CN108061756B - Furnace body lining nondestructive testing method based on shock elastic wave - Google Patents
Furnace body lining nondestructive testing method based on shock elastic wave Download PDFInfo
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/045—Analysing solids by imparting shocks to the workpiece and detecting the vibrations or the acoustic waves caused by the shocks
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B17/00—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations
- G01B17/02—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations for measuring thickness
- G01B17/025—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations for measuring thickness for measuring thickness of coating
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/028—Material parameters
- G01N2291/02854—Length, thickness
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/028—Material parameters
- G01N2291/0289—Internal structure, e.g. defects, grain size, texture
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/04—Wave modes and trajectories
- G01N2291/044—Internal reflections (echoes), e.g. on walls or defects
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/04—Wave modes and trajectories
- G01N2291/045—External reflections, e.g. on reflectors
Abstract
The invention discloses a furnace lining nondestructive testing method based on shock elastic waves, which comprises the following steps: (a) determining a measuring point position and an excitation position on the surface of the furnace body; (b) a sensor is arranged at the measuring point position, and an excitation device is arranged at the excitation position; starting an excitation device to excite vibration, and acquiring a vibration signal through a sensor; (c) analyzing the vibration signal, and storing analysis conditions and analysis results; (d) repeating the steps (b) to (c) at the same measuring point position and the same excitation position in the step (a) after a period of time by using the same excitation device, and analyzing by using the same analysis conditions as in the step (c); (e) analyzing the trend of the analysis results obtained at different times to obtain the variation trend of the lining thickness of the furnace body, and judging the safety of the furnace body. The invention is used for solving the problem that the nondestructive detection of the lining of the furnace body is difficult to accurately carry out in the prior art and realizing the purpose of providing sufficient basis for judging the lining state of the furnace body.
Description
Technical Field
The invention relates to the field of furnace body detection, in particular to a furnace body lining nondestructive detection method based on shock elastic waves.
Background
The blast furnace is an important link in steel production, and the safety state of the blast furnace has important significance. In the production process, due to the flowing of molten materials such as molten iron, slag and the like, erosion can be generated on the blast furnace lining, so that the lining thickness is gradually thinned. Meanwhile, radial and circumferential cracks may be generated inside the lining due to temperature changes in the furnace and the like, thereby aggravating the erosion process of the lining. When the erosion of the furnace lining reaches a certain degree, the heat insulation performance of the furnace lining is reduced, the fuel consumption is increased, and the furnace shell can be burnt through in serious cases, so that extremely serious safety accidents are caused. On the other hand, because the blast furnace is a continuous production closed container and is added with the environment of high temperature, high pressure and much smoke dust, the detection of the erosion condition of the lining is difficult, and particularly, the bottom part of the hearth of the blast furnace is in the environment of high-temperature molten slag iron for a long time, and the detection of the erosion degree of the lining is more difficult.
At present, researchers at home and abroad develop various detection technologies such as a multi-head thermocouple method, a resistance method, a capacitance method, an ultrasonic method, a heat flow detection method, a model inference method and the like in order to accurately detect the erosion change of the blast furnace lining. But all have corresponding disadvantages and have not yet formed a universally accepted reliable method. In recent years, a detection method based on a shock elastic wave has been attracting much attention in many industries, and researchers have also detected the thickness of a blast furnace lining by using the method. According to the method, impact elastic waves are excited on the outer surface of the furnace by knocking the furnace shell by a hammer and the like, and elastic wave signals are reflected after meeting an inner measuring surface or a crack surface. The thickness of the furnace wall can be estimated by receiving the reflected signal and based on the time required for the test signal to return. However, the impact elastic wave test for the lining thickness of the blast furnace in the prior art has a plurality of insurmountable problems: (1) and (4) determining the propagation wave speed. As the blast furnace wall mainly comprises a furnace shell and a brick lining, the elastic wave velocity has large difference, generally the elastic wave P wave velocity of the steel furnace wall is about 5500m/s, and the P wave velocity of the carbon brick is 2000-2500 m/s. Since the brick lining is also a composite material, and the detection is usually performed in a hot state. Therefore, it is difficult to determine the calculated wave velocity reasonably and accurately in practical operation. (2) And (4) determining the reflection time. In the excitation signal actually detected, the excitation signal and the reflected signal are often mixed together, and it is difficult to distinguish the reflected signal from the arrival time, and it is very difficult to determine the time taken for the elastic wave to reflect. In addition, the lining of the blast furnace (including the shell and the brick lining) varies greatly in thickness. When there is erosion, the minimum thickness may be below 0.3 m. At the position of the furnace hearth, the thickness of the furnace lining can exceed 2m, so that the judgment of the reflected signal is very difficult. (3) The influence of the surrounding boundary. In a place where a hearth, a furnace hearth, or the like is easily damaged, facilities such as a taphole, a slag hole, and a fan port are often provided. The elastic waves generated by the excitation also cause reflections at the boundaries of these facilities, which reflections are usually dominated by surface waves and have a non-negligible effect on the direct measurement of the wall thickness. In conclusion, the detection technology for the lining of the blast furnace body in the prior art is restricted by various conditions, and the damage condition of the blast furnace body is difficult to accurately and nondestructively judge.
Disclosure of Invention
The invention aims to provide a furnace lining nondestructive testing method based on shock elastic waves, which aims to solve the problem that the furnace lining is difficult to accurately perform nondestructive testing in the prior art and realize the purpose of providing a sufficient basis for judging the lining state of a furnace.
The invention is realized by the following technical scheme:
the furnace lining nondestructive testing method based on the shock elastic wave comprises the following steps:
(a) determining a measuring point position and an excitation position on the surface of the furnace body;
(b) a sensor is arranged at the measuring point position, and an excitation device is arranged at the excitation position; starting an excitation device to excite vibration, and acquiring a vibration signal through a sensor;
(c) analyzing the vibration signal, and storing analysis conditions and analysis results;
(d) repeating the steps (b) to (c) at the same measuring point position and the same excitation position in the step (a) after a period of time by using the same excitation device, and analyzing by using the same analysis conditions as in the step (c);
(e) analyzing the trend of the analysis results obtained at different times to obtain the variation trend of the lining thickness of the furnace body, and judging the safety of the furnace body.
The invention provides a furnace lining nondestructive testing method based on impact elastic waves, which aims at solving the problem that the furnace lining is difficult to accurately carry out nondestructive testing in the prior art. After a period of time, the same excitation device is adopted to excite at the same excitation position and receive at the same measuring point position, so that a new group of test results after a period of time is obtained, and the new group of test results are analyzed and recorded by using the same analysis conditions. The same analysis conditions are adopted in the steps, and the vibration excitation is carried out at the same measuring point position and the same vibration excitation position, so that the consistency of the vibration excitation conditions is fully ensured, the change of the reflected signal is only related to the lining of the furnace body, and the change of the reflected signal reflects the state change of the furnace shell and the lining. Therefore, the method can obtain the change trend of the lining thickness of the furnace body by analyzing the trend of the analysis results obtained at different times, and can judge the safety of the furnace body according to the change trend. The method avoids the influence of human factors and other uncertain factors in the analysis process to a great extent, and guarantees the objectivity of the analysis result to the greatest extent. Although the method does not directly give the lining thickness, the existence and the position of the lining cracks, through the variation trend and the degree of the test results in different periods, the technicians in the field can deduce the erosion rate of the lining and the generation and development states of the cracks based on the variation trend and the degree, further provide reliable basis for the state evaluation of the lining of the blast furnace, and realize the effect of nondestructive detection on the lining of the blast furnace.
Preferably, the resolving in step (c) comprises: correlation analysis, fast Fourier analysis and maximum entropy analysis by using the vibration signal as a basis function. The three analysis methods in the scheme can process the vibration signals relatively simply and rapidly to obtain an analytic result beneficial to trend analysis.
Preferably, the analyzing includes calculating characteristic parameters in a correlation analysis, a fast fourier analysis, and a maximum entropy analysis using the vibration signal as a basis function. In the analysis process of the vibration signals, besides the three operations on the vibration signals, the characteristic parameters in the three operations are calculated and extracted, so that trend analysis is more accurately carried out on the vibration signals at different times, and the variation trend of the thickness of the lining of the furnace body is clearer.
Preferably, the characteristic parameters include one or more of detection items, test point positions, test dates, analysis dates, excitation times, and statistical parameters of data obtained by testing different excitation times in each time. The scheme can facilitate data independence when a plurality of furnace bodies are monitored for a long time, so that the method can be used for large-scale furnace body detection.
Preferably, the number of excitations in the characteristic parameter includes, for each excitation: maximum amplitude of the excitation signal; the method comprises the following steps of measuring the half-wave time of the first wave of the excitation signal, the time corresponding to the highest order in the fast Fourier analysis, the time of the second order of the fast Fourier analysis in a test range, the amplitude ratio of the second order of the fast Fourier analysis to the highest order in the test range, the time of the third order of the fast Fourier analysis in the test range, the amplitude ratio of the third order of the fast Fourier analysis in the test range to the highest order, the time of the highest order of the maximum entropy analysis in the test range, the time of the third order of the maximum entropy analysis in the test range, the time difference of the maximum reflection signal and the excitation signal in the test range, the amplitude ratio of the maximum reflection signal and the excitation signal in the test range, the time difference of the second order large reflection signal and the excitation signal in the test range, and one or more of the amplitude ratios of the second order large reflection. Namely, during each detection, after performing correlation analysis, fast Fourier analysis and maximum entropy analysis on elastic waves generated by different excitation times, extracting one or more of the data under different excitation times to serve as parameters for judging the furnace lining thickness variation trend, and detecting personnel can select appropriate parameters according to actual needs, so that the application range and the use flexibility of the invention are improved.
Preferably, the statistical parameters include mean and standard deviation.
Preferably, step (d) is carried out N times, where N.gtoreq.2. Namely, N times of excitation are carried out, and each excitation is a period of time away from the previous excitation, so that a longer and more stable detection result trend is obtained.
Preferably, the period of time in step (d) is a fixed length of time. Namely, the time between two adjacent detections is fixed, and the furnace body is detected periodically, so that a continuous detection result is obtained, and the possibility of safety accidents of the furnace body is reduced.
Preferably, the method further comprises marking the position of the measuring point and the position of the excitation on the surface of the furnace body. The sensor and the vibration excitation device can be still arranged at the same position for detection after a period of time, and the error of the method is further reduced.
Preferably, the excitation device is installed at the excitation position through a magnetic clamping seat. The vibration excitation device is convenient to rapidly install on the iron furnace shell, the detection efficiency is improved, and meanwhile, the simple and rapid disassembly is easy.
Compared with the prior art, the invention has the following advantages and beneficial effects:
the furnace lining nondestructive testing method based on the shock elastic waves avoids the influence of human factors and other uncertain factors in the analysis process to a great extent, and ensures the objectivity of the analysis result to the greatest extent. Although the method does not directly give the lining thickness, the existence and the position of the lining cracks, through the variation trend and the degree of the test results in different periods, the technicians in the field can deduce the erosion rate of the lining and the generation and development states of the cracks based on the variation trend and the degree, thereby providing reliable basis for the state evaluation of the lining of the blast furnace and realizing the effect of nondestructive detection on the lining of the blast furnace.
Drawings
The accompanying drawings, which are included to provide a further understanding of the embodiments of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principles of the invention. In the drawings:
FIG. 1 is a diagram illustrating a variation trend of a half period of an excitation signal according to an embodiment of the present invention;
FIG. 2 is a diagram illustrating an exemplary fast Fourier analysis of 1 st order cyclic variation trend in accordance with an embodiment of the present invention;
FIG. 3 is a diagram illustrating a 1 st order cyclic variation trend analyzed by maximum entropy method according to an embodiment of the present invention;
FIG. 4 is a diagram illustrating a trend of correlation analysis reflection time difference according to an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to examples and accompanying drawings, and the exemplary embodiments and descriptions thereof are only used for explaining the present invention and are not meant to limit the present invention.
Example 1:
the furnace lining nondestructive testing method based on the shock elastic wave comprises the following steps: (a) determining a measuring point position and an excitation position on the surface of the furnace body; (b) a sensor is arranged at the measuring point position, and an excitation device is arranged at the excitation position; starting an excitation device to excite vibration, and acquiring a vibration signal through a sensor; (c) analyzing the vibration signal, and storing analysis conditions and analysis results; (d) repeating the steps (b) to (c) at the same measuring point position and the same excitation position in the step (a) after a period of time by using the same excitation device, and analyzing by using the same analysis conditions as in the step (c); (e) analyzing the trend of the analysis results obtained at different times to obtain the variation trend of the lining thickness of the furnace body, and judging the safety of the furnace body.
Example 2:
on the basis of embodiment 1, the analysis in step (c) of the nondestructive testing method for furnace lining based on shock elastic waves includes: correlation analysis, fast Fourier analysis and maximum entropy analysis by using the vibration signal as a basis function. The analysis comprises the calculation of characteristic parameters in correlation analysis, fast Fourier analysis and maximum entropy analysis which take the vibration signals as basis functions. The characteristic parameters comprise one or more of detection items, measuring point positions, test dates, analysis dates, excitation times and statistical parameters of data obtained by testing different excitation times each time. The excitation times in the characteristic parameters comprise that in each excitation: maximum amplitude of the excitation signal; the method comprises the following steps of half-wave time of a first wave of an excitation signal, time corresponding to the highest order in fast Fourier analysis, second-order time of fast Fourier analysis in a test range, relative highest-order amplitude ratio of the second-order analysis to the highest order in the test range, third-order time of fast Fourier analysis in the test range, relative highest-order amplitude ratio of the third-order analysis to the highest order in the test range, highest-order time of maximum entropy analysis in the test range, third-order time of maximum entropy analysis in the test range, time difference of a maximum reflection signal and the excitation signal in the test range, amplitude ratio of the maximum reflection signal and the excitation signal in the test range, time difference of the second-order large reflection signal and the excitation signal in the test range, and second-order large reflection signal and the excitation signal in the test range. The period of time in step (d) is a fixed duration. And marking the position of the measuring point and the position of the excitation on the surface of the furnace body. The excitation device is installed at the excitation position through the magnetic clamping seat. Ten tests were carried out on a certain smelting furnace in ten consecutive months by the method, and some typical parameter values were calculated, as shown in the following table:
| time of day | HW | | MEM1 | REX | |
| 1 month | 0.434 | 0.744727 | 0.67947 | 0.366 | |
| 2 month | 0.314 | 0.682667 | 0.76897 | 0.44 | |
| 3 month | 0.256 | 0.744727 | 0.73597 | 0.324 | |
| 4 month | 0.124 | 0.744727 | 0.80797 | 0.554 | |
| |
0.296 | 0.744727 | 0.77997 | 0.492 | |
| 6 month | 0.292 | 0.744727 | 0.69397 | 0.466 | |
| 7 month | 0.318 | 0.512 | 0.76147 | 0.456 | |
| 8 month | 0.316 | 0.512 | 0.70147 | 0.408 | |
| 9 month | 0.29 | 0.512 | 0.71997 | 0.35 | |
| 10 month | 0.312 | 0.546133 | 0.86097 | 0.488 |
In the above table, HW, FFT1, MEM1, and REX respectively represent half periods of excitation signals, 1-order periods of Fast Fourier Transform (FFT) analysis, 1-order periods of Maximum Entropy Method (MEM) analysis, and reflection time differences of correlation analysis, and the units are ms, and corresponding typical parameter change curves are obtained and respectively represented by fig. 1 to 4. The technical personnel in the field can obtain that the trend of the detection result is in a basically controllable range through the related curve, so that the current running state of the furnace body is accurately deduced, the lining thickness has no obvious defect or damage, the obtained data in the embodiment can also provide sufficient data support and basis for subsequent continuous and stable detection, once the lining thickness is suddenly changed in a certain month, the detection personnel can quickly learn the situation, and the potential safety hazard in the running process of the blast furnace body is greatly reduced.
The above-mentioned embodiments are intended to illustrate the objects, technical solutions and advantages of the present invention in further detail, and it should be understood that the above-mentioned embodiments are merely exemplary embodiments of the present invention, and are not intended to limit the scope of the present invention, and any modifications, equivalent substitutions, improvements and the like made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (10)
1. The furnace lining nondestructive testing method based on the shock elastic wave is characterized by comprising the following steps:
(a) determining a measuring point position and an excitation position on the surface of the furnace body;
(b) a sensor is arranged at the measuring point position, and an excitation device is arranged at the excitation position; starting an excitation device to excite vibration, and acquiring a vibration signal through a sensor;
(c) analyzing the vibration signal, and storing analysis conditions and analysis results;
(d) repeating the steps (b) - (c) at the same measuring point position and the same excitation position in the step (a) after a period of time by using the same excitation device, and analyzing by using the same analysis conditions in the step (c);
(e) analyzing the trend of the analysis results obtained at different times to obtain the variation trend of the lining thickness of the furnace body, and judging the safety of the furnace body.
2. The blast elastic wave-based furnace lining nondestructive testing method according to claim 1, wherein the analysis in the step (c) comprises the following three analysis methods: correlation analysis, fast Fourier analysis and maximum entropy analysis by using the vibration signal as a basis function.
3. The blast elastic wave-based furnace lining nondestructive testing method of claim 2, wherein the analysis includes calculating characteristic parameters in three analysis methods of correlation analysis, fast fourier analysis, and maximum entropy analysis, which use vibration signals as basis functions.
4. The blast elastic wave-based furnace lining nondestructive testing method according to claim 3, wherein the characteristic parameters include one or more of testing items, testing point positions, testing dates, analyzing dates, excitation times, and statistical parameters of data obtained by testing different excitation times in each time.
5. The blast elastic wave-based furnace lining nondestructive testing method according to claim 4, wherein the excitation times in the characteristic parameters comprise, at each excitation: maximum amplitude of the excitation signal; the method comprises the following steps of measuring the half-wave time of the first wave of the excitation signal, the time corresponding to the highest order in the fast Fourier analysis, the time of the second order of the fast Fourier analysis in a test range, the amplitude ratio of the second order of the fast Fourier analysis to the highest order in the test range, the time of the third order of the fast Fourier analysis in the test range, the amplitude ratio of the third order of the fast Fourier analysis in the test range to the highest order, the time of the highest order of the maximum entropy analysis in the test range, the time of the third order of the maximum entropy analysis in the test range, the time difference of the maximum reflection signal and the excitation signal in the test range, the amplitude ratio of the maximum reflection signal and the excitation signal in the test range, the time difference of the second order large reflection signal and the excitation signal in the test range, and one or more of the amplitude ratios of the second order large reflection.
6. The blast furnace body lining nondestructive testing method according to claim 4, wherein the statistical parameters include mean value and standard deviation.
7. The blast elastic wave-based furnace lining nondestructive testing method of claim 1, wherein step (d) is performed N times, wherein N is not less than 2.
8. The blast furnace body lining nondestructive testing method of claim 7 wherein the period of time in step (d) is a fixed length of time.
9. The blast elastic wave-based furnace lining nondestructive testing method of claim 1, further comprising marking a measurement point position and an excitation position on the surface of the furnace body.
10. The blast elastic wave-based furnace lining nondestructive testing method according to claim 1, wherein the excitation device is installed at an excitation position through a magnetic clamping seat.
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| CN110045016B (en) * | 2019-04-24 | 2022-05-17 | 四川升拓检测技术股份有限公司 | Tunnel lining nondestructive testing method based on audio frequency analysis |
| CN115236179B (en) * | 2022-06-02 | 2023-05-02 | 珠海爱必途科技有限公司 | Brick wall quality detection method and system based on vibration condition |
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