ABS 14-2011 GUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS《船体焊缝的无损检测指南》.pdf

1、 Guide for Nondestructive Inspection of Hull Welds GUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS SEPTEMBER 2011 (Updated February 2014 see next page) American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 Copyright 2011 American Bureau of Shipping ABS Plaza

2、16855 Northchase Drive Houston, TX 77060 USA Updates February 2014 consolidation includes: February 2012 version plus Notice No. 2 February 2012 consolidation includes: January 2012 version plus Notice No. 1 and Corrigenda/Editorials January 2012 consolidation includes: September 2011 version plus C

3、orrigenda/Editorials ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2011 iii Foreword Foreword This Guide is the fourth edition of the Guide for Nondestructive Inspection of Hull Welds, which was originally published in 1975 and subsequently updated in 1986 and 2002 (the second and third edit

4、ions). This revision aims to introduce further details of inspection criteria and additional inspection techniques, which are considered as being widely recognized by the industry as a reliable means of inspection of structure members and their welds during the construction of surface vessels and ot

5、her related marine and offshore structures. It is intended that this Guide for test procedures and criteria is to be published as a Guide, rather than Rules, in order to collect more feedback from industry during its use and be able to reflect this feedback back into the Guide in a timely manner. Up

6、on completion of this further calibration period, the Guide is to be published as the Rules for Nondestructive Inspection of Hull Welds. This Guide becomes effective on the first day of the month of publication. Users are advised to check periodically on the ABS website www.eagle.org to verify that

7、this version of this Guide is the most current. We welcome your feedback. Comments or suggestions can be sent electronically by email to rsdeagle.org. iv ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2011 Table of Contents GUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS CONTENTS SECTION 1

8、General 1 1 Preparation for Inspection . 1 1.1 Weld Surface Appearance . 1 1.3 Visual Inspection of Welds . 1 1.5 Inspection for Delayed (Hydrogen Induced) Cracking . 1 3 Methods of Inspection . 2 5 Personnel 2 5.1 NDT Trainee 2 5.3 NDT Level I 3 5.5 NDT Level II . 3 5.7 NDT Level III 3 7 NDT Proced

9、ures and Techniques 4 9 Acceptance Criteria . 4 11 Documentation 4 13 References of Qualification/Certification Programs 4 15 Nondestructive Testing Terminology 4 SECTION 2 Radiographic Inspection 5 1 General . 5 3 Surface Condition . 5 3.1 General 5 3.3 Cause for Rejection . 5 5 Radiographic Proced

10、ure . 5 5.1 Personnel 5 5.3 Technique 5 5.5 Film Identification . 6 5.7 Radiography Quality Level . 6 5.9 Image Quality Indicator (IQI) 8 5.11 Radiographic Density . 11 5.13 Radiographic Film Quality 12 5.15 Radiographic Film Interpretation 12 7 Storage of Radiographs 12 7.1 General 12 7.3 Temperatu

11、re and Humidity Control 12 7.5 Documentation and Filing System . 12 9 Report . 13 ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2011 v 11 Digital Imaging Systems . 13 11.1 General 13 11.3 Procedure and Report . 13 11.5 Record . 14 13 Extent of Radiographic Inspection 14 13.1 General 14 13.3

12、Surface Vessels 14 13.5 Other Marine and Offshore Structures 14 15 Location of Radiographic Inspection . 15 15.1 General 15 15.3 Surface Vessels 15 15.5 Other Marine and Offshore Structures 15 17 Acceptance Criteria for Radiographic Inspection . 15 17.1 Applicability . 15 19 Treatment of Welds with

13、Non-conforming Indications 15 19.1 General 15 19.3 Extent of Indication at One Location 15 19.5 Extent of Indication at the End of a Radiograph 15 19.7 Additional Inspection . 16 21 References 16 TABLE 1 Material and Inspection Method 6 TABLE 2 Geometric Unsharpness Ug7 TABLE 3 Hole-type IQI Selecti

14、on . 9 TABLE 4 Wire IQI Selection . 9 TABLE 5 ASTM Wire IQI Designation, Wire Diameter and Wire Identity . 10 TABLE 6 ISO Wire IQI Designation, Wire Diameter and Wire Identity . 10 FIGURE 1 Geometric Unsharpness . 8 SECTION 3 Ultrasonic Inspection . 17 1 General . 17 3 Ultrasonic Procedure 17 3.1 Pe

15、rsonnel 17 3.3 Technique 17 3.5 Calibration Blocks 18 3.7 Ultrasonic Equipment 18 3.9 Calibration for Examination . 20 3.11 Weld Inspection . 21 3.13 Ultrasonic Inspection Reports 22 5 Extent of Ultrasonic Inspection . 23 5.1 Checkpoints . 23 5.3 Ship-Type Vessels 23 5.5 Other Marine and Offshore St

16、ructures 23 vi ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2011 7 Location of Ultrasonic Inspection 23 7.1 General 23 9 Acceptance Criteria for Ultrasonic Inspection . 24 9.1 Applicability 24 11 Treatment of Welds with Non-conforming Indications 24 11.1 General 24 11.3 Discontinuity Extent

17、 . 24 13 Ultrasonic Inspection of Full Penetration Tee and Corner Joints . 24 15 References 25 FIGURE 1A IIW Reference Block Type US-1 . 26 FIGURE 1B Type MAB Miniature Angle-Beam Reference Block . 27 FIGURE 1C Type DSC Distance and Sensitivity Reference Block . 27 FIGURE 1D IIW Type RC Reference Bl

18、ock 28 FIGURE 2 Basic Calibration Block . 28 FIGURE 3 Scanning Procedure for Welds not Ground Flush 29 FIGURE 4 Typical Ultrasonic Report Form 30 SECTION 4 Liquid Penetrant . 31 1 General . 31 3 Surface Condition . 31 3.1 General 31 3.3 Cause for Rejection . 31 5 Liquid Penetrant Procedure 31 5.1 Ge

19、neral 31 5.3 Personnel 31 5.5 Technique 31 5.7 Procedure 32 7 Examination 32 7.1 General 32 7.3 Final Examination 32 7.5 Visible Penetrant Examination . 32 7.7 Fluorescent Penetrant Examination . 33 9 Extent of Liquid Penetrant Inspection . 33 11 Acceptance Criteria for Liquid Penetrant Inspection 3

20、3 13 Treatment of Welds with Non-conforming Indications 33 13.1 General 33 15 Post-Cleaning . 33 17 References 34 SECTION 5 Magnetic Particle 35 1 General . 35 3 Surface Condition . 35 3.1 General 35 3.3 Cause for Rejection . 35 ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2011 vii 5 Magnet

21、ic Particle Procedure . 35 5.1 General 35 5.3 Personnel 35 5.5 Technique 35 5.7 Equipment . 36 5.9 Visible Particle Inspection 37 5.11 Fluorescent Particle Inspection . 37 7 Extent of Magnetic Particle Inspection 38 9 Acceptance Criteria for Magnetic Particle Inspection . 38 11 Treatment of Welds wi

22、th Non-conforming Indications 38 11.1 General 38 13 Demagnetization . 38 15 Post-cleaning 38 17 References 38 SECTION 6 Alternating Current Field Measurement Technique (ACFMT) 39 1 General . 39 3 Surface Condition . 39 5 ACFMT Testing Procedure . 39 5.1 Personnel 39 7 Technique . 39 7.1 General 39 7

23、.3 Calibration . 39 9 Capability and Performance Check of the Equipment 40 9.1 Instrument Settings . 40 9.3 Equipment Performance Check . 40 9.5 Flaw Sizing 41 9.7 Instrument and Probe Settings Check . 41 11 Extent of ACFMT Inspection . 41 13 References 41 FIGURE 1 Example Bx and Bz Traces as a Prob

24、e Passes Over a Crack . 42 SECTION 7 Eddy Current (EC) Inspection . 43 1 General . 43 3 Surface Condition . 43 5 EC Testing Procedure . 43 5.1 Personnel 43 7 Technique . 43 7.1 General 43 7.3 Calibration . 43 9 EC Application 44 11 Extent of EC Inspection 44 13 References 44 viii ABSGUIDE FOR NONDES

25、TRUCTIVE INSPECTION OF HULL WELDS .2011 SECTION 8 Acceptance Criteria for Hull Welds . 45 1 General . 45 3 Applicable Criteria . 45 3.1 Surface Vessels Class A Criteria 45 3.3 Surface Vessels Class B Criteria 45 3.5 Other Marine and Offshore Structures . 45 5 Evaluation from Visual Inspection (VT),

26、Magnetic Inspection (MT) and Liquid Penetrant Inspection (PT) . 45 5.1 Shape 45 5.3 Flaw Indications (MT) 45 5.5 Evaluation from Surface Inspection . 46 7 Evaluation from Radiographic Inspection . 47 7.1 Cracks . 47 7.3 Incomplete Fusion or Incomplete Penetration . 47 7.5 Slag . 47 7.7 Porosity 47 7

27、.9 Multiple Indications 48 7.11 Undercut 48 9 Evaluation from Ultrasonic Inspection 48 9.1 Class A 48 9.3 Class B 49 FIGURE 1 Class A and Class B Incomplete Fusion and Incomplete Penetration Acceptable Length 50 FIGURE 2 Class A Slag Acceptable Length 51 FIGURE 3 Class B Slag Acceptable Length 52 FI

28、GURE 4 Class A and Class B Porosity Chart for 6.2 mm (0.25 in.) Thick Material 54 FIGURE 5 Class A and Class B Porosity Chart for 9.5 mm (0.375 in.) Thick Material 55 FIGURE 6 Class A and Class B Porosity Chart for 12.5 mm (0.5 in.) Thick Material 56 FIGURE 7 Class A and Class B Porosity Chart for 1

29、9.0 mm (0.75 in.) Thick Material 57 FIGURE 8 Class A and Class B Porosity Chart for 25 mm (1.0 in.) Thick Material . 58 FIGURE 9 Class A and Class B Porosity Chart for 38.0 mm (1.5 in.) Thick Material . 59 FIGURE 10 Class A and Class B Porosity Chart for 50 mm (2.0 in.) Thick Material . 60 FIGURE 11

30、 Class A Maximum Acceptable Lengths for Ultrasonic Flaw Indications Greater than DRL . 61 FIGURE 12 Class B Maximum Acceptable Lengths for Ultrasonic Flaw Indications Greater than DRL . 62 ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2011 ix APPENDIX 1 Guidance for Radiographic (RT) and Ult

31、rasonic (UT) Inspection of Hull Welds 64 1 Purpose of ABS Guide for Nondestructive Inspection of Hull Welds 64 3 Choice of Nondestructive Testing (NDT) Method . 64 5 Extent and Location of RT or UT 65 APPENDIX 2 Guidance for Ultrasonic Inspection 67 1 Ultrasonic Inspection of Full Penetration Tee an

32、d Corner Welds . 67 1.1 General 67 1.3 Inspection of Plate Prior to Welding 67 1.5 Ultrasonic Testing Procedure After Welding 67 1.7 Plate Discontinuities Detected After Welding 67 1.9 Acceptance Criteria . 67 1.11 Alternate Acceptance Criteria 68 1.13 Applicability of Acceptance Criteria . 68 3 Ult

33、rasonic Inspection of Welds in Thin Plate Less Than 8 mm 68 3.1 Selection of Probe Dimensions . 68 FIGURE 1 Ultrasonic Inspection of Tee and Corner Welds . 69 FIGURE 2 Near Zone Positions for 12.5 mm Diameter Element and 6.4 mm Diameter Element Probes 69 FIGURE 3 Nearest Proximity Restrictions with

34、Large Probe Dimensions . 69 FIGURE 4 Probe Beam Pressure Maps Normalized to the 6.4 mm Diameter Element . 70 FIGURE 5 Probe Beam Surface Pressure Maps . 70 APPENDIX 3 Guidance for Monitoring Underwater Inspections 71 1 General . 71 1.1 Visual Inspection . 71 1.3 Magnetic Particle Testing (MT) 71 1.5

35、 Alternative and Supplementary NDT Methods 72 1.7 Ultrasonic Thickness Gauging . 72 1.9 Reporting . 72 FIGURE 1 Checklist for Underwater Inspection . 73 FIGURE 2 Preplanning Checklist . 74 FIGURE 3 Visual Inspection . 75 FIGURE 4 Magnetic Particle Testing (MT) . 76 FIGURE 5 Ultrasonic Thickness Gaug

36、ing 77 FIGURE 6 Reporting Requirements . 78 x ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2011 APPENDIX 4 Guidance Criteria for Nondestructive Tests Not Required by ABS . 79 1 General . 79 APPENDIX 5 Inspection of Hot-dip Galvanizing 80 ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS

37、.2011 1 Section 1: General SECTION 1 General 1 Preparation for Inspection (1 September 2011) 1.1 Weld Surface Appearance Welding in hull construction is to comply with the requirements of Section 2-4-1 “Hull Construction” of the ABS Rules for Materials and Welding (Part 2) and IACS Recommendation No

38、. 47 “Shipbuilding and Repair Quality Standard”. Methods used for preparing and cleaning welds and nondestructive test procedures are to be to the satisfaction of the Surveyor. Slag shall be removed from all completed welds. All welds and adjacent base metal shall be cleaned by wire brushing or by a

39、ny other suitable means prior to inspection. Surface conditions that prevent proper interpretation may be cause for rejection of the weld area of interest. 1.3 Visual Inspection of Welds Welds are to be visually inspected to the satisfaction of the Surveyor. Visual inspection acceptance criteria are

40、 contained in Section 8 of this Guide. Visual inspections of welds may begin immediately after the completed welds have cooled to ambient temperature. However, delayed cracking is a concern for extra high-strength steels, 415 N/mm2(42 kgf/mm2, 60,000 psi) yield strength or greater. When welding thes

41、e high-strength steels, the final visual inspection shall be performed not less than 48 hours after completion of the weld and removal of preheat. Refer to 1/1.5 below for requirements for delayed cracking inspection. 1.5 Inspection for Delayed (Hydrogen Induced) Cracking 1.5.1 Time of Inspection No

42、ndestructive testing of weldments in steels of 415 N/mm2(42 kgf/mm2, 60,000 psi) yield strength or greater is to be conducted at a suitable interval after welds have been completed and cooled to ambient temperature. The following guidance of interval is to be used, unless specially approved otherwis

43、e: Minimum 48 hours of interval time for steels of 415 MPa (42 kgf/mm2, 60,000 psi) yield strength or greater but less than 620 MPa (63 kgf/mm2, 90,000 psi) yield strength. Minimum 72 hours of interval time for steel greater than or equal to 620 MPa (63 kgf/mm2, 90,000 psi) yield strength. At the di

44、scretion of the Surveyor, a longer interval and/or additional random inspection at a later period may be required. The 72 hour interval may be reduced to 48 hours for radiography testing (RT) or ultrasonic testing (UT) inspection, provided a complete visual and random MT or PT inspection to the sati

45、sfaction of the Surveyor is conducted 72 hours after welds have been completed and cooled to ambient temperature. 1.5.2 Delayed Cracking Occurrences When delayed cracking is encountered in production, previously completed welds are to be re-inspected for delayed cracking to the satisfaction of the S

46、urveyor. At the discretion of the Surveyor, re-qualification of procedures or additional production control procedures may be required for being free of delayed cracking in that production welds. Section 1 General 2 ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2011 3 Methods of Inspection (

47、1 February 2012) Inspection of welded joints is to be carried out by approved nondestructive test methods, such as visual inspection (VT), radiography (RT), ultrasonic (UT), magnetic particle (MT), liquid penetrant (PT), etc A plan for nondestructive testing is to be submitted. Radiographic or ultra

48、sonic inspection, or both, is to be used when the overall soundness of the weld cross section is to be evaluated. Magnetic-particle or liquid penetrant inspection or other approved method is to be used when investigating the outer surface of welds or may be used as a check of intermediate weld passe

49、s such as root passes and also to check back-gouged joints prior to depositing subsequent passes. Surface inspection of important tee or corner joints in critical locations, using an approved magnetic particle or liquid penetrant method, is to be conducted to the satisfaction of the Surveyor. Where a method (such as radiographic or ultrasonic) is selected as the primary nondestructive method of inspection, the acceptance standards of that method govern. However, if additional inspection by any method should indicate the presence of defects that could jeopardize the