ABS 14-2017 GUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS.pdf

1、 Guide for Nondestructive Inspection of Hull Welds GUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS JULY 2017 American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 2017 American Bureau of Shipping. All rights reserved. ABS Plaza 16855 Northchase Drive Houston,

2、 TX 77060 USA Foreword Foreword (1 July 2017) This Guide is the fifth 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 editions). The 2011 revision introduced further details of in

3、spection 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 other related marine and offshore structures. The 2017 edition

4、 incorporates a new Section 4 with criteria for Phased Array Ultrasonic Testing (PAUT). PAUT is currently in use in shipyards and offshore structures across the world, as it decreases inspection time. PAUT can replace UT in many applications. Additionally, Sections 1 and 3 have been updated to incor

5、porate aspects of Section 4. 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. Upon completion o

6、f 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 this version of

7、 this Guide is the most current. We welcome your feedback. Comments or suggestions can be sent electronically by email to rsdeagle.org. ii ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2017 Table of Contents GUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS CONTENTS SECTION 1 General 1 1 Pre

8、paration 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 3 5.3 NDT Level I . 3 5.5 NDT Level II 3 5.7 NDT Level III . 4 7 NDT Procedures and Techni

9、ques 4 9 Acceptance Criteria . 4 11 Documentation 4 13 References of Qualification/Certification Standards and Recommended Practices/Guidelines 5 15 Nondestructive Testing Terminology 5 SECTION 2 Radiographic Inspection . 6 1 General . 6 3 Surface Condition . 6 3.1 General 6 3.3 Cause for Rejection

10、. 6 5 Radiographic Procedure . 6 5.1 Personnel 6 5.3 Technique 6 5.5 Film Identification 7 5.7 Radiography Quality Level 7 5.9 Image Quality Indicator (IQI) . 9 5.11 Radiographic Density 12 5.13 Radiographic Film Quality . 13 5.15 Radiographic Film Interpretation . 13 7 Storage of Radiographs 13 7.1

11、 General 13 7.3 Temperature and Humidity Control . 13 7.5 Documentation and Filing System . 13 ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2017 iii 9 Report . 14 11 Digital Imaging Systems . 14 11.1 General 14 11.3 Procedure and Report . 14 11.5 Record . 15 13 Extent of Radiographic Inspec

12、tion 15 13.1 General 15 13.3 Surface Vessels . 15 13.5 Other Marine and Offshore Structures . 15 15 Location of Radiographic Inspection . 16 15.1 General 16 15.3 Surface Vessels . 16 15.5 Other Marine and Offshore Structures . 16 17 Acceptance Criteria for Radiographic Inspection 16 17.1 Applicabili

13、ty 16 19 Treatment of Welds with Non-conforming Indications 16 19.1 General 16 19.3 Extent of Indication at One Location 16 19.5 Extent of Indication at the End of a Radiograph 16 19.7 Additional Inspection 17 21 References 17 TABLE 1 Material and Inspection Method 7 TABLE 2 Geometric Unsharpness Ug

14、8 TABLE 3 Hole-type IQI Selection . 10 TABLE 4 Wire IQI Selection . 10 TABLE 5 ASTM Wire IQI Designation, Wire Diameter and Wire Identity . 11 TABLE 6 ISO Wire IQI Designation, Wire Diameter and Wire Identity . 11 FIGURE 1 Geometric Unsharpness . 9 SECTION 3 Ultrasonic Inspection . 18 1 General . 18

15、 3 Ultrasonic Procedure 18 3.1 Personnel 18 3.3 Technique 19 3.5 Calibration Blocks 19 3.7 Ultrasonic Equipment . 19 3.9 Calibration for Examination 21 3.11 Weld Inspection . 22 3.13 Ultrasonic Inspection Reports 23 5 Extent of Ultrasonic Inspection . 24 5.1 Checkpoints . 24 5.3 Ship-Type Vessels .

16、24 5.5 Other Marine and Offshore Structures . 24 iv ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2017 7 Location of Ultrasonic Inspection 25 7.1 General 25 9 Acceptance Criteria for Ultrasonic Inspection . 25 9.1 Applicability . 25 11 Treatment of Welds with Non-conforming Indications 25 11

17、.1 General 25 11.3 Discontinuity Extent . 25 13 Ultrasonic Inspection of Full Penetration Tee and Corner Joints . 26 15 References 26 FIGURE 1A IIW Reference Block Type US-1 . 28 FIGURE 1B Type MAB Miniature Angle-Beam Reference Block . 29 FIGURE 1C Type DSC Distance and Sensitivity Reference Block

18、. 29 FIGURE 1D IIW Type RC Reference Block 30 FIGURE 2 Basic Calibration Block . 30 FIGURE 3 Scanning Procedure for Welds not Ground Flush 31 FIGURE 4 Typical Ultrasonic Report Form 32 SECTION 4 Phased Array Ultrasonic Inspection . 33 1 General . 33 3 Phased Array Ultrasonic Testing Procedure . 33 3

19、.1 Technique 33 3.3 Terminology . 33 3.5 Personnel 34 3.7 Calibration Blocks 34 3.9 Phased Array Ultrasonic Equipment 34 3.11 Calibration for Examination . 35 3.13 Phased Array Procedure Requirements 36 3.15 Demonstration Blocks . 39 3.17 Phased Array Inspection Reports 39 3.19 Permanent Record 40 5

20、 Location and Extent of PAUT . 40 7 Sizing Techniques . 40 9 Acceptance Criteria for PAUT . 40 11 References 40 SECTION 5 Liquid Penetrant . 42 1 General . 42 3 Surface Condition . 42 3.1 General 42 3.3 Cause for Rejection . 42 5 Liquid Penetrant Procedure 42 5.1 General 42 5.3 Personnel 42 5.5 Tech

21、nique 42 5.7 Procedure 43 ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2017 v 7 Examination 43 7.1 General 43 7.3 Final Examination 43 7.5 Visible Penetrant Examination . 43 7.7 Fluorescent Penetrant Examination . 44 9 Extent of Liquid Penetrant Inspection . 44 11 Acceptance Criteria for Li

22、quid Penetrant Inspection 44 13 Treatment of Welds with Non-conforming Indications 44 13.1 General 44 15 Post-Cleaning . 44 17 References 45 SECTION 6 Magnetic Particle 46 1 General . 46 3 Surface Condition . 46 3.1 General 46 3.3 Cause for Rejection . 46 5 Magnetic Particle Procedure . 46 5.1 Gener

23、al 46 5.3 Personnel 46 5.5 Technique 46 5.7 Equipment . 47 5.9 Visible Particle Inspection 48 5.11 Fluorescent Particle Inspection 48 7 Extent of Magnetic Particle Inspection 49 9 Acceptance Criteria for Magnetic Particle Inspection . 49 11 Treatment of Welds with Non-conforming Indications 49 11.1

24、General 49 13 Demagnetization . 49 15 Post-cleaning 49 17 References 49 SECTION 7 Alternating Current Field Measurement Technique (ACFMT) 50 1 General . 50 3 Surface Condition . 50 5 ACFMT Testing Procedure . 50 5.1 Personnel 50 7 Technique . 50 7.1 General 50 7.3 Calibration . 50 9 Capability and P

25、erformance Check of the Equipment 51 9.1 Instrument Settings 51 9.3 Equipment Performance Check . 51 9.5 Flaw Sizing 52 9.7 Instrument and Probe Settings Check . 52 vi ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2017 11 Extent of ACFMT Inspection . 52 13 References 52 FIGURE 1 Example Bx a

26、nd Bz Traces as a Probe Passes Over a Crack . 53 SECTION 8 Eddy Current (EC) Inspection . 54 1 General . 54 3 Surface Condition . 54 5 EC Testing Procedure . 54 5.1 Personnel 54 7 Technique . 54 7.1 General 54 7.3 Calibration . 54 9 EC Application 55 11 Extent of EC Inspection 55 13 References 55 SE

27、CTION 9 Acceptance Criteria for Hull Welds. 56 1 General . 56 3 Applicable Criteria . 56 3.1 Surface Vessels Class A Criteria 56 3.3 Surface Vessels Class B Criteria 56 3.5 Other Marine and Offshore Structures 56 5 Evaluation from Visual Inspection (VT), Magnetic Inspection (MT) and Liquid Penetrant

28、 Inspection (PT) . 56 5.1 Shape 56 5.3 Flaw Indications (MT) 56 5.5 Evaluation from Surface Inspection . 57 7 Evaluation from Radiographic Inspection . 58 7.1 Cracks . 58 7.3 Incomplete Fusion or Incomplete Penetration . 58 7.5 Slag . 58 7.7 Porosity . 58 7.9 Multiple Indications 59 7.11 Undercut 59

29、 9 Evaluation from Ultrasonic Inspection 59 9.1 Class A 59 9.3 Class B 60 FIGURE 1 Class A and Class B Incomplete Fusion and Incomplete Penetration Acceptable Length 61 FIGURE 2 Class A Slag Acceptable Length 62 FIGURE 3 Class B Slag Acceptable Length 63 FIGURE 4 Class A and Class B Porosity Chart f

30、or 6.2 mm (0.25 in.) Thick Material 65 ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2017 vii FIGURE 5 Class A and Class B Porosity Chart for 9.5 mm (0.375 in.) Thick Material 66 FIGURE 6 Class A and Class B Porosity Chart for 12.5 mm (0.5 in.) Thick Material 67 FIGURE 7 Class A and Class B

31、Porosity Chart for 19.0 mm (0.75 in.) Thick Material 68 FIGURE 8 Class A and Class B Porosity Chart for 25 mm (1.0 in.) Thick Material 69 FIGURE 9 Class A and Class B Porosity Chart for 38.0 mm (1.5 in.) Thick Material 70 FIGURE 10 Class A and Class B Porosity Chart for 50 mm (2.0 in.) Thick Materia

32、l 71 FIGURE 11 Class A Maximum Acceptable Lengths for Ultrasonic Flaw Indications Greater than DRL . 72 FIGURE 12 Class B Maximum Acceptable Lengths for Ultrasonic Flaw Indications Greater than DRL . 73 APPENDIX 1 Guidance for Radiographic (RT) and Ultrasonic (UT) Inspection of Hull Welds . 75 1 Pur

33、pose of ABS Guide for Nondestructive Inspection of Hull Welds 75 3 Choice of Nondestructive Testing (NDT) Method . 75 5 Extent and Location of RT or UT 76 APPENDIX 2 Guidance for Ultrasonic Inspection 78 1 Ultrasonic Inspection of Full Penetration Tee and Corner Welds . 78 1.1 General 78 1.3 Inspect

34、ion of Plate Prior to Welding . 78 1.5 Ultrasonic Testing Procedure After Welding 78 1.7 Plate Discontinuities Detected After Welding . 78 1.9 Acceptance Criteria . 78 1.11 Alternate Acceptance Criteria 79 1.13 Applicability of Acceptance Criteria 79 3 Ultrasonic Inspection of Welds in Thin Plate Le

35、ss Than 8 mm (5/16 in.) 79 3.1 Selection of Probe Dimensions 79 FIGURE 1 Ultrasonic Inspection of Tee and Corner Welds . 80 FIGURE 2 Near Zone Positions for 12.5 mm (1/2 in.) Diameter Element and 6.4 mm (1/4 in.) Diameter Element Probes . 80 FIGURE 3 Nearest Proximity Restrictions with Large Probe D

36、imensions . 80 FIGURE 4 Probe Beam Pressure Maps Normalized to the 6.4 mm (1/4 in.) Diameter Element . 81 FIGURE 5 Probe Beam Surface Pressure Maps . 81 viii ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2017 APPENDIX 3 Guidance for Monitoring Underwater Inspections 82 1 General . 82 1.1 Vis

37、ual Inspection . 82 1.3 Magnetic Particle Testing (MT) 82 1.5 Alternative and Supplementary NDT Methods 83 1.7 Ultrasonic Thickness Gauging . 83 1.9 Reporting . 83 FIGURE 1 Checklist for Underwater Inspection . 84 FIGURE 2 Preplanning Checklist . 85 FIGURE 3 Visual Inspection . 86 FIGURE 4 Magnetic

38、Particle Testing (MT) . 87 FIGURE 5 Ultrasonic Thickness Gauging 88 FIGURE 6 Reporting Requirements . 89 APPENDIX 4 Guidance Criteria for Nondestructive Tests Not Required by ABS 90 1 General . 90 APPENDIX 5 Inspection of Hot-dip Galvanizing 91 ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL WELDS .2

39、017 ix This Page Intentionally Left Blank 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 (

40、Part 2) and IACS Recommendation No. 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 is to be removed from all completed welds. All welds and adjacent base metal are to

41、be cleaned by wire brushing or by any 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

42、 inspection acceptance criteria are contained in Section 9 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 str

43、ength or greater. When welding these high-strength steels, the final visual inspection is to 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) C

44、racking (1 July 2017) 1.5.1 Time of Inspection Nondestructive testing of weldments in steels of 415 N/mm2(42 kgf/mm2, 60,000 psi) minimum specified yield strength or greater is to be conducted at a suitable interval after welds have been completed and cooled to ambient temperature. The following gui

45、dance of interval is to be used, unless specially approved otherwise: Minimum 48 hours of interval time for steels of 415 MPa (42 kgf/mm2, 60,000 psi) minimum specified yield strength or greater but less than 620 MPa (63 kgf/mm2, 90,000 psi) minimum specified yield strength. Minimum 72 hours of inte

46、rval time for steel greater than or equal to 620 MPa (63 kgf/mm2, 90,000 psi) minimum specified yield strength. At the discretion 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

47、testing (RT) or ultrasonic testing (UT) inspection, provided a complete visual and random MT or PT inspection to the satisfaction of the Surveyor is conducted 72 hours after welds have been completed and cooled to ambient temperature. Minimum specified yield strengths are to be referenced from globa

48、lly recognized material specifications such as ASTM, EN, DIN, ISO, API, etc. If the minimum specified yield strengths are significantly exceeded and delayed cracking is present, consideration to increasing the delayed inspection period may be required. ABSGUIDE FOR NONDESTRUCTIVE INSPECTION OF HULL

49、WELDS .2017 1 Section 1 General 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 Surveyor. 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. Note that base metal thickness and combined thickness of a joint influence weld and HAZ cooling rate and subsequently hardness level. Preheat may need to be increa