CN109682881A - 一种一体式连续油管缺陷检测装置 - Google Patents
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Abstract
本发明提供了一种一体式连续油管缺陷检测装置，包括上半检测单元、下半检测单元两个检测单元，两个检测单元相互配合组装后在两者之间产生供油管穿过的通道，通道内设有设置于两个检测单元上的磁发生装置、漏磁检测探头、椭圆度检测探头和导向装置，检测单元外连接有起导向两个检测单元沿油管运动的测量臂总成套件。本发明可以实现对连续油管管柱的腐蚀、裂纹、机械损伤、点蚀、孔洞等各种物理缺陷、壁厚、外径及椭圆度进行实时精确的检测。
Description
技术领域
本发明涉及石油装备制造及无损检测领域，具体涉及一种一体式连续油管缺陷检测装置。
背景技术
连续油管是由若干段长度在百米以上的柔性管段通过对焊或斜焊工艺焊接而成的，长度一般达几百米至几千米。每段管柱是一种由钢带成型经电阻直缝焊接后得到焊接管。近年来，连续油管的在油田现场的应用越来越广泛，例如气举、酸化、钻磨、井下工具打捞、洗井、射孔等。在作业过程中通常会由于疲劳损伤、酸液腐蚀、硫化物致裂、压力或张力过载、外部机械损伤和磨损等造成连续油管的壁厚、椭圆度发生变化，还可能会使油管出现裂纹缺陷。这样就会降低连续油管的使用寿命，增加了连续油管服务公司的作业成本。有必要开发一种连续油管缺陷检测装置，提前检测到油管表面的缺陷、壁厚和椭圆度的变化，以提高连续油管作业的安全性和油管利用率。
发明内容
本发明的目的在于克服现有技术的不足之处，提供一种一体式连续油管缺陷检测装置，可以实现对连续油管管柱的腐蚀、裂纹、机械损伤、点蚀、孔洞等各种物理缺陷、壁厚、外径及椭圆度进行实时精确的检测，帮助用户最直观地了解连续油管的真实性能状态，为分析连续油管的失效和报废提供科学依据。
本发明的目的是通过以下技术措施达到的：
一种一体式连续油管缺陷检测装置，包括上半检测单元、下半检测单元两个检测单元，两个检测单元相互配合组装后在两者之间产生供油管穿过的通道，通道内设有设置于两个检测单元上的磁发生装置、漏磁检测探头、椭圆度检测探头和导向装置，检测单元外连接有起导向两个检测单元沿油管运动的测量臂总成套件。
进一步地，所述上半检测单元与下半检测单元的一侧通过转轴铰接方式相连接，另一侧通过两个锁紧搭扣相连接。
进一步地，所述检测单元还连接有用于连接外围设备的连杆总成套件。
进一步地，所述连杆总成套件包括连接支座、两个万向节和刚性连接杆，所述连接支座通过螺栓与外围设备相连接，所述连杆总成套件的一端通过快速释放销与检测单元相连接。
进一步地，所述测量臂总成套件包括可弯曲的支撑臂、测量滚轮、旋转编码器、可弯曲的支撑臂上装有的拉紧弹簧，所述测量滚轮为柱形轮，表面刻有花纹以增大摩擦作用力。
进一步地，所述磁发生装置包括磁棒和磁轭，磁棒在通道的轴向均匀间隔设置，相邻磁棒之间安装有支撑座，支撑座上安装导向装置和漏磁检测探头。
进一步地，所述导向装置包括导向轮，导向轮安装在支撑座上。
进一步地，所述漏磁检测探头为半圆环式漏磁检测探头，半圆环式漏磁检测探头内部包含有漏磁场信号检测板和油管壁厚检测板。
进一步地，所述磁发生装置、漏磁检测探头和导向装置位于检测单元的中部，椭圆度检测探头位于检测单元的两侧护罩内，磁发生装置、漏磁检测探头、椭圆度检测探头和导向装置在上半检测单元、下半检测单元对应设置，所述装置的上半检测单元和下半检测单元内均安装有四支圆柱形磁棒、两组磁轭、四个导向轮、一个半圆环式漏磁检测探头和三个椭圆度检测探头。
进一步地，待检测连续油管的椭圆度、壁厚、缺陷位置的漏磁场信号通过配套的外围数据采集装置和计算机进行采集、分析处理以及存储记录，实现对所述待检测连续油管的管柱缺陷、壁厚、椭圆度及长度的实时精确检测。
由于采用了上述技术方案，本发明的优点是：
本发明装置采用多功能一体化设计，设置了8支圆柱形磁棒对待检测连续油管进行磁化，包含了两个半圆环式漏磁检测探头、6个椭圆度检测探头，单台检测装置就能实现对连续油管的缺陷、壁厚、长度、外径及椭圆度的精确检测；
本发明装置的设计采用非接触式检测方式，在对待检测连续油管检测过程中，只有8个导向轮和测量臂总成套件上的两个测量滚轮与待检测连续油管直接接触，两个半圆环式漏磁检测探头、6个椭圆度检测探头均与待检测连续油管表面保持一定的安全间隙，不受污垢、油泥等因素的影响；
本发明装置采用翻盖式设计，整体结构由上半检测单元、下半检测单元构成，一侧通过转轴铰接方式相连接，另一侧通过两个锁紧搭扣相连接。可实现随时安装、随时拆卸，现场使用非常方便、快捷。
安装在下半检测单元上的连杆总成套件包括连接支座、两个万向节和刚性连接杆，所述连接支座通过螺栓与外围设备相连接。为了方便安装和拆卸操作，连杆总成套件的另一端采用快速释放销与本发明装置的下半检测单元相连接。在刚性连接杆的两端安装了两个万向节，使本发明装置与外围设备之间建立了柔性连接，当所述待检测连续油管发生上下或左右摆动时，可进行同步位置跟随，确保上半检测单元、下半检测单元与待检测连续油管的相对位置不变，保证了检测的精确度。
在本发明装置通过信号电缆将检测到的连续油管外径(椭圆度)、壁厚、缺陷位置的漏磁场信号传递至配套的外围数据采集装置，由外部计算机进行各项数据的采集、滤波、分析处理以及存储记录，并将结果直观地显示在检测软件的界面上，提供声音报警功能，实现了连续油管管柱缺陷、壁厚、外径(椭圆度)及长度实时检测的自动化，帮助客户最直观的了解连续油管的真实性能状态，为分析连续油管的失效和报废提供科学依据。
下面结合附图和具体实施方式对本发明作进一步说明。
附图说明
图1为本发明的结构示意图；
图2为图1中上半检测单元结构示意图；
图3为图1中下半检测单元结构示意图；
图4为椭圆度检测探头的相对安装位置示意图。
其中，1、上半检测单元，2、下半检测单元，3、测量臂总成套件，3-1、测量滚轮，3-2、旋转编码器，3-3、拉紧弹簧，4、连杆总成套件，4-1、连接支座，4-2、万向节，4-3、刚性连接杆，5、锁紧搭扣，6、护罩，7、圆柱形磁棒，8、椭圆度检测探头，9、导向轮，10、半圆环式漏磁检测探头，10-1、漏磁场信号检测板，10-2、油管壁厚检测板，11、待检测连续油管，12、转轴，13、磁轭。
具体实施方式
如图1所示，一种一体式连续油管缺陷检测装置，包括上半检测单元、下半检测单元两个检测单元，上半检测单元与下半检测单元的一侧通过转轴铰接方式相连接，另一侧通过两个锁紧搭扣相连接，两个检测单元相互配合组装后在两者之间产生供油管穿过的通道，通道内设有设置于两个检测单元上的磁发生装置、漏磁检测探头、椭圆度检测探头和导向装置，检测单元外连接有起导向两个检测单元沿油管运动的测量臂总成套件，所述检测单元还连接有用于连接外围设备的连杆总成套件。
如图1所示，本发明的一体式连续油管缺陷检测装置采用翻盖式设计，整体结构由上半检测单元1、下半检测单元2构成，一侧通过转轴12铰接方式相连接，另一侧通过两个锁紧搭扣5相连接。两组测量臂总成套件3和连杆总成套件4位于下半检测单元2的两侧，并通过快速释放销与下半检测单元2相连接。
如图1至3所示，上半检测单元1、下半检测单元2内均分别安装有4支圆柱形磁棒7(钕铁硼永磁体)，总共8支圆柱形磁棒7围绕圆周方向平行于待检测连续油管11安装，两端固定在侧板上。8支圆柱形磁棒7产生的均匀磁场经过左右两侧的磁轭13后，将待检测连续油管11的局部磁化达到近饱和状态。
如图2至3所示，在上半检测单元1、下半检测单元2的中间位置均安装有4个导向轮9和1个半圆环式漏磁检测探头10。4个导向轮分为左右两组，与待检测连续油管11直接接触，起到上半检测单元1、下半检测单元2与待检测油管之间的支撑作用，使待检测连续油管11始终处在上半检测单元1、下半检测单元2的中心轴线附近。半圆环式漏磁检测探头10安装在左右两组导向轮9的中间，实现对待检测连续油管11上缺陷位置的漏磁场信号和油管壁厚的检测。
如图1至4所示，在上半检测单元1、下半检测单元2左右两侧的护罩6内，分别安装了3个电感式椭圆度检测探头8，相对安装位置如图4所示，用于实现待检测连续油管11的外径检测，依据检测结果获取外径的最大值、最小值，通过以下公式计算待检测连续油管11的椭圆度。
在进行连续油管缺陷检测作业时，首先松开两个锁紧搭扣5，将上半检测单元1、下半检测单元2打开，放入待检测连续油管11后，关闭上半检测单元1、下半检测单元2，再将两个锁紧搭扣5锁紧，使上半检测单元1、下半检测单元2与待检测连续油管11呈紧密抱合状态，此时只有8个导向轮9和测量臂总成套件3上的测量滚轮3-1与待检测连续油管11直接接触。通过待检测连续油管11的轴向移动带动两组测量臂总成套件3上的测量滚轮3-1和旋转编码器3-2转动，实现待检测连续油管11的长度、速度、缺陷位置的检测，半圆环式漏磁检测探头10同步实现对待检测连续油管上缺陷位置的漏磁场信号和油管壁厚的检测。
在本发明中，在上半检测单元1、下半检测单元2内的8支圆柱形磁棒7围绕待检测连续油管11的周向均匀间隔安装，由于相互之间存在很强的磁力作用，必须在相邻圆柱形磁棒7之间安装支撑座，保证了装配和后期维修时的安全性。导向轮9和半圆环式漏磁检测探头10安装在圆柱形磁棒7的内侧，下半检测单元2内的导向轮9支撑结构与下半检测单元2本体之间通过弹簧实现弹性连接，避免因待检测油管的局部变形或污垢堆积而发生卡滞。
在本发明中，所述的半圆环式漏磁检测探头10的圆环内表面与待检测连续油管11的表面预留有一定的安全间隙。如图2至3所示，半圆环式漏磁检测探头10的内部包含有漏磁场信号检测板10-1、油管壁厚检测板10-2。漏磁场信号检测板10-1上包含有半环状磁敏元件阵列，用于实时检测缺陷处的漏磁场信号，实现对待检测连续油管的缺陷检测；油管壁厚检测板10-2上沿着半圆环周向分布的磁敏元件，用于检测连续油管表面的轴向磁场强度，通过数值对比算法和校准的方法，实现对待检测连续油管壁厚的实时测量。
在本发明中，所述的两组测量臂总成套件3均设置有可弯曲的支撑臂、测量滚轮3-1、旋转编码器3-2。其中，测量滚轮3-1与旋转编码器3-2通过联轴器相连接。可弯曲的支撑臂上安装有拉紧弹簧3-3，用于增加测量滚轮3-1与待检测连续油管的接触力，测量滚轮3-1采用柱形轮，并且表面刻有花纹以增大摩擦作用力。当待检测连续油管11的轴向移动带动测量滚轮3-1、旋转编码器3-2转动，实现对待检测连续油管11长度、速度、缺陷位置的检测。
如图1至4所示，所述的连杆总成套件4包括连接支座4-1、两个万向节4-2、刚性连接杆4-3，所述连接支座通过螺栓与外围设备相连接。为了方便安装和拆卸操作，所述的连杆总成套件的另一端采用快速释放销与所述装置的下半检测单元相连接。通过在刚性连接杆4-3的两端安装两个万向节4-2，实现了本检测装置与外围设备之间的柔性连接，用于当所述待检测连续油管发生上下或左右摆动时，进行同步位置跟随，确保上半检测单元1、下半检测单元2与待检测连续油管的相对位置不变，保证了检测的精确度。
在本发明中，所述的一体式连续油管缺陷检测装置，通过信号电缆将检测到的连续油管外径(椭圆度)、壁厚、缺陷位置的漏磁场信号传递至配套的外围数据采集装置，由外部计算机进行各项数据的采集、滤波、分析处理以及存储记录，并将结果直观地显示在检测软件的界面上，实现对所述待检测连续油管11的管柱缺陷、壁厚、外径(椭圆度)及长度的实时检测。
本发明所提供的一体式连续油管缺陷检测装置的工作原理如下：
所述待检测连续油管11穿过本缺陷检测装置时，局部被均匀分布在其周围的圆柱形磁棒7产生的恒定磁场磁化达到近饱和状态，当油管的内外表面存在缺陷时，由于缺陷的磁导率很小，磁阻很大，使磁路中的磁通发生畸变，磁感应线的流向会发生变化，除了部分磁通直接通过缺陷或通过管壁材料内部来绕过缺陷外，还有部分的磁通会泄漏到油管表面上空，通过空气绕过缺陷再度重新进入油管壁，从而在油管表面缺陷处形成漏磁场，圆柱形磁棒7内侧安装了半圆环式漏磁检测探头10，其内部的漏磁场信号检测板10-1上设有半环状磁敏元件阵列，可以实时地检测到油管表面缺陷处的漏磁场信号，实现对待检测连续油管管柱缺陷的检测；同时，半圆环式漏磁检测探头10内部的油管壁厚检测板10-2上设有周向分布的磁敏元件，可同步检测连续油管表面的轴向磁场强度，通过数值对比算法和校准的方法，实现对待检测连续油管壁厚的实时测量；通过在连续油管的周向上安装6个电感式椭圆度检测探头8，测量3组油管外径，依据标准公式计算出油管的椭圆度。
Claims (10)
1.一种一体式连续油管缺陷检测装置，包括上半检测单元、下半检测单元两个检测单元，两个检测单元相互配合组装后在两者之间产生供油管穿过的通道，其特征在于：通道内设有设置于两个检测单元上的磁发生装置、漏磁检测探头、椭圆度检测探头和导向装置，检测单元外连接有起导向两个检测单元沿油管运动的测量臂总成套件。
2.根据权利要求1所述的一种一体式连续油管缺陷检测装置，其特征在于：所述上半检测单元与下半检测单元的一侧通过转轴铰接方式相连接，另一侧通过两个锁紧搭扣相连接。
3.根据权利要求1所述的一种一体式连续油管缺陷检测装置，其特征在于：所述检测单元还连接有用于连接外围设备的连杆总成套件。
4.根据权利要求3所述的一种一体式连续油管缺陷检测装置，其特征在于：所述连杆总成套件包括连接支座、两个万向节和刚性连接杆，所述连接支座通过螺栓与外围设备相连接，所述连杆总成套件的一端通过快速释放销与检测单元相连接。
5.根据权利要求1所述的一种一体式连续油管缺陷检测装置，其特征在于：所述测量臂总成套件包括可弯曲的支撑臂、测量滚轮、旋转编码器、可弯曲的支撑臂上装有的拉紧弹簧，所述测量滚轮为柱形轮，表面刻有花纹以增大摩擦作用力。
6.根据权利要求1所述的一种一体式连续油管缺陷检测装置，其特征在于：所述磁发生装置包括磁棒和磁轭，磁棒在通道的轴向均匀间隔设置，相邻磁棒之间安装有支撑座，支撑座上安装导向装置和漏磁检测探头。
7.根据权利要求1或6所述的一种一体式连续油管缺陷检测装置，其特征在于：所述导向装置包括导向轮，导向轮安装在支撑座上。
8.根据权利要求6所述的一种一体式连续油管缺陷检测装置，其特征在于：所述漏磁检测探头为半圆环式漏磁检测探头，半圆环式漏磁检测探头内部包含有漏磁场信号检测板和油管壁厚检测板。
9.根据权利要求6所述的一种一体式连续油管缺陷检测装置，其特征在于：所述磁发生装置、漏磁检测探头和导向装置位于检测单元的中部，椭圆度检测探头位于检测单元的两侧护罩内，磁发生装置、漏磁检测探头、椭圆度检测探头和导向装置在上半检测单元、下半检测单元对应位置，所述装置的上半检测单元和下半检测单元内均安装有四支圆柱形磁棒、两组磁轭、四个导向轮、一个半圆环式漏磁检测探头和三个椭圆度检测探头。
10.根据权利要求9所述的一种一体式连续油管缺陷检测装置，其特征在于：待检测连续油管的椭圆度、壁厚、缺陷位置的漏磁场信号通过配套的外围数据采集装置和计算机进行采集、分析处理以及存储记录，实现对所述待检测连续油管的管柱缺陷、壁厚、椭圆度及长度的实时精确检测。
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