KR100488366B1 - A system for measuring hydrogen induced cracking and corrosion using ultrasonic and an methode for evaluating stability therefor - Google Patents

Abstract

The present invention is a harmful defect that exists in the hydrogen organic cracks and corrosion, material generated in the refinery of the heat exchanger, pressure vessel, reactor, separation tower, storage tank, piping, etc., equipment of power plants, water and sewage pipes, petrochemical plants In detecting, the ultrasonic transducer detects the shape and surface distance of the subject as an electrical signal using the displacement angle of the encoder and the displacement of the isosceles triangle axis, and uses an algorithm to unfold it on a plane. The actual size is reproduced on the screen as it is, and the ultrasonic signal for each transducer position is displayed on the plane as color images to display defects existing on the inside and the inside of the subject. Hydrogen organic crack and corrosion measurement system using ultrasonic wave that shows the shape and size of defects in three dimensions of side and cross section As a safety assessment.

Description

Hydrogen organic crack and corrosion measurement system using ultrasonic wave and safety evaluation method {A SYSTEM FOR MEASURING HYDROGEN INDUCED CRACKING AND CORROSION USING ULTRASONIC AND AN METHODE FOR EVALUATING STABILITY THEREFOR}

The present invention generates ultrasonic waves on the outer surface of a subject such as various pressure vessels, reactors, and pipes, detects ultrasonic signals inputted by the reflected object, and detects the hydrogen organic cracks, corrosion, inclusions, etc. The present invention relates to a hydrogen organic crack and corrosion measurement system and a method for evaluating safety using ultrasonic waves, which can measure the shape and size of defects harmful to the facility such as lamination and evaluate the safety of the facility using the calculated defect size.

In general, devices used in processes used in oil refineries, petrochemical plants, power plants, water and sewage pipes and offshore structures, or for cooling, condensing, storing, extracting, reacting and transporting fluids and gases in the use environment, and in particular, , Pressure vessel, heat exchanger fuselage, separation tower, storage tank, reaction vessel and piping are the inspections that evaluate the safety by measuring the degree of cracking and corrosion on the device (inspection). Is inevitably done.

Such devices inevitably cause damage such as hydrogen organic cracking, corrosive cracking, or corrosion to the inside of a container or a metal body by harmful substances (hydrogen sulfide, sulfur, acid, etc.) due to fluids, gases, corrosive substances, or reactions. Failure to detect such damage prematurely can result in fire and explosion or environmental pollution, or external leakage of hazardous substances due to destruction or leakage, resulting in material or economic loss due to social safety threats and equipment shutdowns.

Therefore, companies with high temperature, high pressure and hazardous substance handling devices as described above define various expected damages and carry out inspections and inspections on a regular basis to strictly evaluate the use and safety of continuous use by correcting them if necessary. As a result, the inspection apparatus and technology are indispensable.

However, most inspection devices are often impossible to access the inside of the subject during operation, and the large diameter (1-8m) of the steel sheet is as small as 20mm to 400mm in general, non-destructive testing method of radiographic test It is impossible to shoot and the application is more difficult because the equipment is fixed on site.

In addition, the penetration test or magnetic particle test cannot be applied since the main damage of the inspection equipment occurs early on the inner surface of the container or the contents inside the steel plate.

Ultrasonic testing, which is the only conventional method, has the advantage of inspecting the inside and the inside if it is accessible from only one side, but it has to rely solely on manual work, and automatic recording is impossible, making it difficult to detect and evaluate harmful defects. to be.

In other words, the ultrasonic manual examination has no permanent record, it is not only the degree of displaying the result only in one-dimensional geometry, but also greatly influenced by the skill and skill of the examiner. The problem is that the quantitative measurement of height and length is difficult and the measurement error is large.

Therefore, to solve this problem internationally, inspection equipment manufacturers are selling automatic or semi-automated ultrasonic equipment that complements this problem. The dimensional simple display method is adopted, and the scanner also uses an automatic method, which is expensive and limited use is inevitable due to the influence of space or surrounding objects in the field application. In the case of spherical or three-dimensional curved surface, a lot of error occurs.

For example, in the UK, AEA manufactures a supersonic image processing device and markets it internationally.However, when it is applied to a geometric shape such as a complicated structure, an elbow, a spherical tank, the actual inspection position and the position recognized by the device Depending on the curvature and the gradient of the can cause a significant error. This is because the position sensor method cannot recognize the height of the subject's surface by the one-point fixed infrared method.

That is, it is suitable for a large diameter or flat plate having a small gradient, but when applied to a small diameter pipe or a small diameter object, a large error occurs. In addition, since the infrared camera should be installed at a position where the subject can be seen, the installation space is limited, and there is a disadvantage in that infrared rays are not recognized during the day.

In particular, in the over head position, the operator's hand must enter to hold and move the transducer between the sensor and the transducer, and as a result, inspection in the upper position is not possible because it prevents infrared communication.

That is, there is a disadvantage in that the flaw detection in the above position from the bottom of the fixing device. In addition, since the infrared camera should be installed on the subject and the installed camera should be located at the center of the subject, it is necessary to secure an installation space and a tool such as an auxiliary rod.

In addition, the vibration of the subject may not be able to recognize the position due to vibration or shaking because the camera and the sensor are not integrated.

The present invention was devised to solve the above problems, and an object of the present invention is to provide a heat exchanger, a pressure vessel, a reactor, a separation tower, a storage tank, piping, oil refineries, power plants, water and sewage pipes, and petrochemical plants. In detecting the hydrogen organic crack, corrosion, and harmful defects in the material, the ultrasonic transducer is used to determine the shape and surface distance of the subject by using the displacement angle of the encoder and the displacement of the isosceles triangle axis. Using the algorithm to detect and spread it back to the plane, the actual size of the subject is reproduced on the screen as it is, and the ultrasonic signals of each transducer position are present on the inside and the inside of the subject as color images on the plane. The defects can be displayed, and the shape and size of the defects can be measured by representing the inspected object in three dimensions of plane, side, and cross section. The present invention provides a hydrogen organic crack and corrosion measurement system using ultrasonic waves.

Another object of the present invention is to use a quantitative defect dimension of a subject derived from a signal integration process using ultrasonic measurement data, measurement position data, etc. Evaluate the adequacy of use in the state, and determine whether the current defect is destructively mechanically safe to the working stress by evaluating the fracture toughness of the material and the failure parameters. It is to provide a method for evaluating safety of a subject to be identified.

The present invention for achieving the above object is an ultrasonic scanner for measuring the degree of internal cracks or corrosion of the subject, such as pipes, pipes, spherical and flat surfaces using ultrasonic waves from the outside, and the cracks and Signal processing means for receiving the corrosion data, the position data of the place measured by the ultrasonic scanner to convert the digital signal and output the signal, and the signal output from the signal processing means to receive the corrosion of the subject by a predetermined program In the hydrogen organic crack and corrosion measurement system using ultrasonic wave and an output means capable of performing the evaluation and display of the degree of cracking and its safety, and at the same time storing the results, and the safety evaluation method, measurable pipe, pipe Divided the test object such as, sphere, flat plate into small pieces On one plane together this first step of the synthesis shown in software; The analog ultrasonic signal detected on the plane formed through the first process is converted to digital, stored and output in real time, and displayed as a color image corresponding to the thickness of the subject. A second process to recognize the size of the second process; And to evaluate the safety of the subject (M) using the measurement information, such as the thickness range and distribution of the subject, the size of the defect measured through the second process, to perform a material mechanical evaluation and fracture mechanical evaluation Third process; Has the features, including.

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Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.

1 is a block diagram of a hydrogen organic crack and corrosion measurement system using ultrasonic waves according to the present invention.

As shown, the hydrogen organic crack and corrosion measurement system according to the present invention is an isosceles triangle configuration, pipe-shaped cylinders, elbows such as elbows, spherical bodies such as spherical surfaces or flat plates such as heads of pressure vessels ( Ultrasound scanner 100 for measuring the internal crack or corrosion degree of M) from the outside using ultrasonic waves, crack and corrosion data measured by the ultrasound scanner 100, and the place measured by the ultrasound scanner 100 The signal processing means 200 for receiving the position data of the input signal, converting the digital signal into the digital signal, and receiving the signal output from the signal processing means 200; And an output means 300 for performing evaluation of the degree and its safety and displaying the same, and at the same time storing these results.

The output means 300 is preferably a personal computer (hereinafter referred to as a 'PC'), a notebook computer, or a PDA (Personal Digital Assistant).

The configuration of the ultrasound scanner 100 will be described in more detail with reference to FIGS. 2 and 3.

The ultrasound scanner 100 includes a main body 101, a first shaft 108 connected to an upper portion of the main body 101, and a second shaft 113 connected to the other end of the first shaft 108. ), A connecting part 115 connected to the other end of the second shaft 113, a moving part 118 connected to the other end of the connecting part 115, and connected to the other end of the moving part 118 and inside Ultrasonic generator 120 is provided with a transducer 140 for generating an ultrasonic wave, a magnet holder 130 fixed to the side of the main body 101, the permanent magnet is built-in, the main body 101, the first First, second and third encoders 104 installed on the hinge shafts inside the case 105 and the second case 109 to sense the positions of the first shaft 108 and the second shaft 113, respectively. 107, 111 is configured.

More specifically, the main body 101 has a rectangular shape, the hinge shaft 102 of the inside is connected through the first case 105 and the bearing 103, the first around the hinge shaft 102 The case 105 may rotate left and right, and a first encoder 104 is installed around the hinge shaft 102 to rotate the hinge shaft 102, that is, the left and right sides of the first shaft 108 connected thereto. The rotation angle is detected.

The hinge shaft 106 is coupled to the outer both sides of the first case 105 by a c-shaped connector 133 formed at one side of the first shaft 108, and the inner hinge of the first case 105. A second encoder 107 is installed around the shaft 106 to detect the vertical movement angle of the first shaft 108.

In addition, a quadrangular second case 109 is formed at the other end of the first shaft 108, and a c-shaped connector formed at one side of the second shaft 113 on both outer sides of the second case 109. Hinge shaft 110 is coupled through the 112, and the third encoder 111 is installed around the inner hinge shaft 110 of the second case 109, the upper and lower sides of the second shaft 113 The moving angle is detected.

An insertion groove 114 is formed at the other end of the second shaft 113, and an insertion hole 116 of the connection portion 115 is inserted and fixed in the insertion groove 114, and a bearing 117 inside the connection portion 115. The connecting portion 115 is rotatable left and right about the second shaft 113 by the structure.

The other end of the connecting portion 115 is coupled to one end of the moving part 118 and the hinge 119, the other end of the moving part 118 is connected through the ultrasonic generator 120 and the bearing 121, the movement The part 118 is movable up and down with the connection part 115.

One end of the ultrasonic wave generator 120 is connected to the moving part 118 and the bearing 121 structure so as to be rotatable about the moving part 118, and a protective cover 122 outside. Is formed and the transducer 140 for generating an ultrasonic wave is installed therein. In addition, by forming a hollow 123 on both sides of the protective cover 122 of the ultrasonic generator 120, the probe 140 and the signal processing cable can be connected.

In addition, as shown in Figure 4 in the center of the front end portion 124 of the ultrasonic generator 120, the ultrasonic wave output from the probe 140 is emitted and the cross-shaped around the hole 125 The groove 126 is formed to increase the contact force in the spherical surface, the cylinder and the flat plate (M), and the contact medium (water, oil, glycerin, etc.), which is the ultrasonic transfer medium, flows well into the gap.

A permanent magnet is installed inside the magnet holder 130 fixed to the side of the main body 101, and a knob 131 is installed on the outside of the magnet holder 130. The knob 131 serves to mechanically block or release the magnetic force of the permanent magnet, and the structure of the detailed mechanical part is well known in the art and will not be described in detail herein.

Accordingly, the bottom surface of the magnet holder 130 is in contact with or dropped from the surface of the subject M according to the manipulation of the knob 131.

In addition, the upper portion of the magnet holder 130 has a U-shaped mounting portion 134 is formed in the center of the U-shaped mounting portion 134 is fixed, the zero point which is the initial state during the measurement operation of the ultrasound scanner 100 For adjustment (initialization) to form a structure in which the rear end of the ultrasonic generator 120 is inserted.

Reference numeral C is a cable.

The ultrasonic scanner 100 configured as described above is made of aluminum to reduce weight, prevent rust, and to prevent warping. The first and second shafts 108 and 113 have an H-beam structure and a cylindrical shape, respectively. It is configured in the form of pipe to have sufficient strength and to prevent deformation.

First, second and third encoders 104 and 107 formed between the main body 101, the main body 101 and the first axis 108, and the first axis 108 and the second axis 113. (111) measures the displacement displacement of the first axis 108 and the second axis 113, the number of displacement recognition is 2048, one rotation angle has an angle accuracy of 0.175 °.

The material of the ultrasonic generator 120 is made of stainless steel having high abrasion resistance and corrosion resistance, and the outer surface of the ultrasonic generator 120 is formed by infusing the user so that it does not slip when the user picks it up with a finger.

In addition, the ultrasound scanner 100 has a measuring range from 100 mm to 300 mm in radius from the main body 101 when the first axis 108 and the second axis 113 are fully extended. In the case of pipes, curved pipes, pipes of 150 mm or more, spherical surfaces of 150 mm or more, flat plates, etc., or smaller specimens (M), the test surface is divided into small pieces, and the test pieces are collected and synthesized in one plane by software. Can be displayed.

5 is a control circuit block diagram of a hydrogen organic crack and corrosion measurement system using ultrasonic waves according to the present invention.

As shown, the reference numeral 100 denotes a circuit block of the ultrasonic scanner, the probe 140 for emitting ultrasonic waves to a subject M at a constant frequency for crack or corrosion measurement, and the ultrasonic scanner 100 of the ultrasonic scanner 100. It consists of the encoder 150 which detects a measurement position, ie, the measurement position of the subject M from the 1st encoder 104, the 2nd encoder 107, and the 3rd encoder 111 by position displacement.

Symbol 200 is a signal processing means, by applying an ultrasonic pulse signal to the transducer 210, the ultrasonic generator 210 for controlling the transducer 210 to generate ultrasonic waves, and the ultrasonic wave emitted from the transducer 140 The ultrasonic input unit 220 which receives the ultrasonic detection signal (corrosion or crack data) reflected back from the subject M and the analog type ultrasonic detection signal input from the ultrasonic input unit 220 as digital signals. A / D converter 230 for converting and the measurement data input from the A / D converter 230 is signal processed and transmitted to the output means 300, and at the same time ultrasonic generation pulse to the ultrasonic generator 210 Ultrasonic signal processing unit 240 for controlling the output and the analog output signal of each of the first, second and third encoders 104, 107, 111 input from the encoder 150 to digital conversion A / D conversion unit 250 , By treating the A / D signal the displacement data received from the converter 250 is composed of an encoder signal processing unit 260 for outputting to the output means 300.

The reference symbol 300 is an output means, and using the ultrasonic data and the position data input from the ultrasonic signal processor 240 and the encoder signal processor 260 of the signal processor 200, the corrosion of the current subject M and Calculate the degree of cracking, and at the same time calculate and determine the safety of the subject (M), the main body 310 for outputting and storing these results in real time, and the current body by the output of the main body 310 The display unit 320 displays the corrosion and cracking degree of the specimen M in a predetermined form, and inputs a predetermined key value into the main body unit 310 and the display unit 320 for displaying the safety state of the subject in a predetermined form. The keyboard 330 is provided.

The present invention constituted as described above includes pressure vessels, drums, heat exchanger shells, separation towers, storage tanks, and reaction vessels in industrial sites. (M) by simply fixing the ultrasound scanner 100 by using a magnetic chuck on the surface of reactors, process pipe lines, and the like. From the ultrasonic signal and the displacement of the X, Y, Z axis encoder 150 mounted on the isosceles triangle shaped ultrasound scanner 100 is converted into an electrical signal via the signal processing means 200 to the output means 300 Is entered.

At this time, the signals are displayed on the monitor 320 of the output means 300 as shown in Fig. 6, wherein the display method is three types of flaw detection plan 802, flaw cross section 806, flaw detection side view 805 Is expressed.

When the inspection is completed, the defect distribution and connectivity of the cross section and side surfaces of the entire inspection area are moved to the actual size while moving the cursors 809 and 810 on the X axis (length direction) and Y axis (axial direction) on the screen freely. The ruler 803 is comprised so that confirmation is possible.

In each cross section, the most severe damage is selected so that the length 811 in the axial cross section of the defect and the cross section thickness 812 occupied by the defect and the defect length 813 in the side portion (orthogonal to the shaft) and the defect occupy Obtain the thickness of the cross section (814) and use it to determine the defect size according to the standard of defects prescribed by international associations (American Materials Association, Japan Cost Contact Association, etc.) or national standards (ANSI, British Standards, etc.). After conforming, the defects will be evaluated according to the specification.

Hydrogen organic crack and corrosion measurement system using ultrasonic wave and the safety evaluation method according to the present invention, after dividing the inspection surface of the subject such as measurable pipe, curved tube, spherical surface, flat plate into small pieces and inspecting the software on one plane A first process of synthesizing and displaying a color, and converting an analog ultrasonic signal detected on a plane formed by the first process into digital, storing and outputting in real time, and displaying the color as a color image corresponding to the thickness of the subject. Through the second process to recognize the thickness range and distribution of the subject, and the size of the defect through the measurement, the measured information such as the thickness range and distribution of the subject and the size of the defect measured by the second process In order to evaluate the safety of the specimen (M), it comprises a third process of performing a material mechanical evaluation and a fracture mechanical evaluation.

More specifically, the system of the present invention enables to divide the inspection surface such as measurable pipe, curved pipe, spherical surface, flat plate into small pieces, inspect them, and then combine them and display them by software in one plane. In order to automatically recognize the curvature and gradient of the specimen (M), the shape recognition of the cylindrical specimen (M) such as a pipe is to be calculated by reading the six points of the inspection target surface of the specimen, and the elbow (curve) such as elbow Nine points, four spherical surfaces such as the head of a tower, heat exchanger, or pressure vessel, and three points of flat plates are read, and the shape and curvature gradient of the subject are automatically calculated by a program and displayed on a flat surface. give.

Shape recognition and calculation of the subject M using the measurement points are obtained by inputting each point into a predetermined program. Details are calculated by a program using an algorithm described below, and when the final result is derived, it is shown on a plane. do.

(1) Coordinate transformation into a plane when the inspection target is a sphere

When three points P1 (x1, y1) P2 (x2, y2) P3 (x3, y3)

at x2 + y2 + Ax + By + C = 0,

center : radius:

(2) Coordinate transformation to plane (conversion of cylinder surface to X-Y plane coordinate) when the inspection target is a cylinder

(Assuming) As shown in Fig. 7A, P1, P2, P3 and P4, P5, P6 are on the same plane.

      (A) Overview of Conversion Order

① Input point coordinates in order from P1, P2, P3, P4, P5, P6.

② Find the center C1 using P1, P2, and P3.

③ Find the center C2 using P4, P5, and P6.

④ Find the equation of the straight line using C1, C2, and find the conversion equation that converts to the cylindrical coordinate system based on the centers C1 and P3.

⑤ Convert arbitrary measurement coordinates to cylindrical coordinate system based on the conversion formula.

⑥ Convert to the X-Y plane coordinate system based on the converted cylindrical coordinate system.

(B) Equation and derivation process necessary for the actual conversion

① There are three encoders in the measuring instrument, and the method of converting them to the rectangular coordinate system of the measuring instrument is as follows (see Fig. 7b).

② To obtain C1 and C2 using (A) -② and (A) -③

㉮ First, find the equation of the plane passing through P1, P2, and P3. Here it is a circle. Pass three points P1 (x ₁ , y ₁ , z ₁ ), P2 (x ₂ , y ₂ , z ₂ ), P3 (x ₃ , y ₃ , z ₃ ) and the center is C1 (x ₀ , y ₀ , z Find the equation of a circle, ₀ ).

The center C1 can be obtained by the above three equations.

Center C2 (x ₇ , y ₇ , z ₇ ) through remaining P4 (x ₄ , y ₄ , z ₄ ), P5 (x ₅ , y ₅ , z ₅ ), P6 (x ₆ , y ₆ , z ₆ ) Also available.

Through this process, the equation of a circle centered on C1 and C2 is obtained.

Convert to the coordinate system of the plane which consists of P1, P2, P3.

In other words, convert to (x, y, z)-> (x, y, 0). This means projection to the x and y planes. Therefore, it means that x * = x, y * = y, z * = 0, so the transformation matrix representing this is as follows.

Find the transformed plane on the xy plane by the matrix transformation above.

C Convert C1 and C2 obtained by the above method back to the original coordinate system to obtain final C1 and C2. That is, when the cylindrical coordinate system (rθz coordinate system) is represented by a rectangular coordinate system (xy plane coordinate system), x = z and y = rθa. Therefore, we can find the plane projected on the xy plane.

(3) Coordinate transformation into plane when the inspection object is a curved pipe

(Convert the surface of the curve to X-Y plane coordinates)

(Assuming) As in FIG. 8A, P1, P2, P3 and P4, P5, P6 and P7, P8 and P9 are on the same plane.

(A) Conversion order

① Input point coordinates to P1, P2, P3, P4, P5, P6, P7, P8, P9 in order.

② Convert into a coordinate system of a plane consisting of P1, P2, and P3.

In other words, convert to (x, y, z)-> (x, y, 0).

The transformation refers to the transformation into the x and y planes. In the plane coordinate system consisting of P1, P2, and P3, the transformation is performed to transform the matrix into an xyz rectangular coordinate system centering on C0 through parallel and rotational movements. Finding the z-value by finding the center coordinates of each plane of P1, P2, P3, P4, P5, P6, P7, P8, and P9 is to find out if these planes exist on one plane. If it is said to be in one plane through a series of processes, it can be obtained that the coordinate conversion to the plane by the geometric calculation as shown in FIG.

First of all, in order to convert the coordinate system of the measuring machine to the xyz coordinate system where C0 is the center, the coordinate system of the measuring machine is parallel and rotated to match the coordinate system.

The next matrix is a matrix transformation in which P2 (x ₂ , y ₂ , z ₂ ) is moved in parallel in the x, y, z directions by J, K, and L to coincide with the center C0.

In order to match the transformed coordinate system to the xyz Cartesian coordinate system where C0 is the center, it is necessary to rotate and move α along the y axis by the following matrix transformation.

x ^* = xcosα + zsinα

y ^* = y

z ^* = -xsinα + zcosα

Since it is matrix transformation

to be.

Therefore, the conversion formula of P2 centered on C0 and converted to the xyz rectangular coordinate system is as follows.

③ Find the center C1 using P1, P2, and P3, and find the x and y of C1 by the following method.

That is, it passes three points P1 (x ₁ , y ₁ , z ₁ ), P2 (x ₂ , y ₂ , z ₂ ), P3 (x ₃ , y ₃ , z ₃ ) and the center is C1 (x ₀ , y ₀ , z ₀ )

By solving the above three equations, we can find the center C1.

In the same way, the center C2 (x ₁₀ , y ₁₀ , z passing through P4 (x ₄ , y ₄ , z ₄ ), P5 (x ₅ , y ₅ , z ₅ ), P6 (x ₆ , y ₆ , z ₆ ) ₁₀ ) and center C3 (x ₁₁ ) through P7 (x ₇ , y ₇ , z ₇ ), P8 (x ₈ , y ₈ , z ₈ ), P9 (x ₉ , y ₉ , z ₉ ) in the same way. , y ₁₁ , z ₁₁ ).

Through this process, the equation of circle with centers of C1, C2, C3 is obtained. The x and y coordinates of C1, C2, and C3 thus obtained can be obtained.

④ Calculate the z component of the center C by reversing the above ② and show that C0, C1, C2, and C3 are on one plane. To prove this, the z component is found.

Since x and y components are known in (3) above, the z component can be known from the matrix transformation equation.

Here you can see that it is bent on a certain plane by the z component, and you can apply the following equation ⑤ to see that it is in one plane.

⑤ Find the relation that transforms into the xyz rectangular coordinate system passing C1, C2, C3 and the center is C0. In FIG. 8B That

To express what is projected on the x, y plane It can be represented by the x, y plane.

As a result, the system of the present invention observes the ultrasonic reflection signal in the state of the inside of the subject M and the back of the subject M from the front end portion 124 of the ultrasonic generator 140 to corrode the subject M. Understand the situation, thickness reduction, and the presence of internal defects.

In the present invention, by designating the ultrasonic analog signal in a specific range, the analog signal coming into the gate is converted into digital and stored in real time through software through a software and matched to the color palette according to thickness as shown in FIG. Since it is shown on the monitor 320, so as to see the thickness range and distribution, the size of the defects only look at the color.

That is, a system for evaluating the state of the subject M using the color change of the thickness of the subject M, the internal defect length, the depth, the area (size) on the plane, and the shape of the back surface in real time as a color image. to be. At this time, the positioning of the ultrasonic scanner 100 receives three encoder electrical signals, converts them into distances, stores the ultrasonic thickness values of the specific points together with the position values of X, Y, and Z and displays them on one plane.

In addition, as shown in Fig. 6, the horizontal and vertical cursors 809 and 810 are placed on the plan view 802 of the image, so that the minimum thickness value, the maximum thickness value, the position 804 and the side view of the cursor position. 805 and cross-section 806 appear in real time according to the movement of the cursor so that the evaluator can easily identify the shape of the corrosion, the size of the crack, the interconnection, and the depth distribution according to the movement of the cursor when the defect is evaluated after the inspection. To help.

This is to find the maximum damage area in the examined area and to determine the defect dimensions to be used in the calculation of the material mechanics and the fracture safety.

In addition, by calculating the occupancy ratio of each defect thickness in the result of the image processing, it is shown as the area (80 ') so that the defect growth and the area change of the same part over time can be compared with the previous inspection result. Changes over time can be monitored.

When printing and using the ruler 803 attached to the cross-section and side view of the image processing, it is possible to know the depth of the defect and the distance and distance from the surface and the inner surface of the defect without using a separate ruler.

In addition, the present invention performs the material mechanical evaluation and the fracture mechanical evaluation in order to evaluate the safety of the subject (M) using the actual measurement information of the defect obtained by the image processing through the above process.

At this time, the information of defects input for the safety evaluation and the design specification used for the calculation are basically the design specifications of the facility, the thickness of the test object, the temperature, the adjustment value of the inspection equipment, the product name, the device number, and the material. Based on these inputs, the software automatically calculates and displays the final result.

First of all, the theoretical background of the material dynamic evaluation is to calculate the force acting during the current operation of the plant and the strength of the plant material.

The standard repair or replacement limit is obtained from the following equation.

Calculate and compare the axial and circumferential directions respectively.

(1) Calculation of durability

0.9σy (1-a / A), where σy is the yield stress of the material (the material intrinsic properties, quoted in the material strength table), and a is the thickness of the defect length in the longitudinal direction (thickness continuous defect length) Product, and A is the HIC evaluation area (thickness X longitudinal defect length).

In the above formula, the yield stress multiplied by 0.9 is safely evaluated on the risk side when 0.9σy is used for the permissible stress of the sound field unless the calculated working stress σ (sigma) is high enough in consideration of stress concentration in structural discontinuity. 0.9σy is used.

(2) Calculation of working stress

sigma t1 = Pr / t, where sigma t1 is the axial working stress, P is the design pressure (actual pressure during adequacy evaluation), r is the inner radius of the cylinder, and t is the thickness of the subject.

sigma t2 = Pr / 2t, where sigma t2 is the circumferential working stress, P is the design pressure (actual pressure in evaluating adequacy), r is the inner radius of the cylinder, and t is the thickness of the subject.

Fracture mechanics assessments, on the other hand, use stress and strain. That is, the allowable stress determined by considering the safety factor against tensile strength or yield stress is used.

However, if a defect (cracks) is present in the structural member, the problem cannot be solved with information only on the stress and deformation amount. Fracture mechanics design or analysis should use stress intensity factor (K), J-integral (J) and crack tip opening displacement (CTOD.δ).

In the present invention, the crack tip opening displacement (CTOD, δ) used as a failure parameter of the opening amount due to plastic yielding of the crack tip in the elasto-plastic breakdown mechanism (EPFM) is used.

Representative international standards that specify fracture mechanics analysis or evaluation include ASME CODE SECTION XI, Appendix. A and BSI PD6493, the national standard of the UK, and WES2805, the welding association standard of Japan.

Although the standards of the respective countries are roughly the same, in the present invention, Japanese standards are adopted as an embodiment.

The evaluation method according to this standard is as follows.

First, the fracture toughness value δc is obtained as follows. The fracture toughness value (δc) is set to 0.1 when there is no crack opening deformation test (COD) result or no impact value. However, if the subject (M) material is special, additional adjustment is required.

Fracture mechanics calculations are made as follows.

(1) Calculation of stress (σ)

sigma t1 = Pr / t, where sigma t1 is the axial working stress, P is the design pressure (actual pressure during adequacy evaluation), r is the inner radius of the cylinder, and t is the thickness of the subject.

sigma t2 = Pr / 2t, where sigma t2 is the circumferential working stress, P is the design pressure (actual pressure in evaluating adequacy), r is the inner radius of the cylinder, and t is the thickness of the subject.

(2) Calculation of deformation amount (ε)

Axial Strain ε1 = ((m-2) / (2mE)) x (Pr / t), where m is Poisson's channel structural steel applied 3.3, E is Young's modulus, P is design pressure (usability) Is the actual pressure), r is the inner radius of the cylinder, and t is the thickness of the subject.

Circumferential strain ε2 = ((2m-1) / (2mE)) x (Pr / t), where m is Poisson's channel structural steel applied 3.3, E is Young's modulus, P is design pressure Is the actual pressure), r is the inner radius of the cylinder, and t is the thickness of the subject.

The fracture parameter δ = 3.5εa in mild steel and the fracture toughness in mild steel are applied by applying δc = 0.1, so that the fracture toughness is greater than the fracture parameter.

However, obtaining the characteristic dimension a of defect is divided into penetrating, buried, and surface according to the thickness direction of the defect according to the Japan Welding Association standard WES 2805, and assessing the connection of adjacent defects, and reading the defect characteristic dimension a from the table. Let's do it.

According to the above engineering calculation, it is possible to clearly know whether or not defects such as stresses or internal cracks that the current subject acts on grow and lead to destruction, thereby ensuring safe maintenance and operation of the facility.

Since all these calculations and color images are made and stored according to the detailed menu programmed through the output means 300, it is possible to always check and compare and prevent calculation errors by manual operation.

In addition, by automatically evaluating the input value and automatically generating and outputting the report, it is possible to prevent the trouble of report preparation and calculation error by manual operation.

As described above, the present invention investigates and analyzes the secular changes and damage conditions such as hydrogen organic cracks and corrosion conditions generated in the equipment industrial facilities such as petrochemical plants, steel mills, and power plants. It is a device for evaluating the safety of the used equipment.It is a large thickness measurement value (90,000 in the range of 150mm length × width) that cannot be displayed or recorded by the conventional method or other inspection methods, and position data value (270,000). By measuring the thickness of the very dense (0.5 × 0.5mm) measurement pointer and their measurement position by digitizing it and displaying it in real time as a visual image in plane, side, and cross-section on a plane as a color image. Not only can you quantitatively measure the extent, area, location, size, and depth of damage using images, but it is also stored and managed as a digital file on your computer. Monitoring of temporal changes in damage is possible.

In addition, the present invention predicts the service life and ruptures of equipment by evaluating the use of measurement accuracy and permanent record storage that are difficult to display by conventional inspection methods, shortening of inspection time, and safety of use based on the engineering basis of damage using image processing results. It can prevent accidents such as water leakage, explosion and environmental pollution.

In addition, since only one side can be approached and the inside and back shapes can be viewed as a three-dimensional precision image, detailed information such as the size, shape, and depth of metal defects and corrosion damage on the inside and back can be seen. It can be used for application to the inspection part.

The present invention is a disadvantage of the conventional infrared camera communication method foreign products, the excessive occupancy of the installation space and the cumbersome installation, the inspection of the above, impossible to recognize the position due to vibration, difficult to use in an environment where infrared communication is difficult (day) Low space mechanical encoder with 3 axes 6 degrees of freedom eliminating shortcomings, etc. Smart (within 250mm height) structure and aluminum lightweight structure that can be detached with one-touch permanent magnet. Permanent use is possible by preventing abrasion, and there is an advantage that the supply of contact medium is also smoothed by processing a cross groove in the lower part of the guard to increase the contact force of the ultrasonic sensor in the pipe or spherical surface.

Above all, the present invention uses a three-axis scanner to detect the serious measurement errors that occur when measuring non-flat parts such as curved pipes, pipes, and spherical surfaces of existing products. Minimized development and measurement error on the plane by using mathematical surface and curvature correction algorithm, the error of ultrasonic image processing result can be within max. + 1.5mm, which makes it possible to quantitatively and precisely evaluate defects using image results. . This increases the reliability of the safety assessment, which directly calculates the size of the defects obtained from the images, and is an important engineering basis for determining continuous use, reinforcement, and renewal of equipment.

In addition, the evaluation method is made by using procedures and procedures in accordance with national and international standards or internationally recognized associations, and its theoretical and engineering basis is clear, so it can be used internationally. The user's convenience is improved by programming the final inspection result image processing result and safety evaluation result to be automatically calculated and printed by the input value according to the screen for the user who does not have error in calculation or engineering knowledge.

1 is a block diagram of a hydrogen organic crack and corrosion measurement system using ultrasonic waves according to the present invention,

2 is a perspective view of an ultrasound scanner according to the present invention;

3 is a side configuration diagram of an ultrasound scanner according to the present invention;

4 is a detailed configuration diagram of the ultrasonic generator of the ultrasonic scanner according to the present invention;

5 is a control circuit block diagram of a hydrogen organic crack and corrosion measurement system using ultrasonic waves according to the present invention,

6 is a screen showing an ultrasonic image processing result according to the present invention;

7A is a schematic diagram for explaining coordinate transformation into a plane when a subject under test is a cylinder during a measurement operation according to the present invention;

FIG. 7B is a schematic diagram showing an end-effect when using three encoders according to the present invention for explaining FIG. 7A;

8A is a schematic diagram for explaining coordinate transformation into a plane when a subject under test is a curved tube according to the present invention;

FIG. 8B is a cross-sectional view illustrating C0, P7, P8, and P9 of FIG. 8A.

Explanation of symbols on the main parts of the drawings

100: ultrasonic scanner 200: signal processing means

300: output means 104: first encoder

107: second encoder 111: third encoder

108: first axis 113: second axis

120: ultrasonic generator 140: transducer

130: magnet holder 210: ultrasonic generator

220: ultrasonic input unit 230,250: A / D conversion unit

240: ultrasonic signal processor 260: encoder signal processor

Claims (23)

delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete Ultrasonic scanner 100 that measures internal cracks and corrosion of the object M such as pipes, curved pipes, spheres, and planes using ultrasonic waves from outside, and cracks and corrosion data measured by the ultrasonic scanner 100. And a signal processing unit 200 which receives the position data of the place measured by the ultrasound scanner 100, converts the digital signal into a digital signal, and outputs the converted signal, and receives a signal output from the signal processing unit 200. Hydrogen organic crack and corrosion measurement system using ultrasonic waves, including an output means 300 capable of performing evaluation and displaying the degree of corrosion and cracking and the safety of the subject M according to the program and simultaneously storing these results. And in the safety evaluation method, A first process of dividing and inspecting a subject inspection surface such as a measurable pipe, a curved tube, a sphere, a flat plate, and then collecting the same and synthesizing it on a plane by software; The analog ultrasonic signal detected on the plane formed through the first process is converted to digital, stored and output in real time, and displayed as a color image corresponding to the thickness of the subject. A second process to recognize the size of the second process; And In order to evaluate the safety of the subject (M) by using the measurement information such as the thickness range and distribution of the subject, the size of the defect and the like measured through the second process, the material and the fracture mechanics evaluation is carried out 3 courses; Safety evaluation method of the subject according to the hydrogen organic crack and corrosion measurement using ultrasonic waves, characterized in that it comprises a. The method of claim 17, In the first process, in order to automatically convert the curvature and the gradient of the subject M into a plane and recognize the shape, the shape recognition of the pipe is 6 points on the object to be inspected, 9 points on the curved line, 4 points on the sphere, and A method for evaluating the safety of a subject according to the hydrogen organic crack and corrosion measurement using ultrasonic waves, characterized in that to read and calculate each of the three points. The method of claim 17, The design specification input used for calculation and information of defects basically input for the safety evaluation of the third process is the design specification of the facility, the thickness of the test object, the temperature, the adjustment value of the inspection equipment, the product name, the device number and the material. A method for evaluating the safety of a subject according to the measurement of hydrogen organic crack and corrosion using ultrasonic waves. The method of claim 17, The material dynamic evaluation for the safety of the third process is to calculate the force acting on the current subject during operation and the strength of the subject to endure, and if the force is less than the strength, the ultrasonic wave is judged as passing. A method for evaluating the safety of a subject according to the hydrogen organic crack and corrosion measurement used The method of claim 20, The material dynamic evaluation is calculated by comparing the axial direction and the circumferential direction, respectively, σy is the yield stress of the material (material intrinsic properties cited in the material strength table), a is the thickness defect length (thickness direction continuous defect length) and length The product of the directional defect length, A is the HIC evaluation area (thickness X longitudinal defect length), σt1 is the axial working stress, σt2 is the circumferential working stress, P is the design pressure (actual pressure during adequacy evaluation), and r is Assuming that the inner radius of the cylinder, t, is the thickness of the subject, the durability is calculated using 0.9σy (1-a / A) and the working stress is calculated using σt1 = Pr / t and σt2 = Pr / 2t. A method for evaluating the safety of a subject according to the measurement of hydrogen organic crack and corrosion using ultrasonic waves. The method of claim 17, Fracture mechanics evaluation for the safety of the third process is to determine the safety of the subject by calculating the current stress and deformation amount of the safety of the subject according to the hydrogen organic crack and corrosion measurement using ultrasonic waves . The method of claim 22, The fracture mechanics evaluation is σt1 is the axial acting stress, σt2 is the circumferential acting stress, P is the design pressure (actual pressure in evaluating adequacy), r is the inner radius of the cylinder, t is the thickness of the specimen, m is the Poisson's If 3.3 is applied to the structural structural steel and E is the Young's modulus, the stress (σ) is calculated as σt1 = Pr / t, σt2 = Pr / 2t, and the deformation amount (ε) is calculated as ε1 = ( (m-2) / (2mE)) x (Pr / t), the circumferential deformation amount is ε2 = ((2m-1) / (2mE)) x (Pr / t) hydrogen using ultrasonic waves Method for evaluating safety of subject under organic crack and corrosion measurement.