CN112114030A - Drill rod thread detection device and method based on ferrite eddy current thermal imaging - Google Patents
Drill rod thread detection device and method based on ferrite eddy current thermal imaging Download PDFInfo
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Abstract
The invention discloses a drill rod thread detection device based on ferrite eddy current thermal imaging, which comprises a rotary fixing device for fixing a drill rod, wherein an induction coil is arranged beside the rotary fixing device, a manganese-zinc-iron oxygen rod is arranged in the induction coil, two ends of the induction coil are fixed on an alternating current heating device, and two ends of the induction coil are electrically connected with the alternating current heating device; the alternating current heating device is fixed on the mobile device; an infrared thermal imager is arranged above the rotary fixing device, and the controller and the infrared thermal imager are both electrically connected with the PC end. The thread defect detection method adopting the detection device comprises the following steps: setting the motion tracks of all the parts, exciting the induction coils, recording the temperature change of the surface of the thread by an infrared thermal imager, judging the position of the defect by utilizing the temperature change and the like. The scheme has high detection efficiency and provides data support for predicting the residual service life of the threads and repairing the arranged threads. Has stronger universality and high automation degree.
Description
Technical Field
The invention relates to the technical field of nondestructive testing, in particular to a drill rod thread detection device and method based on ferrite eddy current thermal imaging.
Background
The drill rod is a steel pipe with threads at the tail part and is used for connecting surface equipment of a drilling machine and drilling and grinding equipment or a bottom hole device at the bottom end of a drilled well. The purpose of the drill pipe is to carry drilling mud to the drill bit and, together with the drill bit, raise, lower or rotate the bottom hole assembly. The drill pipe must be able to withstand large internal and external pressures, twists, bends and vibrations. In the process of oil and gas exploitation and extraction, the drill pipe can be used for multiple times. The drill rods are divided into a kelly, a drill rod and a weighted drill rod. The total amount of the drill rods used in each oil field in China is about 23-25 ten thousand tons, and accounts for about 1/4 of the total demand of oil well pipes in China. Similar problems exist in the using process of the drill rod thread, under the conditions of bearing alternating force for a long time, repeated screwing and poor working environment, various thread failure modes such as drill rod thread root cracks, thread breakage, thread release, corrosion leakage, change of thread zone taper and the like can be caused, the drill rod can be seriously broken, and great economic loss and labor loss are brought to production and operation. Particularly, in recent years, with the acceleration of the localization process of the special petroleum pipe, the thread gluing failure accident of the drill rod happens frequently, the service life of the drill rod is greatly shortened, the well repairing operation amount of an oil well is increased, the production of the oil field is affected, and meanwhile, great economic loss is brought to the oil field. Therefore, the developed effective drill rod thread detection device has great engineering significance and practical value.
For the detection of the thread of the drill rod, common detection methods such as manual visual inspection, magnetic powder detection, penetration detection, magnetic flux leakage detection, ultrasonic detection and the like are mainly used at present.
The manual visual inspection is suitable for detecting the threads of the drill rods with small batches; the penetration detection is similar to the magnetic particle detection principle, and adopts a penetrating agent as a detection medium, and the penetrating agent is added on the thread surface of the drill rod. After the permeation is completed, the excess penetrant is removed, and the defect can be discovered by the penetrant remaining in the defect by using a corresponding developing method. The penetrant can permeate into the defect with smaller size, so the two methods have better detection effect on the micro-cracks; because the thread of the drill rod is positioned at the end part of the drill rod, the conventional magnetic leakage detection signal can be submerged in a strong interference magnetic field and is difficult to detect. In engineering, a weak magnetic detection method is adopted to detect the threads of the drill rod, so that partial defects can be detected; ultrasonic testing can adopt the echo method to detect the defect of drilling rod screw thread bottom, because the supersound can propagate longer distance in the drilling rod screw thread, consequently has great advantage to the detection of darker defect or puncture crack.
The manual detection method is time-consuming and labor-consuming, and cannot meet the requirement of large-batch detection of the threads of the drill rods. Although the infiltration is detected and is had higher detection precision with magnetic particle testing, because the infiltration, processes such as formation of image and defect observation all need the manual work to accomplish, and is inefficient, and pollutes the screw surface, can cause certain influence to the environment moreover. Due to the end effect, the magnetic flux leakage detection has large background noise even if weak magnetic detection is adopted, and the detection rate is not high. Although the ultrasonic detection can detect a deeper defect, the detection rate is not high because the thread structure of the drill rod is complex and only partial defects at the bottom can reflect ultrasonic waves back to the probe. And the ultrasonic detection needs a coupling agent, and the efficiency is also influenced to a certain extent. Therefore, the existing drill rod thread detection schemes have a large problem.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a drill rod thread detection device and method based on ferrite eddy current thermal imaging, which are convenient for detecting the defects of the root positions of drill rod threads.
In order to achieve the purpose of the invention, the technical scheme adopted by the invention is as follows:
the drill rod thread detection device comprises a rotary fixing device for fixing a drill rod, wherein an induction coil is arranged beside the rotary fixing device, a manganese-zinc-iron oxygen rod is arranged in the induction coil, two ends of the induction coil are fixed on an alternating current heating device, and two ends of the induction coil are electrically connected with the alternating current heating device; the alternating-current heating device is fixed on a sliding block of a vertical first linear moving module, and the first linear moving module is fixed on a sliding block of a horizontal second linear moving module; the stepping motors of the first linear moving module and the second linear moving module are electrically connected with a motor driver, and the motor driver is electrically connected with the controller; an infrared thermal imager is arranged above the rotary fixing device, and the controller and the infrared thermal imager are both electrically connected with the PC end.
A thread defect detection method adopting a drill rod thread detection device based on ferrite eddy current thermal imaging comprises the following steps:
s1: inputting thread parameters of a drill rod to be detected to a PC end, wherein the thread parameters comprise a thread pitch, a thread diameter and a thread form;
s2: generating a moving path of the first linear moving module and the second linear moving module and the rotating speed of a three-phase asynchronous motor driving roller according to the thread pitch, the thread diameter and the thread shape, and ensuring that the manganese-zinc ferrite rod can move along the axial direction of the drill rod by being attached to the surface of the thread in the rotating process of the drill rod;
s3: the drill rod is placed on the two pairs of rollers, and a certain gap is ensured between the manganese zinc iron oxygen rod and the bottom of the thread;
s2: the three-phase asynchronous motor drives the roller to rotate to drive the drill rod to rotate around the axis, the alternating current heating device applies excitation to the induction coil, and the infrared thermal imager records the temperature change of the surface of the thread;
s5: taking the temperature which does not enter a thread detection area when the detection is started as a comparison temperature;
s6: after entering the detection area, the infrared thermal imager compares the temperature detected in each frame with the comparison temperature;
s7: if the temperature of a certain position on the thread is detected to be higher than the contrast temperature by a certain threshold value H, starting to generate thread defects at the position, wherein the position is the starting position of the thread defects, otherwise, generating no thread defects;
s8: if the temperature of a certain position on the thread is detected to be smaller than the contrast temperature by a certain threshold value h, the position is the middle position of the thread defect, otherwise, the thread defect does not occur;
s8: two adjacent defect starting positions on two sides of the middle position of the defect are used as two ends of a complete defect, the length between the two defect starting positions is the length of the complete defect, and the position of the defect on the surface of the thread is marked;
s9: and judging the size of the defect by adopting the difference value between the temperature of the initial position of the defect and the contrast temperature, wherein the larger the difference value between the temperature of the initial position of the defect and the contrast temperature is, the larger the defect size is, and otherwise, the smaller the defect size is.
The invention has the beneficial effects that: this scheme compares with traditional drilling rod screw thread detection device, and induction heating produces thermal fast, can accomplish the detection in the time of the utmost point short, and for non-contact measurement, need not the couplant, can not influence the screw surface, and is pollution-free to the environment. Therefore, the detection process can be carried out at a higher speed and with higher efficiency.
Due to the skin effect of induction heating, eddy current can be distributed along the near surface of the thread, so that the temperature field can be disturbed by the crack with small depth, and the thermal imaging detection has high detection rate on the fatigue crack of the surface.
And the defect causes disturbance to the eddy current, so that the generated uneven temperature distribution can be transmitted to a computer in a numerical matrix mode by depending on an infrared thermal imager. The thermal imaging detection method not only can detect the defects, but also can mark the geometrical sizes of the defects, and can provide data support for predicting the residual life of the threads and scheduling the repair work of the threads.
When the thermal imaging detection is adopted, the shape similar to the thread surface is adopted, so that the lifting influence caused by the unevenness of the thread surface can be reduced, the bottom surface of the thread can be uniformly heated, and the defect calibration is facilitated. The rotary scanning thermal imaging detection method realizes scanning detection on the surface of the thread. This can achieve the need for full-circle testing of the threads.
The scheme can fit the trend of the surface of the thread by setting the rotating speed of the motor and the motion track of the induction coil aiming at the drill rod threads of different models, and has strong universality and high automation degree.
Drawings
FIG. 1 is a block diagram of a drill pipe thread inspection device based on ferrite eddy current thermal imaging.
FIG. 2 is a schematic view of the contact between the Mn-Zn-Fe-O rod and the screw thread.
Fig. 3 is a temperature distribution diagram of the infrared thermal imager when a defect is detected.
The device comprises a PC (personal computer) end 1, a PC (personal computer) end 2, a controller 3, a motor driver 4, a stepping motor 5, an alternating current heating power supply 6, a circulating water tank 7, a support 8, an alternating current heating device 9, a hollow copper pipe 10, threads 11, a three-phase asynchronous motor 12, a drill rod 13, a roller 14, a manganese-zinc-iron-oxygen rod 15, an infrared thermal imager 16, a thread bottom 17, a heated temperature field 18 and defects.
Detailed Description
The following description of the embodiments of the present invention is provided to facilitate the understanding of the present invention by those skilled in the art, but it should be understood that the present invention is not limited to the scope of the embodiments, and it will be apparent to those skilled in the art that various changes may be made without departing from the spirit and scope of the invention as defined and defined in the appended claims, and all matters produced by the invention using the inventive concept are protected.
As shown in fig. 1, the drill pipe thread detection device based on ferrite eddy current thermal imaging in the present scheme includes a rotation fixing device for fixing a drill pipe 12, an induction coil is arranged beside the rotation fixing device, a manganese zinc iron oxygen rod 14 is arranged in the induction coil, two ends of the induction coil are fixed on an alternating current heating device 8, and two ends of the induction coil are electrically connected with the alternating current heating device 8; the alternating-current heating device 8 is fixed on a sliding block of a vertical first linear moving module, the first linear moving module is fixed on a sliding block of a horizontal second linear moving module, and the second linear moving module is fixed on the bracket 7; the stepping motors 4 of the first linear moving module and the second linear moving module are electrically connected with the motor driver 3, and the motor driver 3 is electrically connected with the controller 2; an infrared thermal imager 15 is arranged above the rotary fixing device, and the controller 2 and the infrared thermal imager 15 are both electrically connected with the PC end 1.
The infrared thermal imager 15 continuously reads thermal radiation in a viewing angle at a certain frequency, converts the thermal radiation into temperature distribution parameters, and transmits the temperature distribution parameters into the PC terminal 1; the induction coil outputs high-frequency alternating current to provide a high-frequency magnetic field for the manganese-zinc ferrite rod 14; the Mn-Zn-Fe-O rod 14 can gather a high-frequency magnetic field induced by the induction coil and form a magnetic loop with the detection part of the thread 10 to form fixed-point heating. The infrared thermal imager 15 is perpendicular to the thread 10 detection surface of the drill pipe 12 to minimize the attenuation of thermal radiation, thereby improving the accuracy of temperature capture.
The first linear motion module and the second linear motion module are perpendicular to each other and provide motion to the induction coil in the circumferential and horizontal directions of the drill rod 12 to accommodate changes in the height of the threads 10 of the drill rod 12 during rotation.
The rotary fixing device comprises two pairs of rollers 13, each pair of rollers 13 are meshed with each other, the two pairs of rollers 13 are arranged on the same straight line, each pair of rollers 13 is driven by a three-phase asynchronous motor 11, and the three-phase asynchronous motor 11 is electrically connected with the controller 2. The three-phase alternating current motor drives the two pairs of rollers 13 to rotate, so that the drill rod 12 is driven to rotate around the axial direction, and rotary motion is provided for rotary scanning detection.
Circulation tank 6, circulation tank 6 pass through the water pump and are connected with AC heating device 8, and the water pump is connected with controller 2 electricity, and AC heating device 8 is connected with AC heating power supply 5 electricity, can provide recirculated cooling water for AC heating device 8, guarantees heating device's constancy of temperature.
The two ends of the induction coil are connected with an alternating current heating device 8 through a hollow copper pipe 9, and the alternating current heating coil is surrounded on the periphery of the ferrite by adopting an even multi-turn structure, so that the magnetic field intensity at the center of the coil is increased, more energy is provided for a manganese-zinc ferrite rod 14, and the situation that the threads 10 are heated sufficiently in the detection process can be ensured. The induction coil can be freely placed, so that the detection requirements under various working conditions are met.
The front end of the Mn-Zn-Fe-O rod 14 is fitted with the edge of the thread 10 of the drill rod 12, so that the Mn-Zn-Fe-O rod 14 can extend into the bottom of the thread 10, and the problem of uneven energy distribution of the crest and the root when the thread 10 is heated is solved.
As shown in fig. 2, the method for detecting the thread defect of the drill rod thread detection device based on ferrite eddy current thermal imaging comprises the following steps:
s1: inputting thread parameters of the drill rod 12 to be detected into the PC end 1, wherein the thread parameters comprise a thread pitch, a thread diameter and a thread form;
s2: generating a moving path of the first linear moving module and the second linear moving module and the rotating speed of a driving roller 13 of the three-phase asynchronous motor 11 according to the thread pitch, the thread diameter and the thread shape, and ensuring that the manganese-zinc ferrite rod 14 can move along the axial direction of the drill rod 12 by being attached to the surface of the thread 10 in the rotating process of the drill rod 12; the thread 10 of the drill rod 12 detects the root of the stress concentration in the most important position, and therefore a rotational sweep is required in order to cover the entire circumference of the thread 10.
S3: the drill rod 12 is placed on the two pairs of rollers 13, and a certain gap is ensured between the manganese zinc iron oxygen rod 14 and the thread bottom 16;
s2: the three-phase asynchronous motor 11 drives the roller 13 to rotate, the drill rod 12 is driven to rotate around the axis, the alternating current heating device 8 applies excitation to the induction coil, and the infrared thermal imager 15 records the temperature change of the surface of the thread 10;
the calculation method of the surface temperature of the thread 10 is as follows:
wherein, JeThe density of eddy current induced by the induction coil is sigma, the conductivity of the material is sigma, rho is the density of the material, C is the specific heat capacity of the threaded material of the drill rod, k is the heat conductivity coefficient of the threaded material of the drill rod, u is the linear velocity vector of the thread 10 at the detection position, T is the temperature of the thread surface, T is time, and Q is the total energy output by the induction coil to the thread of the drill rod. It can be seen that the higher eddy current density can induce higher temperature, therefore, as shown in fig. 3, the temperature distribution on the surface of the thread 10 is distorted due to the heated temperature field 17 on the surface of the thread 10, and the distortion point of the temperature can be identified by the infrared thermal imaging camera 15, so as to judge the existence of the defect 18.
The infrared thermal imaging camera 15 is kept fixed in the detection process, the visual angle of the infrared thermal imaging camera is always kept in an area at the upper end of the thread 10 of the drill rod 12, and all surfaces of the thread 10 of the drill rod 12 pass through the area in time in the rotation process, so that the whole-circle detection of the thread 10 of the drill rod 12 can be ensured. The infrared thermal imager 15 disperses the temperature distribution in the field of view into 640 × 120 pixel points, each pixel point corresponds to a temperature value, and the temperature of the surface of the screw thread 10 is read with data of 200 times per second and transmitted to the PC terminal 1.
S5: taking the temperature which does not enter the detection area of the thread 10 when the detection is started as the contrast temperature;
s6: after entering the detection area, the infrared thermal imager 15 compares the temperature detected in each frame with the comparison temperature;
s7: if the temperature of a certain position on the thread 10 is detected to be greater than the contrast temperature by a certain threshold value H, the thread defect 18 begins to appear at the position, the position is the initial position of the thread defect 18, otherwise, the thread defect 18 does not appear;
s8: if the temperature of a certain position on the thread 10 is detected to be smaller than the contrast temperature by a certain threshold value h, the position is the middle position of the thread defect 18, otherwise, the thread defect 18 does not appear;
s8: taking two starting positions of the defects 18 adjacent to two sides of the middle position of the defect 18 as two ends of a complete defect 18, wherein the length between the starting positions of the two defects 18 is the length of the complete defect 18, and marking the positions of the defects 18 on the surface of the thread 10;
s9: and judging the size of the defect 18 by adopting the difference value between the temperature of the initial position of the defect 18 and the contrast temperature, wherein the larger the difference value between the temperature of the initial position of the defect 18 and the contrast temperature is, the larger the size of the defect 18 is, and otherwise, the smaller the size of the defect 18 is.
This scheme compares with traditional drilling rod screw thread detection device, and induction heating produces thermal fast, can accomplish the detection in the time of the utmost point short, and for non-contact measurement, need not the couplant, can not influence 10 surfaces on the screw thread, and is pollution-free to the environment. Therefore, the detection process can be carried out at a higher speed and with higher efficiency.
Because eddy currents are distributed along the near-surface of the thread 10 due to the skin effect of induction heating, cracks with small depths can also cause perturbations to the temperature field, which results in a high detection rate of fatigue cracks on the surface for thermal imaging inspection.
And the temperature maldistribution caused by the disturbance of the eddy current by the defect 18 can be transmitted to the computer by means of the infrared thermal imaging camera 15 in a numerical matrix manner. The thermographic inspection method not only detects the defects 18, but also calibrates the geometry of the defects 18, which provides data support for predicting the remaining life of the thread 10 and scheduling the repair work of the thread 10.
When the thermal imaging detection is adopted, the shape similar to the surface of the thread 10 is adopted, so that the lifting-off influence caused by the unevenness of the surface of the thread 10 can be reduced, the bottom surface of the thread 10 can be uniformly heated, and the defect 18 can be calibrated. The rotary scanning thermal imaging detection method realizes scanning detection on the surface of the thread 10. This may be desirable for full-circle inspection of the thread 10.
Aiming at the drill rod 12 threads 10 of different models, the surface trend of the threads 10 can be fitted by setting the rotating speed of the motor and the motion track of the induction coil, and the method has strong universality and high automation degree.
Claims (9)
1. The drill rod thread detection device based on ferrite eddy current thermal imaging is characterized by comprising a rotary fixing device for fixing a drill rod (12), wherein an induction coil is arranged beside the rotary fixing device, a manganese-zinc-iron-oxygen rod (14) is arranged in the induction coil, two ends of the induction coil are fixed on an alternating current heating device (8), and two ends of the induction coil are electrically connected with the alternating current heating device (8); the alternating-current heating device (8) is fixed on a sliding block of a vertical first linear moving module, and the first linear moving module is fixed on a sliding block of a horizontal second linear moving module; the stepping motors (4) of the first linear moving module and the second linear moving module are electrically connected with a motor driver (3), and the motor driver (3) is electrically connected with the controller (2); an infrared thermal imager (15) is arranged above the rotary fixing device, and the controller (2) and the infrared thermal imager (15) are electrically connected with the PC end (1).
2. The ferrite eddy current thermal imaging-based drill pipe thread detection device as claimed in claim 1, wherein the rotary fixing device comprises two pairs of rollers (13), each pair of rollers (13) is meshed with each other, the two pairs of rollers (13) are installed on the same straight line, each pair of rollers (13) is driven by a three-phase asynchronous motor (11), and the three-phase asynchronous motor (11) is electrically connected with the controller (2).
3. The drill pipe thread detection device based on ferrite eddy current thermal imaging is characterized by further comprising a circulating water tank (6), wherein the circulating water tank (6) is connected with an alternating current heating device (8) through a water pump, the water pump is electrically connected with the controller (2), and the alternating current heating device (8) is electrically connected with an alternating current heating power supply (5).
4. The drill pipe thread detection device based on ferrite eddy current thermal imaging as claimed in claim 1, wherein two ends of the induction coil are electrically connected with the alternating current heating device (8) through hollow copper pipes (9).
5. The ferrite eddy current thermal imaging-based drill pipe thread inspection device as claimed in claim 1, wherein the induction coil is a uniform multi-turn structure surrounding the periphery of the Mn-Zn-Fe-O rod (14).
6. The ferrite eddy current thermal imaging based drill pipe thread detection device as claimed in claim 1, wherein the end of the Mn-Zn-Fe-O rod (14) is fitted to the edge of the thread (10) of the drill pipe (12).
7. A thread defect detection method adopting the ferrite eddy current thermal imaging-based drill pipe thread detection device as claimed in any one of claims 1 to 6, and is characterized by comprising the following steps of:
s1: inputting thread parameters of a drill rod (12) to be detected to the PC end (1), wherein the thread parameters comprise a thread pitch, a thread diameter and a thread form;
s2: generating a moving path of the first linear moving module and a moving path of the second linear moving module and the rotating speed of a driving roller (13) of a three-phase asynchronous motor (11) according to the thread pitch, the thread diameter and the thread form, and ensuring that a manganese zinc iron oxygen rod (14) can be attached to the surface of a thread (10) to move axially along the drill rod (12) in the rotating process of the drill rod (12);
s3: the drill rod (12) is placed on the two pairs of rollers (13) and a certain gap is ensured between the manganese zinc iron oxygen rod (14) and the thread bottom (16);
s2: a three-phase asynchronous motor (11) drives a roller (13) to rotate to drive a drill rod (12) to rotate around an axis, an alternating current heating device (8) applies excitation to an induction coil, the tip of a manganese-zinc-iron-oxygen rod (14) forms eddy current, the surface of a thread (10) is heated, and an infrared thermal imager (15) records the temperature change of the surface of the thread (10);
s5: taking the temperature which does not enter the detection area of the thread (10) at the beginning of detection as a contrast temperature;
s6: after entering the detection area, the infrared thermal imager (15) compares the temperature detected in each frame with the comparison temperature;
s7: if the temperature of a certain position on the thread (10) is detected to be higher than the contrast temperature by a certain threshold value H, the defect (18) begins to appear at the position, the position is the starting position of the defect (18), otherwise, the defect (18) does not appear;
s8: if the temperature of a certain position on the thread (10) is detected to be smaller than the contrast temperature by a certain threshold value h, the position is the middle position of the defect (18), otherwise, the defect (18) does not appear;
s8: taking two starting positions of two adjacent defects (18) at two sides of the middle position of the defect (18) as two ends of a complete defect (18), wherein the length between the two starting positions of the defects (18) is the length of the complete defect (18), and marking the position of the defect (18) on the surface of the thread (10);
s9: and judging the size of the defect (18) by adopting the difference value between the temperature of the initial position of the defect (18) and the contrast temperature, wherein the larger the difference value between the temperature of the initial position of the defect (18) and the contrast temperature is, the larger the size of the defect (18) is, and otherwise, the smaller the size of the defect (18) is.
8. The method for detecting the thread defect of the drill pipe thread detection device based on the ferrite eddy current thermal imaging is characterized in that the calculation method of the surface temperature of the thread (10) is as follows:
wherein, JeThe density of eddy current induced by the induction coil is sigma, the conductivity of the material is sigma, rho is the density of the material, C is the specific heat capacity of the threaded material of the drill rod, k is the heat conductivity coefficient of the threaded material of the drill rod, u is the linear velocity vector of the thread (10) at the detection position, T is the temperature of the thread surface, T is time, and Q is the total energy output by the induction coil to the thread of the drill rod.
9. The method for detecting the thread defect of the drill pipe thread detection device based on the ferrite eddy current thermal imaging according to claim 7, wherein the infrared thermal imaging instrument (15) disperses the temperature distribution in the visual field into 640 x 120 pixels, each pixel corresponds to a temperature value, and the temperature of the surface of the thread (10) is read at 200 times per second and transmitted into the PC end (1).
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