CN102778507A - Petroleum storage tank bottom plate ultrasonic guided wave detection method and system - Google Patents
Petroleum storage tank bottom plate ultrasonic guided wave detection method and system Download PDFInfo
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- CN102778507A CN102778507A CN2011101246471A CN201110124647A CN102778507A CN 102778507 A CN102778507 A CN 102778507A CN 2011101246471 A CN2011101246471 A CN 2011101246471A CN 201110124647 A CN201110124647 A CN 201110124647A CN 102778507 A CN102778507 A CN 102778507A
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Abstract
The invention relates to an ultrasonic guided wave detection method and a system of a large flat plate component or a petroleum storage tank bottom plate. Ultrasonic guided wave sensors are installed at different positions of the bottom plate so as to make ultrasonic guided waves focus on all positions of the storage tank bottom plate. The detection method consists of the processes of: 1) setting the following parameters: a total emission channel number M, a total receiving channel number N, a data length, and a gain; 2) setting: a current energizing channel, and a current receiving channel; 3) entering a single collection cycle; 4) determining whether all receiving channels are completed, and if not completed, conducting returning for setting; and if completed, entering the next step; and 5) determining whether all emission channels are completed, and if not completed, conducting returning for setting; and if completed, ending the process. The method and the system provided in the invention have the advantages of great energizing energy, long detection distance, as well as accurate precision and positioning.
Description
Technical field
The present invention is a kind of large flat class A of geometric unitA or petroleum storage tank base plate ultrasonic guided wave detecting method and system, relates to hyperacoustic measurement and piping system technical field.
Background technology
Petroleum storage tank is as the visual plant of national strategic oil reserve, and its effect has significance to strategic realization of goal.The enforcement of As China's oil strategic reserve plan, the capacity of large-scale petroleum storing tank and quantity will further increase.
Large-scale petroleum storing tank moves under physical environment and liquid level change condition all the year round, receives multiple unfavorable factor influence, receives various damages inevitably.Corrosion failure, the crack propagation that particularly chemical corrosion and the galvanic corrosion in the environment caused and breaking etc. causes dielectric leakage, causes major disaster and environmental pollution, brings about great losses to national wealth.According to relevant survey data, in the oil tank corrosion, the base plate corrosion accounts for 80%.Therefore, the corrosion situation of storage tank bottom plate has become the whole storage tank of the evaluation foundation in serviceable life.Regular inspection all must be carried out to storage tank with the substantive requirements of form of law in countries in the world, and the emphasis of inspection is exactly the base plate of storage tank.
Yet conventional storage tank bottom detection method all will stop oil tank transmitting-receiving operation and clear jar, rust cleaning even tear operation such as insulation open, and its oil product loss and working measure expense are very high, and length consuming time, efficient are low.Therefore, research and develop a kind of low-loss lossless detection method that can be implemented in the labour detection, become one of focus of petrochemical industry Non-Destructive Testing research storage tank bottom plate.
CN101762635A discloses a kind of oil tank bottom plate ultrasonic guided wave detecting method.CN101666783A discloses a kind of oil tank tank bottom ultrasonic guided wave detecting method that is used for." Non-Destructive Testing " the 32nd volume o. 11th discloses a kind of image rebuilding method of phased array supersonic guided wave of storage tank bottom plate defective.Though these methods have certain effect to the detection of storage tank bottom plate defective, it is not long to detect distance, and precision and positional accuracy are all limited.
Summary of the invention
The objective of the invention is to invent petroleum storage tank base plate ultrasonic guided wave detecting method and the system that a kind of excitation energy is big, detect distance, precision and accurate positioning.
Need to above-mentioned actual detected, according to the shape facility of storage tank bottom plate, promptly typical thin-slab construction; The present invention utilizes supersonic guide-wave that storage tank bottom plate is detected; Promptly, sonac is installed, is made supersonic guide-wave focus on each position of storage tank bottom plate at the diverse location of storage tank bottom plate.Fig. 4-Fig. 8 has provided the installation site of various sonacs and the synoptic diagram of focusing.
This petroleum storage tank base plate ultrasonic guided wave detecting method is seen Fig. 1, and the data acquisition main-process stream is:
1) parameter setting: total transmission channel is counted M, and total receiving cable is counted N, data length, gain etc.;
2) set: current excitation passage (channel number ...), current receiving cable (channel number ...);
3) get into the single acquisition circulation;
4) whether all receiving cables are accomplished, and do not accomplish, and then return setting; Accomplish, then get into the step down;
5) whether all transmission channels are accomplished, and do not accomplish, and then return setting; Accomplish, then finish.
Wherein single acquisition circulation process (see figure 2) is:
1) dedicated tunnel excitation;
2) set communication channel delay and receive (one or more);
3) raw data is uploaded to software section;
4) data amalgamation;
5) reach predetermined acquisition length? In this way, then finish to gather, form wave file; As not, then receive and return the dedicated tunnel excitation after time-delay increases.
The collection of ultrasound detection signal realizes through three nested cyclic processes that with storing process emission circulates, reception circulates, single acquisition circulates by being respectively in reaching according to the level of nesting outward; In the layout of accomplishing the supersonic guide-wave sensor array, and on software interface, accomplish total transmission channel number, total receiving cable number, each passage emission delay, after image data length, the isoparametric setting of passage receiving gain, system promptly gets into the emission cyclic process;
The emission circulation is provided with and triggers the excitation passage of setting successively, all accomplishes end loop up to the used transmission channel of setting;
Receive circulation and be second layer circulation, when the excitation passage of a certain setting or excitation combination of channels were launched, the receiving cable of the correspondence of all settings received successively, after the reception combination completion of all settings, jumps out this circulation;
The single acquisition circulation is innermost loop, is implemented in to specify excitation passage and the data acquisition of specifying under the receiving cable condition.Because the data volume that the petroleum storage tank base plate detects is bigger, buffer memory can not satisfy the data conversion storage requirement on the plate of general ultrasound electronics system, therefore adopts the method for acquisition time splicing to carry out the collection of data.Time-delay through changing receiving cable obtains the detection signal in the bigger time range; After accomplishing, each time-delay collection is about to data upload to host computer; Accomplish splicing by the data splicing module, and feed back the data length of having gathered, if the data length of having gathered does not reach preset length; Then increase delay value, the collection of next time delaying time; If the data length of having gathered has reached preset length, then finish to gather, and generate storage file automatically, with the data storage of gathering under predetermined directory.
According to said method, the composition of petroleum storage tank base plate ultrasonic guided wave detecting of the present invention system (see figure 3) comprises three parts: the processing and the acoustic imaging system of the detection data of supersonic guide-wave sensor array, channel ultrasonic electronic system and hardware components.
Said channel ultrasonic electronic system is made up of driver unit and receiving unit; The processing of said detection data and acoustic imaging system by detected parameters module, data acquisition and concatenation module are set, data processing harmony image-forming module three parts are formed.
The output of supersonic guide-wave sensor array connects the receiving unit of channel ultrasonic electronic system, and the output of receiving unit connects array collection and concatenation module, and array collection and concatenation module output connect data processing harmony image-forming module; Detected parameters is provided with the driver unit that module output connects the channel ultrasonic electronic system, and the output of driver unit connects the supersonic guide-wave sensor array.
The layout of said supersonic guide-wave sensor array: detecting sensor adopts bonding mode to be arranged in the margin plate place of storage tank bottom plate, and as shown in Figure 4, bonding preceding the need done simple process to gluing of surfaces, to guarantee that sensor contacts with the tight of margin plate;
According to parameters such as the diameter of seized base plate, decay, defect characteristics; Select right sensors grouping (every group sensor number; And this group sensor is used for emission, reception or internal loopback etc.) and the detection position, under the prerequisite that guarantees detection sensitivity, realize maximum sensing range; According to the different-diameter and the attenuation of seized storage tank bottom plate, can select following four kinds of detection modes:
Shown in Figure 5, for storage tank bottom plate than minor diameter, with several/the group sensor is distributed on the circumference of margin plate, each sensor is launched successively, all the sensors receives;
Shown in Figure 6 for all the sensors is arranged in a side of base plate, different according to detecting the degree of depth, according to different excited rules, form the focus of different depth; Then as required, select the sensor of certain several position to carry out the synthetic aperture reception, or use all sensors to receive when receiving detection signal;
Shown in Figure 7 was the transmission-type detection of diameter, bigger for diameter, or the more serious storage tank bottom plate of decay, adopted this mode; All the sensors is divided into two groups, is used separately as phased emission and phased reception, on circumference, carry out 180 ° of scannings successively, realize detection the base plate interior defective;
Very big for diameter, the serious storage tank bottom plate of decaying adopts the mode of Fig. 8 to detect; Under the prerequisite that guarantees detection sensitivity, sensor is divided into two groups, be arranged on the circumference by certain angle, the public coverage of this two sensors is effective surveyed area; Through seized base plate is divided into zones of different, then accomplish each regional detection successively; For the part that under current sensitivity, can't detect, then need switch the sensor of lower frequency, sacrifice detection sensitivity to exchange bigger sensing range for;
Said channel ultrasonic electronic system is:
For ease of expanding and reducing cost, the channel ultrasonic electronic system is become with 4 digital channel group by 16 analog channels, and each interchannel running parameter and sequential are controlled by software section; Because the independence each other of each analog channel and digital channel, this detection system expands to more hyperchannel comparatively easily, and Control Software does not need to revise basically;
The processing of said detection data and acoustic imaging system are:
Because this detection system has been preserved the most original obtainable radiofrequency signal to the signal storage mode that ultrasonic testing signals adopts full-wave train to gather; Therefore in the poster processing soft, detection signal is adopted multiple processing mode; The signal processing method that uses comprises: various filtering, difference, extraction, auto-correlation and simple crosscorrelation, power spectrumanalysis, wavelet transformation, Fourier analysis, Fourier analysis in short-term etc.; The acoustic imaging mode that adopts comprises: B scanning imagery, C scanning imagery, P scanning imagery etc.;
Wherein:
Channel ultrasonic electronic system in the petroleum storage tank base plate ultrasonic guided wave detecting of the present invention system and to detect the electric principle of processing and acoustic imaging system of data as shown in Figure 9; There is the host computer of main control software control to be connected with slave computer control core CPU, cpu bus interface and a plurality of four-way ultrasonic signal card connection of the input of matrix keyboard, liquid crystal display output, storage element and power supply unit power supply arranged through network interface;
Host computer is communicated by letter with slave computer control core (CPU (ARM9)) through network interface, writes each item detected parameters of being set by main control software; CPU (ARM9) is according to each ultrasonic signal card work of detected parameters control, according to the sequential excitation with receive ultrasonicly, simultaneously the ultrasonic signal that receives carried out buffer memory, and when host computer allows to interrupt, is transferred to host computer, further analyzed by main control software;
Four-way ultrasonic signal card is the important component part of this system hardware, and its electric principle is shown in figure 10; The FPGA that is connected with cpu bus interface (EP2C8Q) output connects high-pressure modular, and high-pressure modular output connects a plurality of transmitter units; A plurality of receiving element outputs connect 4 and select 1 channel to channel adapter, and 4 select the output of 1 channel to channel adapter to be connected in series programmable amplifier, traffic filter, A/D converter successively, and A/D converter output meets FPGA, and programmable amplifier, traffic filter also have output to meet FPGA;
The control core of this four-way ultrasonic signal card is FPGA, and communicates by letter with slave computer control core ARM through cpu bus.After FPGA reads in each item detected parameters from bus, control high-pressure modular and channel to channel adapter, according to the time ordered pair each passage transmitter unit encourage, and gather the signal of respective channel; Set the time length of field in, the ultrasonic signal card carries out program control amplification according to preset parameter to signal, the A/D conversion is carried out in filtering at last, the ultrasound detection signal that converts digital signal into is transferred to slave computer control core CPU (ARM) through FPGA.
This detection system is directed against the base plate detection demand of petroleum storage tank and develops, but also can be applicable to the Ultrasonic NDT of other big template class A of geometric unitA.
The present invention is applicable to the detection of storage tank bottom plate defective, this method excitation energy bigger (400W), detects distance longer (greater than 3 meters), precision and location more accurately (less than 10 centimetres), can be the storage tank bottom plate defects detection faster more economical mode is provided.
Description of drawings
Fig. 1 detection system control flow chart (outer circulation)
Fig. 2 detection system control flow chart (interior loop)
Fig. 3 petroleum storage tank base plate ultrasonic guided wave detecting system principle diagram
Fig. 4 sensor array is arranged signal
The detection method synoptic diagram of Fig. 5 minor diameter base plate
Fig. 6 is to the focused view of diverse location
The focusing that Fig. 7 crosses the center transmits and receives synoptic diagram
The deflection focusing of Fig. 8 target spot transmits and receives synoptic diagram
Fig. 9 detection system circuit theory diagrams
Figure 10 four-way ultrasonic signal card circuit theory diagrams
The seized test specimen imaging region of Figure 11 synoptic diagram
Figure 12 detects imaging results figure
Embodiment
Embodiment. embodiment of the present invention is described and the present invention is further described with this example.This example is an experimental prototype, and its formation is as shown in Figure 3, is made up of the processing and the acoustic imaging system of the detection data of supersonic guide-wave sensor array, channel ultrasonic electronic system and hardware components.
The processing of channel ultrasonic electronic system that this is routine and detection data and the electric principle of acoustic imaging system are as shown in Figure 9; There is the host computer of main control software control to be connected with slave computer control core CPU, cpu bus interface and a plurality of four-way ultrasonic signal card connection of the input of matrix keyboard, liquid crystal display output, storage element and power supply unit power supply arranged through network interface;
Four-way ultrasonic signal card is the important component part of this system hardware, and its electric principle is shown in figure 10; The FPGA that is connected with cpu bus interface (EP2C8Q) output connects high-pressure modular, and high-pressure modular output connects a plurality of transmitter units; A plurality of receiving element outputs connect 4 and select 1 channel to channel adapter, and 4 select the output of 1 channel to channel adapter to be connected in series programmable amplifier, traffic filter, A/D converter successively, and A/D converter output meets FPGA, and programmable amplifier, traffic filter also have output to meet FPGA;
Wherein:
The host computer choosing;
Host computer selects A-790 can expand military reinforced notebook computer;
FPGA selects EP2C8Q;
High-pressure modular selects 500V ACDC module;
Transmitter unit selects IRF 840s;
Receiving element selects RLC sensor impedance matching network;
4 select 1 channel to channel adapter to select 74HC4051;
Programmable amplifier selects AD603;
Traffic filter selects passive secondary pi network;
A/D converter selects AD9215.
This example is tested at the base plate of the crude oil storage tank of one 5 ten thousand steres.Seized test specimen imaging region synoptic diagram is shown in figure 11.Shown in Figure 12ly, the detection signal Applied Digital of native system carries out the acoustic imaging process result for being focused on the inversion imaging algorithm.
Test employed linear transducer array and form, arrange the mode that adopts Fig. 6 by 10 supersonic guide-wave sensors.The material that detects test specimen is identical with the material of petroleum storage tank margin plate, and thickness is 10mm.Be processed with following artificial defect apart from probe 2500mm place, forward position, as shown in Figure 4: 1, the through hole of diameter 5mm; 2, be of a size of the cutting of 30mm * 4mm * 2.5mm, 2.5mm is a groove depth; 3, the through hole of diameter 10mm; 4, the through hole of diameter 20mm.Level interval between four artificial defects is following: differ 100mm between 1 and 2; Differ 100mm between 2 and 3; Differ 200mm between 3 and 4, defective 3 is 2500mm with the sensor array Front distance.
The data acquisition main-process stream is:
1) parameter setting: total transmission channel is counted M, and total receiving cable is counted N, data length, gain etc.;
2) set: current excitation passage (channel number ...), current receiving cable (channel number ...);
3) get into the single acquisition circulation;
4) whether all receiving cables are accomplished, and do not accomplish, and then return setting; Accomplish, then get into the step down;
5) whether all transmission channels are accomplished, and do not accomplish, and then return setting; Accomplish, then finish.
Wherein single acquisition circulation process (see figure 2) is:
1) dedicated tunnel excitation;
2) set communication channel delay and receive (one or more);
3) raw data is uploaded to software section;
4) data amalgamation;
5) reach predetermined acquisition length? In this way, then finish to gather, form wave file; As not, then receive and return the dedicated tunnel excitation after time-delay increases.
The acoustic imaging result that Applied Digital focusing inversion imaging algorithm draws is as shown in Figure 5, and the acoustic imaging result of each artificial defect marks with the numeral of correspondence.Imaging results has correctly reflected the relative position relation between each artificial defect, but the lateral resolution of imaging still remains to be improved.Through revising imaging algorithm, perhaps select other more suitably imaging algorithms for use, then can effectively improve imaging results.
Claims (12)
1. a petroleum storage tank base plate ultrasonic guided wave detecting method is characterized in that the diverse location at storage tank bottom plate, and sonac is installed, and makes supersonic guide-wave focus on each position of storage tank bottom plate; The collection of ultrasound detection signal realizes through three nested cyclic processes that with storing process emission circulates, reception circulates, single acquisition circulates by being respectively in reaching according to the level of nesting outward; In the layout of accomplishing the supersonic guide-wave sensor array, and on software interface, accomplish total transmission channel number, total receiving cable number, each passage emission delay, after the setting of image data length, passage receiving gain parameter, system promptly gets into the emission cyclic process;
The emission circulation is provided with and triggers the excitation passage of setting successively, all accomplishes end loop up to the used transmission channel of setting;
Receive circulation and be second layer circulation, when the excitation passage of a certain setting or excitation combination of channels were launched, the receiving cable of the correspondence of all settings received successively, after the reception combination completion of all settings, jumps out this circulation;
The flow process of detection method is:
1) parameter setting: total transmission channel is counted M, and total receiving cable is counted N, data length, gain;
2) set: current excitation passage, current receiving cable;
3) get into the single acquisition circulation;
4) whether all receiving cables are accomplished, and do not accomplish, and then return setting; Accomplish, then get into the step down;
5) whether all transmission channels are accomplished, and do not accomplish, and then return setting; Accomplish, then finish.
2. petroleum storage tank base plate ultrasonic guided wave detecting method according to claim 1 is characterized in that said single acquisition circulation is innermost loop, adopts the method for acquisition time splicing to carry out the collection of data; Time-delay through changing receiving cable obtains the detection signal in the bigger time range; After accomplishing, each time-delay collection is about to data upload to host computer; Accomplish splicing by the data splicing module, and feed back the data length of having gathered, if the data length of having gathered does not reach preset length; Then increase delay value, the collection of next time delaying time; If the data length of having gathered has reached preset length, then finish to gather, and generate storage file automatically, with the data storage of gathering under predetermined directory; Its flow process is:
1) dedicated tunnel excitation;
2) setting communication channel delay receives;
3) raw data is uploaded to software section;
4) data amalgamation;
5) reach predetermined acquisition length? In this way, then finish to gather, form wave file; As not, then receive and return the dedicated tunnel excitation after time-delay increases.
3. a petroleum storage tank base plate ultrasonic guided wave detecting system that uses the said method of claim 1 is characterized in that it comprises the processing and acoustic imaging system three parts of the detection data of supersonic guide-wave sensor array, channel ultrasonic electronic system and hardware components.
4. petroleum storage tank base plate ultrasonic guided wave detecting according to claim 3 system is characterized in that said channel ultrasonic electronic system is made up of driver unit and receiving unit; The processing of said detection data and acoustic imaging system by detected parameters module, data acquisition and concatenation module are set, data processing harmony image-forming module three parts are formed;
The output of supersonic guide-wave sensor array connects the receiving unit of channel ultrasonic electronic system, and the output of receiving unit connects array collection and concatenation module, and array collection and concatenation module output connect data processing harmony image-forming module; Detected parameters is provided with the driver unit that module output connects the channel ultrasonic electronic system, and the output of driver unit connects the supersonic guide-wave sensor array.
5. petroleum storage tank base plate ultrasonic guided wave detecting according to claim 3 system; The layout that it is characterized in that said supersonic guide-wave sensor array: according to diameter, decay, the defect characteristic parameter of seized base plate; Select right sensors to divide into groups and the detection position; Under the prerequisite that guarantees detection sensitivity, realize maximum sensing range;
Detecting sensor adopts bonding mode to be arranged in the margin plate place of storage tank bottom plate, and bonding preceding the need done simple process to gluing of surfaces, and sensor contacts with the tight of margin plate.
6. according to claim 3 or 5 described petroleum storage tank base plate ultrasonic guided wave detecting systems, it is characterized in that for storage tank bottom plate than minor diameter, with several/the group sensor is distributed on the circumference of margin plate, each sensor is launched successively, all the sensors receives.
7. according to claim 3 or 5 described petroleum storage tank base plate ultrasonic guided wave detecting systems, it is characterized in that all the sensors is arranged in a side of base plate, different according to detecting the degree of depth, according to different excited rules, form the focus of different depth; Then as required, select the sensor of certain several position to carry out the synthetic aperture reception, or use all sensors to receive when receiving detection signal.
8. according to claim 3 or 5 described petroleum storage tank base plate ultrasonic guided wave detecting systems; The transmission-type that it is characterized in that diameter detects; Bigger for diameter, or the more serious storage tank bottom plate of decay, all the sensors is divided into two groups; Be used separately as phased emission and phased reception, on circumference, carry out 180 ° of scannings successively.
9. according to claim 3 or 5 described petroleum storage tank base plate ultrasonic guided wave detecting systems; It is characterized in that for diameter very big; The serious storage tank bottom plate of decaying under the prerequisite that guarantees detection sensitivity, is divided into two groups with sensor; Be arranged on the circumference by certain angle, the public coverage of this two sensors is effective surveyed area; Through seized base plate is divided into zones of different, then accomplish each regional detection successively; For the part that under current sensitivity, can't detect, then need switch the sensor of lower frequency, sacrifice detection sensitivity to exchange bigger sensing range for.
10. petroleum storage tank base plate ultrasonic guided wave detecting according to claim 3 system is characterized in that said channel ultrasonic electronic system is become with 4 digital channel group by 16 analog channels, and each interchannel running parameter and sequential are controlled by software section.
11. petroleum storage tank base plate ultrasonic guided wave detecting according to claim 3 system; The processing that it is characterized in that the channel ultrasonic electronic system in the oil tank base plate ultrasonic guided wave detecting system and detect data with the electric principle of acoustic imaging system is: have the host computer of main control software control to control core CPU through network interface and slave computer and be connected the cpu bus interface and a plurality of four-way ultrasonic signal card connection that have the input of matrix keyboard, liquid crystal display output, storage element and power supply unit to supply power;
Host computer is communicated by letter with slave computer control core CPU through network interface, writes each item detected parameters of being set by main control software; CPU is according to each ultrasonic signal card work of detected parameters control, according to the sequential excitation with receive ultrasonicly, simultaneously the ultrasonic signal that receives carried out buffer memory, and when host computer allows to interrupt, is transferred to host computer, further analyzed by main control software.
12. petroleum storage tank base plate ultrasonic guided wave detecting according to claim 11 system is characterized in that said four-way ultrasonic signal card is: the FPGA output that is connected with cpu bus interface connects high-pressure modular, and high-pressure modular output connects a plurality of transmitter units; A plurality of receiving element outputs connect 4 and select 1 channel to channel adapter, and 4 select the output of 1 channel to channel adapter to be connected in series programmable amplifier, traffic filter, A/D converter successively, and A/D converter output meets FPGA, and programmable amplifier, traffic filter also have output to meet FPGA;
The control core of this four-way ultrasonic signal card is FPGA, and communicates by letter with slave computer control core ARM through cpu bus; After FPGA reads in each item detected parameters from bus, control high-pressure modular and channel to channel adapter, according to the time ordered pair each passage transmitter unit encourage, and gather the signal of respective channel; Set the time length of field in, the ultrasonic signal card carries out program control amplification according to preset parameter to signal, the A/D conversion is carried out in filtering at last, the ultrasound detection signal that converts digital signal into is transferred to slave computer control core CPU through FPGA.
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| CN104833628A (en) * | 2015-04-29 | 2015-08-12 | 中国石油天然气股份有限公司 | Storage tank base plate detection analog device and analog storage tank |
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| CN106066365A (en) * | 2016-08-22 | 2016-11-02 | 中国石油化工股份有限公司 | Storage tank bottom plate In-service testing System and method for based on mangneto formula horizontal shear wave |
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