CN103336055A - The Method of Detecting the Weld Seam Quality of the Main Circuit Pipeline of Nuclear Power Plant Using Phased Array Ultrasonic - Google Patents
The Method of Detecting the Weld Seam Quality of the Main Circuit Pipeline of Nuclear Power Plant Using Phased Array Ultrasonic Download PDFInfo
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Abstract
Description
技术领域technical field
本发明涉及一种用相控阵超声检测核电站主回路管道焊缝质量的方法,其属于超声无损检测与评价技术领域。The invention relates to a method for detecting the weld seam quality of a main loop pipeline of a nuclear power plant by using phased array ultrasound, which belongs to the technical field of ultrasonic nondestructive testing and evaluation.
背景技术Background technique
壁厚66~99mm的离心铸造奥氏体不锈钢(Centrifugal CastingAustenitic Stainless Steel,CCASS)是压水堆核电站一回路冷却剂管道使用的主要材料之一,管道之间一般通过焊接进行连接,焊接质量的好坏直接关系着核电站运行的安全性和可靠性。在核电站和核动力装置的检验规范和大纲(IWA-2232APP.I)中,对主回路管道焊缝的加工质量及服役期间的状况提出了无损检测的强制性要求。准确、可靠的主回路管道焊缝无损检测技术的研究与开发是核电站安全运行的迫切工程需求。Centrifugal Casting Austenitic Stainless Steel (CCASS) with a wall thickness of 66-99 mm is one of the main materials used in the primary circuit coolant pipes of pressurized water reactor nuclear power plants. The pipes are generally connected by welding, and the welding quality is good. Damage is directly related to the safety and reliability of nuclear power plant operation. In the inspection specification and outline (IWA-2232APP.I) of nuclear power plants and nuclear power plants, mandatory requirements for non-destructive testing are put forward for the processing quality of the main circuit pipeline welds and the conditions during service. The research and development of accurate and reliable non-destructive testing technology for main loop pipeline welds is an urgent engineering demand for the safe operation of nuclear power plants.
目前的检测标准和技术条件要求对此类焊缝进行分层渗透检测和射线检测并利用常规超声检测作为辅助手段。但是,分层渗透只能检测焊缝表面开口缺陷,检测程序繁琐,速度慢,周期长;射线检测对人体有害,且对危害性很大的裂纹、未熔合等面积型缺陷并不敏感,很容易发生漏检,给核电设施的安全运行带来很大隐患;常规超声检测可达性较差,检测结果准确性易受耦合条件以及技术人员水平影响,难以进行快速准确的检测。Current testing standards and technical conditions require layered penetrant testing and radiographic testing for such welds with conventional ultrasonic testing as an auxiliary means. However, layered penetration can only detect opening defects on the surface of the weld, and the detection procedure is cumbersome, slow, and long. Radiographic detection is harmful to the human body, and it is not sensitive to area-type defects such as cracks and incomplete fusion, which are very harmful. Missed detection is prone to occur, which brings great hidden dangers to the safe operation of nuclear power facilities; the accessibility of conventional ultrasonic detection is poor, and the accuracy of detection results is easily affected by coupling conditions and the level of technical personnel, making it difficult to perform fast and accurate detection.
发明内容Contents of the invention
本发明的目的是提供一种用相控阵超声检测核电站主回路管道焊缝质量的方法。与常规超声检测方法相比,该方法通过调整探头中各个阵元发射/接收的相位延迟,产生偏转和聚焦声束,从而有效改善可达性。同时,通过优化控制焦点位置、焦区尺寸和声束方向,还能极大地提高检测分辨力、信噪比和灵敏度。超声相控阵采用电子方法控制声束的扫描,在不移动或少移动探头的情况下完成快速扫查,不仅提高了检测的速度,更保证了耦合条件的稳定一致。丰富的扫查模式也有助于缺陷信号的正确识别。The purpose of the present invention is to provide a method for detecting the quality of the welding seam of the main loop pipeline of a nuclear power plant by using phased array ultrasonic. Compared with the conventional ultrasonic detection method, this method effectively improves the accessibility by adjusting the phase delay of each element in the probe to transmit/receive to deflect and focus the sound beam. At the same time, the detection resolution, signal-to-noise ratio and sensitivity can be greatly improved by optimizing the control of the focus position, focal area size and sound beam direction. The ultrasonic phased array uses electronic methods to control the scanning of the sound beam, and completes the fast scanning without moving or less moving the probe, which not only improves the detection speed, but also ensures the stability and consistency of the coupling conditions. The rich scanning mode also helps to correctly identify the defect signal.
本发明解决其技术问题所采用的技术方案是:一种用相控阵超声检测核电站主回路管道焊缝质量的方法,其特征是:它采用包括Dynaray Lite超声相控阵检测仪、UltraVision3.2R9相控阵操作系统、低频双晶纵波面阵探头、扫查器和校准试块构成检测66~99mm厚的离心铸造奥氏体不锈钢主管道焊缝区域的装置。它采用的测量步骤如下:The technical solution adopted by the present invention to solve the technical problem is: a method for detecting the quality of the weld seam of the main circuit pipeline of a nuclear power plant using phased array ultrasonic, which is characterized in that: it adopts a Dynaray Lite ultrasonic phased array detector, UltraVision3.2R9 A phased array operating system, a low-frequency double-crystal longitudinal-wave surface array probe, a scanner and a calibration test block constitute a device for detecting the weld area of a centrifugally cast austenitic stainless steel main pipe with a thickness of 66-99 mm. It uses the following measurement steps:
(1)了解被检测件的材料牌号、焊缝型式、焊接工艺、尺寸以及范围;对被检测件进行表面处理:对于接触表面,清除阻碍探头的自由移动或者削弱超声震动传播的焊接溅滴和任何粗糙的东西,确保表面粗糙度Ra不超过6.3μm,使探头在完全的接触表面上可以自由的移动;对于焊缝表面,清除使缺陷信号模糊或者不能被发现的不规则形状;在被检测件表面做出清晰的焊缝标识、焊接位置标识线及焊缝位置参考点;根据被检测材料选取合适的耦合剂;(1) Understand the material grade, weld type, welding process, size and scope of the tested part; carry out surface treatment on the tested part: for the contact surface, remove welding spatter and splashes that hinder the free movement of the probe or weaken the propagation of ultrasonic vibration. For any rough things, ensure that the surface roughness Ra does not exceed 6.3 μm, so that the probe can move freely on the complete contact surface; for the weld surface, remove the irregular shape that makes the defect signal blurred or cannot be found; Make a clear weld mark, weld position mark line and weld position reference point on the surface of the workpiece; select the appropriate coupling agent according to the material to be tested;
(2)在UltraVision3.2R9相控阵操作系统内建立试样模型,对被检区域纵波声速、衰减进行测量;(2) Establish a sample model in the UltraVision3.2R9 phased array operating system, and measure the sound velocity and attenuation of the longitudinal wave in the inspected area;
(3)根据被检区域的纵波声速、衰减的测试结果,编辑模型中材料属性,选择合适的检测角度;(3) According to the test results of longitudinal wave sound velocity and attenuation in the inspected area, edit the material properties in the model and select an appropriate inspection angle;
(4)对被检测件焊缝及邻近母材至少10mm的范围在厚度方向进行检测区域分层,使用1.5MHz面阵探头检测扫查表面以下0~20mm区域;1.0MHz面阵探头检测扫查表面以下20~60mm区域;0.5MHz面阵探头检测扫查表面以下60mm至底面范围;(4) Layer the detection area in the thickness direction for the weld seam of the tested part and the area adjacent to the base metal of at least 10mm, use a 1.5MHz area array probe to detect and scan the area 0-20mm below the surface; 1.0MHz area array probe to detect and scan 20-60mm area below the surface; 0.5MHz area array probe detects and scans the range from 60mm below the surface to the bottom surface;
(5)连接1.5MHz面阵探头与Dynaray Lite超声相控阵检测仪,组装相控阵检测系统;选取标准块上距表面以下0~20mm区域的人工横通孔,根据缺陷的深度确定相控阵系统的聚焦法则、超声设置和机械设置,在UltraVision3.2R9相控阵操作系统的检测界面添加动态体积校正过的扇扫图、B扫图、C扫图和D扫图;在UltraVision3.2R9相控阵操作系统的分析界面添加静态体积校正过的扇扫图、B扫图、C扫图和D扫图;对相控阵检测系统进行楔块延迟和纵波声速校准;(5) Connect the 1.5MHz area array probe and the Dynaray Lite ultrasonic phased array detector to assemble the phased array detection system; select the artificial horizontal through hole in the area 0-20mm below the surface on the standard block, and determine the phase control according to the depth of the defect. The focal law, ultrasonic settings and mechanical settings of the array system, add dynamic volume corrected sector scan pictures, B scan pictures, C scan pictures and D scan pictures in the detection interface of the UltraVision3.2R9 phased array operating system; in UltraVision3.2R9 The analysis interface of the phased array operating system adds static volume corrected sector scans, B scans, C scans and D scans; performs wedge delay and longitudinal wave sound velocity calibration for the phased array detection system;
(6)校准扫查器的步进速度,组装1.5MHz面阵探头与扫查器;设定扫查轨迹、分辨率和扫查步进速度;启动扫查器对被检测件进行扫查,记录扫查结果;分析扫查结果,在得到的静态扇扫图、A扫图和B扫图中读取扫查表面以下0~20mm区域的缺陷信息,判断缺陷类型并记录缺陷尺寸;对于扫查过程中遇到的面积型缺陷,结合多视图利用-6dB法测量缺陷长度;(6) Calibrate the stepping speed of the scanner, assemble the 1.5MHz area array probe and the scanner; set the scanning trajectory, resolution and scanning stepping speed; start the scanner to scan the tested part, Record the scanning results; analyze the scanning results, read the defect information in the 0-20mm area below the scanned surface in the obtained static sector scan, A-scan and B-scan, determine the type of defect and record the size of the defect; Area-type defects encountered in the inspection process, combined with multi-view using -6dB method to measure the defect length;
(7)使用1.0MHz和0.5MHz面阵探头分别检测扫查表面以下20~60mm和60mm至底面区域时,分别选取标准块上距表面以下20~60mm区域的人工横通孔和60mm至底面区域的人工横通孔进行相控阵系统的校准,其余步骤方法与(5)、(6)步相同。(7) When using 1.0MHz and 0.5MHz area array probes to detect and scan the areas 20-60mm below the surface and 60mm to the bottom, respectively, select the artificial horizontal through holes in the area 20-60mm below the surface on the standard block and the area 60mm to the bottom. Calibrate the phased array system through the artificial horizontal through hole, and the remaining steps are the same as steps (5) and (6).
本发明的有益效果是:克服了分层渗透只能检测焊缝表面开口缺陷,检测程序繁琐,速度慢,周期长;射线检测对人体有害,且对危害性很大的裂纹、未熔合等面积型缺陷并不敏感,很容易发生漏检,给核电设施的安全运行带来很大隐患;常规超声检测可达性较差,检测结果准确性易受耦合条件以及技术人员水平影响,难以进行快速准确的检测等缺点。本发明可迅速准确的检测核电站主回路管道焊缝的质量以及服役状态,所用设备可调节性强,测量精度高,现场检测结果稳定可靠,对核电站的顺利建设和安全运行具有十分重大的意义。The beneficial effect of the present invention is: to overcome layered penetration can only detect the surface opening defect of the weld, the detection procedure is cumbersome, the speed is slow, and the cycle is long; the ray detection is harmful to the human body, and it is very harmful to cracks, unfused areas, etc. Type defects are not sensitive, and it is easy to miss detection, which brings great hidden dangers to the safe operation of nuclear power facilities; the accessibility of conventional ultrasonic detection is poor, and the accuracy of detection results is easily affected by coupling conditions and the level of technical personnel, so it is difficult to conduct rapid Accurate detection and other shortcomings. The invention can quickly and accurately detect the quality and service state of the main loop pipeline of the nuclear power plant, the equipment used has strong adjustability, high measurement accuracy, stable and reliable on-site detection results, and is of great significance to the smooth construction and safe operation of the nuclear power plant.
附图说明Description of drawings
下面结合附图和实施例对本发明作进一步说明。The present invention will be further described below in conjunction with drawings and embodiments.
图1是一种用相控阵超声检测核电站主回路管道焊缝加工质量及服役状态的方法所用装置的硬件结构连接示意图。Figure 1 is a schematic diagram of the hardware structure connection of the device used in the method for detecting the processing quality and service status of the main circuit pipeline weld seam of a nuclear power plant by using phased array ultrasound.
图2是相控阵检测周向试块焊缝上30mm和50mm深度孔对应的扇扫图。Figure 2 is a sector scan diagram corresponding to the 30mm and 50mm depth holes on the weld seam of the phased array detection circumferential test block.
图3是相控阵检测周向试块焊缝上一处裂纹所对应的回波幅度最强位置扇扫图。Fig. 3 is a fan scan diagram of the position with the strongest echo amplitude corresponding to a crack on the weld seam of the circumferential test block detected by the phased array.
图4是相控阵检测周向试块焊缝上两处临近裂纹所对应的B扫图。Figure 4 is a B-scan corresponding to two adjacent cracks on the weld of the circumferential test block detected by the phased array.
图5是相控阵检测轴向试块焊缝上35mm和60mm深度孔对应的扇扫图。Figure 5 is a sector scan diagram corresponding to the 35mm and 60mm depth holes on the weld seam of the phased array detection axial test block.
图6是相控阵检测轴向试块一处裂纹所对应的回波幅度最强位置扇扫图。Fig. 6 is a sector scan diagram of the position with the strongest echo amplitude corresponding to a crack in the axial test block detected by the phased array.
图7是相控阵检测轴向试块一处裂纹所对应的B扫图。Fig. 7 is a B-scan corresponding to a crack in the axial test block detected by the phased array.
具体实施方式Detailed ways
本相控阵超声检测核电站主回路管道焊缝质量的方法由图1所示的Dynaray Lite超声相控阵检测仪、UltraVision3.2R9相控阵操作系统、低频双晶纵波面阵探头、扫查器和校准试块构成。可检测壁厚66~99mm的离心铸造奥氏体不锈钢核电站主回路管道。所述检测过程如下:The phased array ultrasonic detection method for the weld quality of the main circuit pipeline of nuclear power plant consists of Dynaray Lite ultrasonic phased array detector, UltraVision3.2R9 phased array operating system, low frequency dual crystal longitudinal wave area array probe and scanner shown in Figure 1. and calibration test block. It can detect centrifugally cast austenitic stainless steel nuclear power plant main circuit pipes with a wall thickness of 66-99mm. The detection process is as follows:
(1)针对厚度为92mm的离心铸造奥氏体不锈钢相控阵检测轴向试块,了解到其焊接方式为窄间隙自动焊,必须对焊缝及邻近母材10mm的范围进行100%检测。对被检测件进行表面处理:对于接触表面,清除阻碍探头的自由移动或者削弱超声震动传播的焊接溅滴和任何粗糙的东西,确保表面粗糙度Ra不超过6.3μm,使探头在完全的接触表面上可以自由的移动;对于焊缝表面,清除使缺陷信号模糊或者不能被发现的不规则形状。在被检测件表面做出清晰的焊缝标识、焊接位置标识线及焊缝位置参考点。耦合剂选用奥氏体不锈钢专用耦合剂。(1) For the centrifugally cast austenitic stainless steel phased array test axial test block with a thickness of 92mm, it is known that the welding method is narrow gap automatic welding, and 100% inspection must be carried out on the weld seam and the range of 10mm adjacent to the base metal. Surface treatment of the tested part: For the contact surface, remove welding spatter and any rough things that hinder the free movement of the probe or weaken the propagation of ultrasonic vibrations, and ensure that the surface roughness Ra does not exceed 6.3 μm, so that the probe is completely on the contact surface It can move freely on the surface; for the surface of the weld, remove the irregular shape that makes the defect signal obscure or cannot be found. Make a clear weld mark, weld position mark line and weld position reference point on the surface of the tested part. The couplant is a special couplant for austenitic stainless steel.
(2)根据管段尺寸信息,在UltraVision3.2R9相控阵操作系统试样设计模块中建立管段焊缝模型,选取0.5MHz面阵探头组装超声相控阵检测系统。在UltraVision3.2R9相控阵操作系统中设定参数。①聚焦律的设置:检测仪器硬件选择Dynaray Lite;探头选择0.5MHz面阵TRL探头,主动轴晶片数量10个,晶片间距6.5mm,晶片大小6.4mm,从动轴晶片数量5个,晶片间距7mm,晶片大小6.9mm;楔块斜楔角设置20.5°,屋顶角0°,第一晶片高度16mm,纵波声速2330m/s,横波声速1157m/s,楔块长90mm,宽51mm,高60mm。声束角度选择从-30°到30°的扇扫;声束聚焦方式为投影聚焦,聚焦位置距离参考点8mm;晶片接口选择双Hypertronics,晶片激发数量选择全晶片。②超声设置:增益值设置为45dB;时基设置为0.43mm到58.31mm;数字化频率设置为100MHz;脉冲重复频率125Hz;激发电压100V;脉冲宽度500ns。③机械设置:类型选择内部时钟;分辨率设置为1mm;范围设置为200mm。选用标准块上底面,进行楔块延迟和纵波声速校准。在UltraVision3.2R9相控阵操作系统的检测界面添加动态体积校正过的扇扫图和在线A扫图,测得焊缝周围区域的纵波声速为5793m/s,衰减为0.08dB/mm。(2) According to the size information of the pipe section, the weld seam model of the pipe section is established in the sample design module of the UltraVision3.2R9 phased array operating system, and a 0.5MHz area array probe is selected to assemble an ultrasonic phased array inspection system. Set parameters in the UltraVision3.2R9 phased array operating system. ①Setting of focusing law: Dynaray Lite is selected for the hardware of the testing instrument; 0.5MHz area array TRL probe is selected for the probe, the number of active axis chips is 10, the chip spacing is 6.5mm, the chip size is 6.4mm, the number of driven axis chips is 5, and the chip spacing is 7mm , wafer size 6.9mm; wedge wedge angle setting 20.5°, roof angle 0°, first wafer height 16mm, longitudinal wave sound velocity 2330m/s, transverse wave sound velocity 1157m/s, wedge length 90mm, width 51mm, height 60mm. The sound beam angle is fan-swept from -30° to 30°; the sound beam focusing method is projection focusing, and the focus position is 8mm away from the reference point; the chip interface is double Hypertronics, and the number of chip excitations is full chip. ②Ultrasonic settings: the gain value is set to 45dB; the time base is set to 0.43mm to 58.31mm; the digitization frequency is set to 100MHz; the pulse repetition frequency is 125Hz; the excitation voltage is 100V; the pulse width is 500ns. ③Mechanical setting: select internal clock for type; set resolution to 1mm; set range to 200mm. Use the upper and lower surfaces of the standard block to calibrate the wedge delay and longitudinal wave sound velocity. In the detection interface of UltraVision3.2R9 phased array operating system, dynamic volume-corrected sector scan and online A-scan are added, and the measured sound velocity of longitudinal wave in the area around the weld is 5793m/s, and the attenuation is 0.08dB/mm.
(3)在UltraVision3.2R9相控阵操作系统试样设计模块内,设定材料纵波声速为5793m/s。(3) In the sample design module of the UltraVision3.2R9 phased array operating system, set the sound velocity of the longitudinal wave of the material to 5793m/s.
(4)对被检测件焊缝及邻近母材至少10mm的范围在厚度方向进行检测区域分层,使用1.5MHz面阵探头检测扫查表面以下0~20mm区域;1.0MHz面阵探头检测扫查表面以下20~60mm区域;0.5MHz面阵探头检测扫查表面以下60mm至92mm区域。(4) Layer the detection area in the thickness direction for the weld seam of the tested part and the area adjacent to the base metal of at least 10mm, use a 1.5MHz area array probe to detect and scan the area 0-20mm below the surface; 1.0MHz area array probe to detect and scan 20-60mm area below the surface; 0.5MHz area array probe detects and scans the area 60mm-92mm below the surface.
(5)选取1.5MHz面阵探头组装超声相控阵检测系统。在UltraVision3.2R9相控阵操作系统中修改部分参数。①聚焦律的设置:探头选择1.5MHz面阵TRL探头,主动轴晶片数量8个,晶片间距3.5mm,晶片大小3.4mm,从动轴晶片数量4个,晶片间距4mm,晶片大小3.9mm;楔块斜楔角设置为19°,屋顶角0°,第一晶片高度8.5mm,纵波声速2330m/s,横波声速1157m/s,楔块长44mm,宽22.23mm,高25mm;声束角度选择从11°到70°的扇扫;声束聚焦方式为投影聚焦,聚焦位置距离参考点8mm;②超声设置:增益值设置为45dB;时基设置为0.43mm到50.3mm;脉冲宽度300ns。在UltraVision3.2R9相控阵操作系统的检测界面添加动态体积校正过的扇扫图、B扫图、C扫图和D扫图;在UltraVision3.2R9相控阵操作系统的分析界面添加静态体积校正过的扇扫图、B扫图、C扫图和D扫图;选用标准块上10mm深度孔,进行楔块延迟和纵波声速校准。(5) Select a 1.5MHz area array probe to assemble an ultrasonic phased array detection system. Modify some parameters in the UltraVision3.2R9 phased array operating system. ①Setting of focusing law: 1.5MHz area array TRL probe is selected as the probe, the number of chips on the driving axis is 8, the chip spacing is 3.5mm, the chip size is 3.4mm, the number of driven axis chips is 4, the chip spacing is 4mm, and the chip size is 3.9mm; The wedge angle of the block is set to 19°, the roof angle is 0°, the height of the first chip is 8.5mm, the sound velocity of the longitudinal wave is 2330m/s, the sound velocity of the transverse wave is 1157m/s, the length of the wedge is 44mm, the width is 22.23mm, and the height is 25mm; the sound beam angle is selected from Sector scan from 11° to 70°; the sound beam focusing method is projection focusing, and the focus position is 8mm away from the reference point; ②Ultrasonic settings: the gain value is set to 45dB; the time base is set to 0.43mm to 50.3mm; the pulse width is 300ns. Add dynamic volume corrected sector scan, B scan, C scan and D scan to the detection interface of UltraVision3.2R9 phased array operating system; add static volume correction to the analysis interface of UltraVision3.2R9 phased array operating system The passed sector scan, B scan, C scan and D scan; select the 10mm deep hole on the standard block to perform wedge delay and longitudinal wave sound velocity calibration.
(6)校准扫查器的步进速度,组装1.5MHz面阵探头与扫查器。设定扫查器以1mm/s进行匀速直线运动,扫查范围为200mm。启动扫查器进行扫查,记录扫查结果。分析扫查结果,在得到的静态扇扫图、A扫信号和B扫图中观察到扫查表面以下0~20mm区域有两处气孔和四处裂纹,对于气孔,使其成像在扇扫图中间位置,左右移动探头,使气孔对应的A扫信号幅度最大,读取气孔深度;对于裂纹,使其始终成像在扇扫图上30°位置,在得到的B扫图中应用UltraVision3.2R9相控阵操作系统上-6dB区域尺寸测量工具进行裂纹长度定量。(6) Calibrate the stepping speed of the scanner, assemble the 1.5MHz area array probe and the scanner. Set the scanner to move in a straight line at a constant speed of 1mm/s, and the scanning range is 200mm. Start the scanner to scan and record the scan results. Analyzing the scanning results, it is observed in the obtained static sector scan image, A-scan signal and B-scan image that there are two air holes and four cracks in the region of 0-20mm below the scanning surface, and the air holes are imaged in the middle of the fan-scan image Position, move the probe left and right to maximize the amplitude of the A-scan signal corresponding to the stomata, and read the depth of the stomata; for cracks, make it always image at 30° on the sector-scan map, and use UltraVision3.2R9 phase control in the obtained B-scan map The -6dB area size measurement tool on the array operating system is used to quantify the crack length.
(7)选取1.0MHz面阵探头组装超声相控阵检测系统。在UltraVision3.2R9相控阵操作系统中修改部分参数。①聚焦律的设置:探头选择1.0MHz面阵TRL探头,主动轴晶片数量12个,晶片间距5mm,晶片大小4.5mm,从动轴晶片数量5个,晶片间距6mm,晶片大小5.5mm;楔块斜楔角设置为19.5°,屋顶角0°,第一晶高度12mm,纵波声速2330m/s,横波声速1157m/s,楔块长77mm,宽51mm,高35.7mm,声束角度选择11°到70°的扇扫。②超声设置:增益值设置为45dB;时基设置为0.43mm到80.31mm;脉冲宽度500ns。在UltraVision3.2R9相控阵操作系统的检测界面添加动态体积校正过的扇扫图、B扫图、C扫图和D扫图;在UltraVision3.2R9相控阵操作系统的分析界面添加静态体积校正过的扇扫图、B扫图、C扫图和D扫图。选用标准块上50mm深度孔,进行楔块延迟和纵波声速校准。(7) Select a 1.0MHz area array probe to assemble an ultrasonic phased array detection system. Modify some parameters in the UltraVision3.2R9 phased array operating system. ①Setting of focusing law: the probe selects 1.0MHz area array TRL probe, the number of active axis chips is 12, the chip spacing is 5mm, and the chip size is 4.5mm, the number of driven axis chips is 5, the chip spacing is 6mm, and the chip size is 5.5mm; The wedge angle is set to 19.5°, the roof angle is 0°, the height of the first crystal is 12mm, the sound velocity of the longitudinal wave is 2330m/s, the sound velocity of the transverse wave is 1157m/s, the length of the wedge is 77mm, the width is 51mm, the height is 35.7mm, and the sound beam angle is selected from 11° to 70° fan sweep. ②Ultrasonic settings: the gain value is set to 45dB; the time base is set to 0.43mm to 80.31mm; the pulse width is 500ns. Add dynamic volume corrected sector scan, B scan, C scan and D scan to the detection interface of UltraVision3.2R9 phased array operating system; add static volume correction to the analysis interface of UltraVision3.2R9 phased array operating system Passed sector scans, B-scans, C-scans and D-scans. Choose a 50mm deep hole on the standard block to calibrate the wedge delay and longitudinal wave sound velocity.
(8)校准扫查器的步进速度,组装1.0MHz面阵探头与扫查器。设定扫查器以1mm/s进行匀速直线运动,扫查范围为200mm。启动扫查器进行扫查,记录扫查结果。分析扫查结果,在得到的静态扇扫图、A扫信号和B扫图中观察到扫查表面以下20~60mm区域有四处气孔,其中一处30mm深孔和50mm深孔如图2所示,使气孔出现在扇扫图中间位置,左右移动探头,使气孔对应的A扫信号幅度最大,读取气孔深度。(8) Calibrate the stepping speed of the scanner, assemble the 1.0MHz area array probe and the scanner. Set the scanner to move in a straight line at a constant speed of 1mm/s, and the scanning range is 200mm. Start the scanner to scan and record the scan results. Analyzing the scanning results, it was observed in the obtained static sector scan image, A-scan signal and B-scan image that there were four air holes in the area 20-60mm below the scanning surface, one of which was a 30mm deep hole and a 50mm deep hole as shown in Figure 2 , so that the stomata appear in the middle of the sector scan image, move the probe left and right to maximize the amplitude of the A-scan signal corresponding to the stomata, and read the stomata depth.
(9)选取0.5MHz面阵探头组装超声相控阵检测系统。在UltraVision3.2R9相控阵操作系统中修改部分参数。①聚焦律的设置:探头选择0.5MHz面阵TRL探头,主动轴晶片数量10个,晶片间距6.5mm,晶片大小6.4mm,从动轴晶片数量5个,晶片间距7mm,晶片大小6.9mm;楔块斜楔角设置为20.5°,屋顶角0°,第一晶片高度16mm,纵波声速2330m/s,横波声速1157m/s,楔块长90mm,宽51mm,高60mm。声束角度选择11°到70°的扇扫。②超声设置:增益值设置为45dB;时基设置为0.43mm到100mm;脉冲宽度1000ns。在UltraVision3.2R9相控阵操作系统的检测界面添加动态体积校正过的扇扫图、B扫图、C扫图和D扫图;在UltraVision3.2R9相控阵操作系统的分析界面添加静态体积校正过的扇扫图、B扫图、C扫图和D扫图。选用标准块上80mm深度孔,进行楔块延迟和纵波声速校准。(9) Select a 0.5MHz area array probe to assemble an ultrasonic phased array detection system. Modify some parameters in the UltraVision3.2R9 phased array operating system. ①Setting of focusing law: 0.5MHz area array TRL probe is selected for the probe, the number of chips on the driving axis is 10, the chip spacing is 6.5mm, the chip size is 6.4mm, the number of driven axis chips is 5, the chip spacing is 7mm, and the chip size is 6.9mm; The wedge angle of the block is set to 20.5°, the roof angle is 0°, the height of the first wafer is 16mm, the sound velocity of the longitudinal wave is 2330m/s, the sound velocity of the transverse wave is 1157m/s, the length of the wedge is 90mm, the width is 51mm, and the height is 60mm. The sound beam angle selects sector sweep from 11° to 70°. ②Ultrasonic settings: the gain value is set to 45dB; the time base is set to 0.43mm to 100mm; the pulse width is 1000ns. Add dynamic volume corrected sector scan, B scan, C scan and D scan to the detection interface of UltraVision3.2R9 phased array operating system; add static volume correction to the analysis interface of UltraVision3.2R9 phased array operating system Passed sector scans, B-scans, C-scans and D-scans. Choose the 80mm deep hole on the standard block for wedge delay and longitudinal wave sound velocity calibration.
(10)校准扫查器的步进速度,组装0.5MHz面阵探头与扫查器。设定扫查器以1mm/s进行匀速直线运动,扫查范围为200mm。启动扫查器进行扫查,记录扫查结果。分析扫查结果,在得到的静态扇扫图、A扫信号和B扫图中观察到扫查表面以下60mm至底面区域有四处气孔和六处裂纹。对于气孔,使其成像在扇扫图中间位置,左右移动探头,使气孔对应的A扫信号幅度最大,读取气孔深度;对于裂纹,使其始终成像在扇扫图上30°位置如图3所示,在得到的B扫图中应用UltraVision3.2R9相控阵操作系统上-6dB区域尺寸测量工具进行裂纹长度定量如图4所示。(10) Calibrate the stepping speed of the scanner, assemble the 0.5MHz area array probe and the scanner. Set the scanner to move in a straight line at a constant speed of 1mm/s, and the scanning range is 200mm. Start the scanner to scan and record the scan results. Analyzing the scanning results, four air holes and six cracks were observed in the area from 60mm below the scanning surface to the bottom surface in the obtained static sector scan image, A-scan signal and B-scan image. For pores, make it image in the middle of the sector scan map, move the probe left and right, make the A-scan signal amplitude corresponding to the pores maximum, and read the depth of the pores; for cracks, make it always image at the 30° position on the sector scan map as shown in Figure 3 As shown, in the obtained B-scan image, the -6dB area size measurement tool on the UltraVision3.2R9 phased array operating system is used to quantify the crack length, as shown in Figure 4.
对上述相控阵周向试块利用相控阵超声检测结果及误差如表1和表2所示。Table 1 and Table 2 show the results and errors of the above-mentioned phased array circumferential test block using phased array ultrasonic testing.
表1相控阵检测周向试块上气孔检测结果及误差分析Table 1 Detection results and error analysis of air holes on the circumferential test block by phased array detection
注:其中气孔的实际直径为3mm。Note: The actual diameter of the pores is 3mm.
表2相控阵检测周向试块上裂纹结果及误差分析Table 2 Phased array detection results and error analysis of cracks on the circumferential test block
注:其中深度为83mm的裂纹为轴向,其它均为周向排布。Note: The cracks with a depth of 83mm are axial, and the others are circumferentially arranged.
(11)按照上述的方法对92mm厚的相控阵检测轴向试块进行检测,相控阵检测轴向试块焊缝上35mm和60mm深度孔对应的扇扫图如图5所示,相控阵检测轴向试块一处裂纹所对应的回波幅度最强位置扇扫图如图6所示,该处裂纹所对应的B扫图如图7所示。缺陷测量结果及误差如表3与表4所示。(11) According to the above method, the 92mm thick phased array test axial test block is tested. The sector scan diagrams corresponding to the 35mm and 60mm deep holes on the weld seam of the phased array test axial test block are shown in Figure 5. Figure 6 shows the fan-scan diagram of the position with the strongest echo amplitude corresponding to a crack in the axial test block detected by the array control, and Figure 7 shows the B-scan diagram corresponding to the crack at this place. The defect measurement results and errors are shown in Table 3 and Table 4.
表3相控阵检测轴向试块上气孔检测结果及误差分析Table 3 Detection results and error analysis of air holes on the axial test block by phased array detection
注:其中气孔的实际直径为3mm。Note: The actual diameter of the pores is 3mm.
表4相控阵检测轴向试块焊缝上裂纹结果及误差分析Table 4 Phased array detection results and error analysis of cracks on the axial test block weld
注:其中第二处深度为83mm的裂纹为轴向,其它均为周向排布。Note: The second crack with a depth of 83mm is axial, and the others are arranged circumferentially.
ASME锅炉与压力容器规范第Ⅺ卷核电厂设备在役检查规则中对粗晶奥氏体管道焊缝超声检验验证要求进行了规定,若定量性能验证结果满足如下准则,则检验规程、设备和人员在定量方面经验收合格。ASME Boiler and Pressure Vessel Code Volume XI Nuclear Power Plant Equipment In-Service Inspection Rules stipulates the requirements for ultrasonic inspection and verification of coarse-grained austenitic pipe welds. If the quantitative performance verification results meet the following criteria, the inspection procedures, equipment and personnel Quantitatively accepted.
(a)同缺陷实际长度相比,超声测量缺陷长度均方根误差小于或等于0.75in.(19mm),测量在75%母材金属壁厚处的母材金属裂纹长度。(a) Compared with the actual length of the defect, the root mean square error of the defect length measured by ultrasonic is less than or equal to 0.75in. (19mm), and the crack length of the base metal at 75% of the base metal wall thickness is measured.
(b)同缺陷实际深度相比,超声测量缺陷深度均方根误差不超过0.125in.(3.2mm)。(b) Compared with the actual depth of the defect, the root mean square error of the ultrasonic measurement of the defect depth shall not exceed 0.125in. (3.2mm).
超声测量长度时定量试样中缺陷布置要求。Requirements for arrangement of flaws in quantitative samples when ultrasonically measuring length.
(a)至少有10个缺陷。(a) At least 10 defects.
(b)至少缺陷总数的1/3,取整,其深度应为5%-30%管道名义壁厚。至少缺陷总数的1/3,取整,其深度应大于30%管道名义壁厚。至少有一个且最多为缺陷总数的10%,取整,应为轴向。(b) At least 1/3 of the total number of defects, rounded up, the depth shall be 5%-30% of the nominal wall thickness of the pipe. At least 1/3 of the total number of defects, rounded up, and its depth should be greater than 30% of the nominal wall thickness of the pipe. At least one and at most 10% of the total number of defects, rounded up, shall be axial.
该方法检测裂纹时对长度进行了定量,相控阵检测周向试块上裂纹总数为10个,其中深度在5-30%壁厚裂纹的裂纹有4个,深度大于30%管道名义壁厚的裂纹有6个,其中一处为轴向裂纹;相控阵检测轴向试块上裂纹总数为10个,其中深度在5-30%壁厚裂纹的裂纹有5个,深度大于30%管道名义壁厚的裂纹有5个,其中一处为轴向裂纹。两试块缺陷布置均满足要求,按照(a)标准对长度定量进行验收,相控阵检测周向试块和轴向试块上裂纹长度定量的均方根差分别为5.03mm和6.01mm,均小于19mm,满足标准要求。This method quantifies the length when detecting cracks. The total number of cracks on the circumferential test block detected by phased array is 10, of which 4 cracks are cracks with a depth of 5-30% of the wall thickness, and the depth is greater than 30% of the nominal wall thickness of the pipeline. There are 6 cracks, one of which is an axial crack; the total number of cracks on the axial test block detected by phased array is 10, of which 5 are cracks with a depth of 5-30% of the wall thickness, and the depth is greater than 30% of the pipeline There are 5 cracks in the nominal wall thickness, one of which is an axial crack. The defect layout of the two test blocks meets the requirements, and the length quantification is checked and accepted according to the standard (a). The root mean square difference of the crack length quantification on the circumferential test block and axial test block detected by phased array is 5.03mm and 6.01mm respectively. All are less than 19mm, meeting the standard requirements.
超声测量长度时定量试样中缺陷布置要求。Requirements for arrangement of flaws in quantitative samples when ultrasonically measuring length.
(a)至少有10个缺陷。(a) At least 10 defects.
(b)深度定量试样组中的缺陷应按如下描述(b) Defects in depth quantified specimen sets shall be described as follows
其余的缺陷应属上述任一类别。The remaining defects shall fall into any of the above categories.
该方法检测气孔时对深度进行了定量,相控阵检测周向试块上气孔总数为10个,其中深度在5-30%壁厚气孔的气孔有3个,深度在31-60%壁厚的气孔有3个,深度在61-100%壁厚的气孔有4个;相控阵检测轴向试块上气孔总数为18个,其中深度在5-30%壁厚气孔的气孔有5个,深度在31-60%壁厚的气孔有7个,深度在61-100%壁厚的气孔有6个。两试块缺陷布置均满足要求,按照(b)标准对深度定量进行验收,相控阵检测周向试块和轴向试块上气孔深度定量的均方根差分别为1.29mm和1.31mm,均小于3.2mm,满足标准要求。This method quantifies the depth when detecting pores. The total number of pores on the circumferential test block detected by phased array is 10, among which there are 3 pores whose depth is 5-30% of the wall thickness, and the depth is 31-60% of the wall thickness. There are 3 air holes, and 4 air holes with a depth of 61-100% of the wall thickness; the total number of air holes on the phased array test axial test block is 18, of which there are 5 air holes with a depth of 5-30% of the wall thickness , there are 7 pores with a depth of 31-60% of the wall thickness, and 6 pores with a depth of 61-100% of the wall thickness. The defect layout of the two test blocks meets the requirements, and the depth quantification is checked and accepted according to the standard (b). The root mean square difference of the pore depth quantification on the circumferential test block and the axial test block detected by phased array is 1.29mm and 1.31mm, respectively. Both are less than 3.2mm, meeting the standard requirements.
分析表明,相控阵检测周向试块和相控阵检测轴向试块上缺陷布置和检测结果满足ASME锅炉与压力容器规范,证明该检验规程和设备在定量方面验收合格,在工程应用方面有及其重要的意义。The analysis shows that the defect layout and detection results on the phased array detection circumferential test block and the phased array detection axial test block meet the ASME boiler and pressure vessel code, which proves that the inspection regulations and equipment are qualified in quantitative aspects, and in engineering application has an extremely important meaning.
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