should keep indoor temperature and hum

24、idity, film preservation should be light, cool, dry place, away from the radiation source. 4.3.7 materials of recipients shall establish accounting, according to the size limit of quantities acquisition, film, such as colouring agent shall not be stored in special warehouse outside. 4.4 test impleme

25、ntation 4.4.1 before testing, testing personnel according to the contract signed with the customer or entrust requirement, prepare NDT process CARDS, process card by level staffing has a corresponding detection methods, nondestructive testing responsibility division for approval. 4.4.2 testing perso

26、nnel should be on the basis of test construction plan or process card, completes the equipment, instruments, materials, tools, and the preparation of protective equipment and ancillary testing personnel equipped, and is responsible for on-site testing conditions (such as test specimen, water supply,

27、 power supply, ventilation, lighting, ladder, platform, etc.) cooperate with the owner and the process, construction units, such as contact, to ensure the inspection work smoothly. 4.4.3 nondestructive testing problems should be paid attention to in operation: A) properly chosen instrument, equipmen

28、t and materials; B) to primary qualified personnel as the lowest site operation; C) operating personnel should have a high sense of responsibility and good mental state; D) the environment after meet or take steps to meet the requirements of nondestructive testing; E) the weld appearance inspection

29、qualified; F) testing personnel should strictly according to standard test procedures and inspection process to operate; G) strict control according to the requirements of orders on-site inspection proportion, should press each welder (day) joint (or welding seam length) spot check. 4.4.4 live on go

30、od film by site inspection personnel and personnel handover process darkroom wash. 4.4.5 has X-ray flaw detection of weld shall be positioned on the physical mark or logo on the cloth bitmap, radiographic film on the product (engineering) tag, weld number, date, such as identification, such as repai

31、r, should repair logo (R); Such as expansion agent should be added on the negatives with expansion agent logo (K). 4.4.6 by detection of weld shall be marked on the weld number chart (table), radiographic cloth is formed (table). 4.4.7 darkroom wash personnel, should be strictly in accordance with t

32、he canonical operation, and deliver qualified negative evaluation personnel. 4.4.8 with RT level (or above) by qualified inspection personnel to conduct the negative. 4.4.9 on perspective of substandard film should be timely to fill. 4.4.10 shooting quality control A) filming personnel should accord

33、ing to the thickness of the workpiece, transillumination mode and equipment conditions, such as the rational selection of energy gamma ray source; B) the quality of film and film cutting, piece should comply with the requirements; C) accurately choose like quality meter, like a mass of put to correc

34、t; D) a bitmap, the number and plate number on the workpiece, the three must agree. E) film on the workpiece number, weld number, location markers, and through symbols such as year, month, should be clear; F) transillumination mode and transillumination should be reasonable, the selection of geometr

35、ic parameters of transillumination operation (for X-ray machine operation, selection of exposure conditions, etc.) should be correct. 4.5 the film quality control 4.5.1 dark room should choose skilled operation, work carefully, strong sense of quality of personnel; 4.5.2 has exposed films to timely

36、processing, especially the high temperature, high humidity season; 4.5.3 fixing formula, the fixing time and temperature control should be according to the film specification recommended method; 4.5.4 in the conditional case, show, fixing bath used distilled water preparation. Irrigation water to cl

37、ean, shall not be affected by the chemical pollution. , 4.6 when appear unqualified plate, distinguish the responsibility of the shooting and wash as the case may be, when severe unqualified negatives, reason should be analyzed and the responsible for processing. 4.7 the complex agent, expanding age

38、nt 4.7.1 the inspection unqualified parts welds, evaluation of inspection personnel to fill in the repair after notice, notify the project commissioned units, in order to repair immediately. 4.7.2 after weld repair, construction unit to carry on the test of the written entrustment, inspection person

39、nel should use the same level of testing methods and test. 4.7.3 via joint inspection is unqualified, should add to the welder is welding the weld inspection (expansion agent), the number should comply with the relevant rules and regulations of construction and acceptance. 4.8 inspection orders, rep

40、air notice, inspection report and other data in transmission process nondestructive measure the librarians and the project technical personnel should supervise the registration formalities. 4.9 test marks 4.9.1 weld inspection, from the weld 50 mm to 100 mm, identify the corresponding inspection &qu

41、ot;RT" or "UT". 4.9.2 each joint piece number order to are-receive place as the basis, the flow direction of medium to as a benchmark, with his right hand spiral rule to determine, with the marker on the joint identification number. 4.9.3 of radiographic transparent film, logo content

42、: product code, weld number, part number, date of transillumination. 4.9.4 logo done by nondestructive testing personnel, supervision and inspection of the qc inspectors. 4.10 test report 4.10.1 test report shall be issued by the corresponding detection method of class II (or above) personnel assess

43、ment, nondestructive testing responsibility audit. 4.10.2 nondestructive testing report issued by NDT to the examination and approval of duty engineer and build a special seal for nondestructive testing, test report in triplicate, two by the librarians to entrust unit, a copy of the file. 4.10.3 rep

44、ort duty personnel (shooting, evaluation, audit, etc.) shall strictly perform signature (or seal) procedure, signature must be carried out by himself, replace signature with stamp, will be implemented by oneself, responsible personnel should be responsible for the validity of the signature (seal). 4.10.4 nondestructive testing personnel should be at the end of the test according to the testing records and engineering division situation, timely detection in concl