CN105067702A - Plugged T-junction weld non-destructive detection method by using ultrasonic phased array - Google Patents
Plugged T-junction weld non-destructive detection method by using ultrasonic phased array Download PDFInfo
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Abstract
The invention discloses a plugged T-junction weld non-destructive detection method by using ultrasonic phased array. The method comprises the following steps: carrying out detection technology simulation on a plugged T-junction to be detected; establishing a whole three-dimensional model of the plugged T-junction; carrying out profile scanning on the whole model in different angles; carrying out ultrasonic cover simulation on the weld area of each profile; determining the scanning route range of the profile; connecting all profile scanning route ranges together to form a plugged T-junction intersecting line weld scanning route belt and a detection route technology curve; and finally detecting the plugged T-junction by a ultrasonic phased array instrument. The method has the advantages that profile scanning is performed on the intersecting line weld in different angles, thus the scanning route belt of plugged T-junction intersecting line weld can be precisely simulated; compared with the conventional non-destructive technology, the detection efficiency is improved, solved are the problems that the plugged T-junction is not easy to detect and the detection speed is slow; the human and material investment is greatly reduced; and strong guarantee is provided for the plugged T-junction manufacturing and on-site installation.
Description
Technical field
The present invention relates to a kind of detection method of weld seam, particularly relate to a kind of detection method of shutoff threeway intersection welding seam.
Background technology
Pressure pipeline is the device for carrying the fluid media (medium) such as gas, liquid, is also the extraordinary bearing device of all kinds of medium of conveying.Because its pipeline transportation freight volume is large, security is higher, construction cost and transportation cost lower, be used widely in heat supply, air feed, long distance delivery oil and natural gas and various commercial plant.
But along with the development of Present Economical, the quantity of in-service pressure pipeline increases year by year, and the continuous accumulation of its working time.Make the problem in design, manufacture, installation and operational management produce gradually and expose, cause the generation of accident.
The pipeline maintenance of heavy complexity, only relies on single stop production to overhaul working method to be difficult to meet need of production.And once keep in repair not in time, the pipeline that in pipe network, single line runs exists the possibility occurring accident of serious failure, and conveying not only can be caused to occur bottleneck or fault, produce upstream pressure and suppress the problem such as height, downstream pressure deficiency, and may major accident be caused.
Although pipe network part pipeline arranges multiple line in the design, majority has carried out again high-low pressure point flow process, and high pressure line stopping transportation, low-pressure line cannot bear two-wire throughput rate equally.Along with pipeline stop production to overhaul workload increase, scope becomes wide, impact strengthens, the contradiction continuing to increase the weight of with pipe network operations task is becoming increasingly acute, and must have new service technique to balance this contradiction.
Stopping transportation pressure blocking technology a kind ofly under on-line production state, carries out replace tubes, perforate, touches mouth, connects the maintenance process technology of head, the economic loss avoiding the stopping transportation because of construction operation to cause and living the harmful effect caused to social production, eliminates the potential safety hazard of conventional belt pressure pipeline operation.As a kind of new maturation process, it is a kind of important supplement to original stopping transportation maintenance craft, becomes the important means guaranteeing pipe network stable operation.
Shutoff threeway is the workpiece indispensable in implementation process of stopping transportation pressure blocking technology, and when pipeline carries out shutoff operation, this equipment is used for associated line and sandwich valve; Construct complete, for the plug-hole of pipeline.Fig. 1 is the floor map of shutoff threeway, shutoff threeway is primarily of backplate up and down, the plug composition such as handle and locking ring device of flange, blind flange, adapter, dimension as shown in Figure 1, can according to conduit running pressure, medium, pipeline outer through design dimension shutoff threeway.
On the other hand, when same operational throughput, to build several low pressure small-bore pipelines more economical than parallel to build a high-pressure large-caliber pipeline.Such as a discharge pressure is 7.5MPa, and the gas pipe line of diameter 1400mm can replace 3 pressure 5.5MPa, the pipeline of diameter 1000mm, but the former can reduce investment outlay 35%, save steel 19%, therefore, the diameter expanding pipeline has become the mark of the scientific and technological progress of pipe-line construction.Meanwhile, improve discharge pressure within the specific limits and can increase economic benefit.
The increase of caliber and the raising of discharge pressure, mean the increase of pipeline wall thickness, means the increase of shutoff threeway wall thickness, and this will cause manufacturing process more complicated.Along with the growth of number of tubes, the prolongation of active time, the probability that pipeline has an accident increases, the use of shutoff threeway is tending towards frequent, the welding method of manual multilayer all position welding that what current many manufacturing planies adopted is, weld seam easily produces defect, is often that weldering twice will check one time in the fabrication process, wastes time and energy.
At present there are infiltration, magnetic, ray, ultrasonic, eddy current, acoustic emission, phased array, TOFD etc. for the detection method of weld seam, based on the geomery of shutoff threeway, inapplicablely carry out eddy current and TOFD detects; At present for shutoff threeway detection with infiltration and Magnetic testing comparatively general.
In the related art, Wang Bin etc. have carried out ultrasound examination to the casting three-way of thermal power plant, but wherein do not comprise weld seam; Yuan person of outstanding talent adopts straight beam method head detection technique to analyze threeway wall thickness; Dong Ji former channel angular threeway field joint has carried out ray detection, but threeway wall thickness only 12.7mm, and be not suitable for the situation of heavy wall, for heavy wall workpiece, the transillumination of ray is comparatively difficult; Lin Tong etc. apply acoustic emission testing technology to threeway base while carrying out the hydraulic testing to supercritical power station boiler, but pipeline carries out acoustic emission detection when on-line production, and interference can be very large.
Summary of the invention
Technical matters to be solved by this invention is, provides a kind of detection method detecting shutoff threeway intersection welding seam.
The technical solution adopted in the present invention is: a kind of shutoff threeway welding line ultrasonic phased array lossless detection method, comprises the following steps,
A. characterization processes simulation is carried out to shutoff threeway to be detected, obtain process curve;
B. the block mold of three-dimensional shutoff threeway is set up;
C. angularly profile scanning is carried out to block mold;
D. ultrasonic covering simulation is carried out to the welded seam area of each section;
E. the scanning path domain of this section is determined;
F. the scanning path domain of all sections is coupled together, form the scanning path band of shutoff threeway intersection welding seam, form one and detect path process curve;
G. ultrasonic phased array inspection instrument detects shutoff threeway.
Described steps A adopts ultrasonic phase array simulation softward to complete characterization processes simulation; Described step C angularly carries out cutting to intersection welding seam and divides.
The dissimilar probe of described step G Instrumental selected frequency to be the number of wafers of 2-5MHz be 16-256.
Described step G Instrumental, according to precision and workpiece size, arranges unlatching 16,32,64,128 or 256 wafers.
The invention has the beneficial effects as follows: owing to angularly carrying out profile scanning to intersection welding seam, therefore can accurate simulation to the scanning path band of shutoff threeway intersection welding seam, ultrasonic phased array technology is used in shutoff threeway detects, compared with conventional lossless detection technique, improve detection efficiency, solve the bad inspection of shutoff threeway, examine unhappy problem, greatly reduce the input of man power and material; Especially the manufacture of shutoff threeway and field erected reliability provide sound assurance; It is 20mm to 80mm that this detection method is specially adapted to shutoff threeway heavy wall, the workpiece sensing of radius in 80mm to 1000mm scope.
Accompanying drawing explanation
The floor map of the existing shutoff threeway of Fig. 1;
Fig. 2 is the detection method process flow diagram of shutoff threeway weld seam intersection of the present invention;
Fig. 3 is shutoff threeway drawing result figure;
Fig. 4 to Fig. 6 is respectively 0 degree of section, 36 degree of sections and 90 degree of sectional schematic diagrams;
Fig. 7 to Fig. 9 is respectively the ultrasonic covering scanning path domain schematic diagram of corresponding 0 degree of section, 36 degree of sections and 90 degree of sections;
Figure 10 is gained characterization processes curve after smooth optimization.
In figure:
1. arm 2. intersection welding seam 3. is responsible for 4. ultrasonic probe 5. process curves.
Embodiment
Below in conjunction with the drawings and specific embodiments, the present invention is described in further detail:
Ultrasonic phased array technology has the developing history of nearly more than 20 years, and the initial stage is mainly used in medical field, in medical ultrasound image with the quick mobile acoustic beam of phase array transducer to tested imaging organs; Utilize its controlled focus characteristics local heating thermotherapy for cancer, destination organization is heated up and reduces the power absorption of non-target tissues.At first, the complicacy of wave propagation and cost is high etc. that reason makes that its application in industrial nondestructive testing is limited in the complicacy of system, solid.In recent years, ultrasonic phased array technology more and more causes the attention of people with its acoustic beam deflection flexibly and focusing performance.
Ultrasonic phased array technology uses difform many element transducer produce and receive ultrasound beamformer, the time delay of (or reception) pulse is launched by controlling each array element in transducer array, change phase relation when sound wave arrives certain point in (or from) object, realize the change of focus point and sound beam direction, the method then adopting mechanical scanning and electron scanning to combine is to realize image imaging.Compared with detecting with conventional ultrasound, because the controlled and dynamic of acoustic beam angle focuses on, ultrasonic phased array technology has can detection of complex structural member and the feature such as blind zone position defect and higher detection frequency, can realize at a high speed, comprehensive and multi-orientation detection.For the detected object of some rules, as tubular weld seam, sheet material and tubing etc., ultrasonic phased array technology can improve detection efficiency, simplified design, reduction technical costs.Particularly in weld seam detection, adopt rational phased array detection technique, only the covering scanning that transducer can realize butt welded seam along bead direction scanning need be detected, conventional ultrasonic wave detector need detect the regular hour, and just can complete under using ultrasonic phased array technology several.Therefore, unique advantage is had at many places inspection occasion phased-array technique.
Due to the integrated application of multiple new and high technology in ultrasonic phased array imaging field such as piezo-electricity composite material, the control of nanosecond pulse signal, Data Management Analysis, software engineering and computer simulations, ultrasonic phase array detection technique is made to be able to fast development, be applied to industrial nondestructive testing gradually, particularly in the field such as nuclear industry and aircraft industry.Ultrasonic phased array technology current application is extensive, as the detection etc. of the detection to blade of gas turbine (root) and turbine disc, oil and gas pipeline weld seam detection, train axle detection and pressure vessel, high energy pipe welding seam and oil pipeline weld seam.Although ultrasonic phased array technology obtains multi-field application, but existing ultrasonic phased array inspection instrument and analysis software equal None-identified shutoff threeway intersection, therefore, ultrasonic phase array detection probe, the choosing and actual testing of correlation parameter cannot be carried out, more cannot to shutoff threeway wall thickness in 20mm to 80mm, the intersection welding seam of radius in 80mm to 1000mm scope detects.
Shutoff threeway ultrasonic phase array lossless detection method of the present invention, comprises the following steps,
A. characterization processes simulation is carried out to shutoff threeway to be detected, obtain process curve;
B. the block mold of three-dimensional shutoff threeway is set up;
C. angularly profile scanning is carried out to block mold; Angularly carry out cutting to intersection welding seam to divide, angle is 1-3 degree;
D. ultrasonic covering simulation is carried out to the welded seam area of each section;
E. the scanning path domain of this section is determined;
F. the scanning path domain of all sections is coupled together, form the scanning path band of shutoff threeway intersection welding seam, form one and detect path process curve;
G. ultrasonic phased array inspection instrument detects shutoff threeway; Instrument selection frequency is 2-5MHz, and instrument, according to precision and test specimen, is applicable to the shutoff threeway of more than wall thickness 20mm, and debugging arranges the dissimilar probe of unlatching 16,32,64,128 or 256 wafers.
It is worthy of note: selected frequency is the phased array probe of 2-5MHz, general detect wall thickness be 25mm or following time, diameter is when 500mm or following threeway, and probe number of wafers is 16 or 32 or 64.Wall thickness is greater than 25mm, and when diameter is greater than 500mm, probe number of wafers is 128 or 256.As long as the wall thickness cross section covering product when namely ensureing that probe detects is just passable.
embodiment:be now that example is described with shutoff threeway diameter 600mm, wall thickness 30mm, use drawing software to draw to workpiece to be detected.
As shown in Figure 3, the workpiece to be detected of drafting includes arm 1, intersection welding seam 2 and supervisor 3.
By every 2 degree of sections, profile scanning is carried out to intersection welding seam 2.
Fig. 4 to Fig. 6 is respectively 0 degree of section, 36 degree of sections and 90 degree of sectional schematic diagrams.
Carry out ultrasonic covering simulation to the welded seam area of each section, analog detection process employing frequency is the dissimilar probe of 128 wafers of 2-5MHz.The determination of ultrasonic probe 4 at the scanning path domain of this section is realized by software simulation; Fig. 7 to Fig. 9 is respectively the ultrasonic covering scanning path domain schematic diagram of corresponding 0 degree of section, 36 degree of sections and 90 degree of sections.
The scanning path domain of all sections is coupled together, forms the scanning path band of shutoff threeway intersection welding seam, then form a characterization processes curve 5 by level and smooth, Optimum Synthesis; Figure 10 is the characterization processes curve obtained after smooth optimization.
The process curve of ultrasonic phased array inspection instrument to shutoff threeway detects.
The present invention is owing to angularly carrying out tomoscan to intersection welding seam, can accurate simulation to the scanning path band of shutoff threeway intersection welding seam, solve and cannot it be simulated using ultrasound phased array software, characterization processes curve whether reasonably problem cannot be verified, ultrasonic phased array technology is used in shutoff threeway detects, ultrasonic phased array technology is used in shutoff threeway detects, compared with conventional lossless detection technique, improve detection efficiency, solve the bad inspection of shutoff threeway, examine unhappy problem, greatly reduce the input of man power and material, especially the manufacture of shutoff threeway and field erected reliability provide sound assurance, and this patent will bring huge social benefit, it is 20mm to 80mm that this detection method is specially adapted to shutoff threeway heavy wall, the workpiece sensing of radius in 80mm to 1000mm scope.
Claims (4)
1. a shutoff threeway welding line ultrasonic phased array lossless detection method, is characterized in that, comprise the following steps,
A. characterization processes simulation is carried out to shutoff threeway to be detected, obtain process curve;
B. the block mold of three-dimensional shutoff threeway is set up;
C. angularly profile scanning is carried out to block mold;
D. ultrasonic covering simulation is carried out to the welded seam area of each section;
E. the scanning path domain of this section is determined;
F. the scanning path domain of all sections is coupled together, form the scanning path band of shutoff threeway intersection welding seam, form one and detect path process curve;
G. ultrasonic phased array inspection instrument detects shutoff threeway.
2. shutoff threeway welding line ultrasonic phased array lossless detection method according to claim 1, is characterized in that, described steps A adopts ultrasonic phase array simulation softward to complete characterization processes simulation; Described step C angularly carries out cutting to intersection welding seam and divides.
3. shutoff threeway welding line ultrasonic phased array lossless detection method according to claim 1, is characterized in that, the dissimilar probe of described step G Instrumental selected frequency to be the number of wafers of 2-5MHz be 16-256.
4. shutoff threeway welding line ultrasonic phased array lossless detection method according to claim 3, is characterized in that, described step G Instrumental, according to precision and workpiece size, arranges unlatching 16,32,64,128 or 256 wafers.
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| CN109946382A (en) * | 2019-01-31 | 2019-06-28 | 中国兵器科学研究院宁波分院 | An automatic detection method of ultrasonic C-scanning based on industrial robot |
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Address after: No. 32 Space Road, Nankai District, Tianjin City, 300192 Patentee after: Tianjin Institute of Special Equipment Supervision and Inspection Technology (Tianjin Special Equipment Accident Emergency Investigation and Treatment Center) Address before: No. 32 Space Road, Nankai District, Tianjin City, 300192 Patentee before: Tianjin Inst of Special Appliances Supervision and Check Tech |