CN114166157A - Method for intelligently quantifying oxide skin in pipe according to ray intensity curve - Google Patents
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- G—PHYSICS
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- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B15/00—Measuring arrangements characterised by the use of electromagnetic waves or particle radiation, e.g. by the use of microwaves, X-rays, gamma rays or electrons
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- G01F23/28—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring the variations of parameters of electromagnetic or acoustic waves applied directly to the liquid or fluent solid material
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Abstract
The invention provides a method for intelligently quantifying the height of oxide scale accumulated inside a detected pipe according to the curve shape of the intensity of the oxide scale accumulation detection rays, which is used for a micro gamma-ray source or a micro X-ray source automatic detection device. The whole ray intensity curve received by the receiver of the detection device is processed by a data processing system and is divided into three sections of smooth curves, wherein two turning points are obvious; when the oxide scale or other solid foreign matters exist in the pipe, the smooth curve of the middle section breaks the smooth state, and an inflection point appears, wherein the inflection point is the height of the accumulated oxide scale or the solid foreign matters in the pipe. The method does not need to process films and images, has relatively high detection speed, good economy and less influence on the health of workers, and has reliable detection results as long as equipment is reliable.
Description
Technical Field
The invention relates to the field of internal detection of a heated pipe of a thermal power generation boiler, in particular to a method for intelligently quantifying according to the curve shape of the intensity of ray for detecting oxide scale accumulation.
Background
At present, thermal power generation boilers develop towards high-parameter supercritical (supercritical) boilers, the high temperature and pressure enable the phenomenon of high-temperature steam oxidation inside a high-temperature heating surface pipe of the boiler to be inevitable, and oxide skins generated by steam oxidation can be peeled off under certain conditions and accumulated in a U-shaped bent pipe to block the bent pipe, so that the safe operation of a thermal generator set is seriously threatened. To solve this problem, the amount of accumulated scale inside the boiler tube should be detected in time. When the accumulated scale inside the tube reaches an amount that affects the operational safety of the boiler, the tube should be cut and the accumulated scale inside the tube should be cleaned.
The general detection methods include various methods such as ray detection, electromagnetic detection, ultrasonic detection and the like, and each method has advantages and disadvantages. The radiographic inspection includes various radiographic inspection, real-time imaging inspection, DR inspection, CR inspection and the like, relates to a photographic or electronic imaging mode, has the disadvantages of complex inspection process, high labor intensity, complex process method and equipment, low inspection speed, great influence of ionizing radiation on the health of workers and low accuracy of inspection result judgment, and needs to solve the electronic imaging problem.
Disclosure of Invention
In order to solve the problems, the invention provides a method for intelligently quantifying according to the shape of the intensity curve of the oxide scale accumulation detection ray by using a miniature gamma-ray source or a miniature x-ray source automatic detection device, which does not need to process films and images, has relatively high detection speed, good economy and less influence on the health of workers, and has reliable detection results as long as equipment is reliable.
A method for intelligently quantifying an oxide skin in a pipe according to a ray intensity curve is characterized by comprising the following steps:
(1) according to the theory of interaction between rays and substances, calculating the ray intensity curve of the rays after passing through the tubes according to the specification and the material of the tubes of the high-temperature heating surface of the common boiler;
(2) presetting detection process program parameters and a detection program;
(3) testing to obtain a detection curve and verification data of the detected pipe;
(4) and (4) carrying out test detection by using the sample tube, and checking the accuracy and reliability of the detection result according to the actual accumulated height of the oxide skin or the foreign matter inside the tube.
Preferably, in the step (1), the ray intensity curve obtained by calculation is a theoretical curve; the calculated theoretical curve forms of the ray intensities of the pipes with different specifications and materials are the same, the calculated theoretical curve forms are three-section curves, and the maximum intensity value I is at the position without the pipe0The shape is a straight line; the curvature of each section of the curve is different when the specification and the material of the pipe are different.
Preferably, in the step (2), the traveling speed v of the automatic detection system is set; setting the intensity of the ray received by the receiver as I0(ii) a The intensity of the ray received by the receiver after the ray passes through the tube wall is Ip, and an Ip curve graph is formed in the process that the ray emitter and the receiver synchronously pass through the detected tube; the sensitivity of the radiation receiver is adjusted according to the detection test condition or the emission intensity of the radiation emitting device is adjusted according to the sensitivity of the receiver.
Preferably, the Ip curve has a fixed shape, and in the fixed shape, the instrument system can calculate and confirm that no foreign matter exists in the pipe by ignoring the Ip value according to the curve shape; when the oxide skin or foreign matter is accumulated in the tube, the oxide skin or foreign matter attenuates the ray, a certain strength attenuation area is arranged on the Ip curve, and the Ip curve changes.
Preferably, in the step (3), according to a specific detection object, testing and obtaining a ray intensity curve of the pipe with corresponding specification size and material; during the test, the error between the actual advancing speed and the set value is determined according to the set detection advancing speed v and curve point sampling timing, and the data of the actual wall thickness, the inner diameter and the outer diameter of the pipe, and the error is adjusted to be the minimum value.
Preferably, the specific manner of acquiring the radiation intensity curve is as follows: the system records that the sampling frequency of the intensity value Ip is 50-100 times/second, the detection device and the pipe move at a constant speed at a v relative speed, and the system obtains a curve of the ray intensity value Ip. According to the instrument configuration, a proper sampling frequency is adopted. The frequency is too high, the operation speed of the instrument is slow, and the detection speed is slow.
Preferably, the specific way of adjusting the error is as follows:
setting O as the starting position of the ray emitter and the receiver, and A, B, C as the position of the ray emitter and the receiver;
starting from 0, it is denoted t0(ii) a Ray emitter and receiverThe time at point A is denoted as tAThe time from the line to the point B is denoted as tBThe time from the line to the point C is denoted as tC；
The actual pipe has an outside diameter D, and the data measured by the test is 0C-v x tC；
The actual internal diameter of the pipe is Di, and the measured data AB is v x (t)B-tA)；
The actual wall thickness of the tube is δ, and the test measurement data 0A BC v × tA＝v×(tC-tB)。
The set value v of the detected traveling speed is adjusted to v' according to the error of the test data and the actual pipe size data, and the calculation formula of the error adjustment is as follows:
v′＝v×D÷(0C)＝v×Di÷(AB)＝v×δ÷(0A)＝v×δ÷(BC)
preferably, in the step (4), the scale or foreign matter deposition height is determined by: when no oxide skin or foreign matter and water exist in the pipe, the whole curve is divided into three sections of smooth curves, wherein two obvious turning points are arranged; when oxide scale or foreign matters exist in the pipe, the smooth curve of the middle section breaks the smooth state, and an inflection point h appears, wherein the inflection point h is the height corresponding position of accumulated oxide scale or solid foreign matters; the height of the oxide skin accumulation or foreign bodies is recorded as h, and the system calculation formula is as follows:
h＝v′×(th-tA)
in the formula, h is the stacking height of oxide skin in the tube;
v' — the travel speed set by the instrument after error calibration;
ththe instrument starts timing from point 0 to point h;
tAthe instrument starts timing from point 0 to point a.
Preferably, the size or the proportion of the inner section of the pipe is converted according to the relation between the deposition height of the scale or the solid foreign matter and the inner section of the pipe, or the mass equivalent of the scale deposited in the pipe is converted through test comparison data.
Preferably, a micro gamma-ray source or a micro X-ray source automatic detection device and a data processing system are adopted; the receiver transmits the received ray intensity to a data processing system, the data processing system comprises a program setting module, a data receiving module, an analysis module and a processing module, the advancing speed v is the synchronous uniform advancing speed when the ray emitter and the receiver which are set in the data processing system in advance detect, the processing program and the data verification formula for processing an Ip curve obtained by test detection are set in advance through the program setting module, and A, B, C and the test values of h points are input into the data processing system to calibrate the detection device.
Compared with the prior art, the invention has the advantages that:
the method is simple and feasible, and can be used for carrying out detection according to the existing automatic detection device of the miniature gamma-ray source or the miniature x-ray source, setting a program in a data processing system in advance to carry out data processing, and obtaining the accumulated height of the oxide skin and the foreign matters through the positions of inflection points of three sections of curves;
the method does not need to process films and images, has relatively high detection speed, good economy and less influence on the health of workers, and has reliable detection results as long as equipment is reliable.
Drawings
FIG. 1 is a comparison graph of a method for intelligent quantification of the shape of a scale deposit detected ray intensity curve according to the present invention;
wherein, the left side of the graph a is a schematic diagram of relative positions of the ray emitter and the receiver, and the right side is an Ip curve when no scale or solid foreign matters exist in the tube;
the left side of the diagram is a schematic diagram of the relative positions of the ray emitter and the ray receiver in the detection process, and the right side is an Ip curve when oxide skin or solid foreign matters exist in the tube.
In the figure, 1-tube wall; 2-a transmitter; 3-a receiver; 4-ray intensity curve
Detailed Description
The drawings are for illustration purposes only and are not to be construed as limiting the invention; for a better understanding of the present embodiments, certain features of the drawings may be omitted, enlarged or reduced, and do not represent the size of an actual product; for those skilled in the art, some well-known structures in the drawings and descriptions thereof may be omitted; the terms "upper", "lower", "front", "rear", "radial", "lateral", "longitudinal", "horizontal", "parallel", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience in describing and simplifying the description, but do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus should not be construed as limiting the invention.
In the present invention, the terms "mounted," "connected," "secured," and the like are to be construed broadly unless otherwise specifically indicated and limited. For example, the connection can be fixed, detachable or integrated; may be mechanically coupled, may be electrically coupled or may be in communication with each other; the terms may be directly connected or indirectly connected through an intermediate, and may be used for communicating the inside of two elements or interacting relation of two elements, unless otherwise specifically defined, and the specific meaning of the above terms in the present invention is understood by those skilled in the art according to specific situations.
As shown in fig. 1, a method for intelligently quantifying an oxide scale in a tube according to a ray intensity curve is characterized by comprising the following steps:
(1) according to the theory of interaction of rays and substances, calculating an obtained ray intensity curve as a theoretical curve; the calculated theoretical curve forms of the ray intensities of the pipes with different specifications and materials are the same, the calculated theoretical curve forms are three-section curves, and the maximum intensity value I is at the position without the pipe0The shape is a straight line; the curvature of each section of the curve is different when the specification and the material of the pipe are different.
(2) Presetting detection process program parameters and detection programs: setting the traveling speed v of the automatic detection system; the ray emitted by the ray emitter 2 is directly irradiated on the receiver 3 without passing through other solid or liquid substances, and the intensity of the ray received by the receiver 3 is set as I0(ii) a After the ray passes through the pipe wall 1, the intensity of the ray received by the receiver 3 is Ip, and the ray emitter and the receiver synchronously pass through the detected rayIn the process of testing the pipe, forming an Ip curve 4; the sensitivity of the radiation receiver 3 is adjusted according to the test situation or the emission intensity of the radiation emission device is adjusted according to the sensitivity of the receiver.
The Ip curve 4 presents a fixed shape, under which the instrument system can ignore the Ip value according to the curve shape, calculate and confirm that no foreign body exists in the tube; when the oxide skin or foreign matter is accumulated in the tube, the oxide skin or foreign matter attenuates the ray, a certain strength attenuation area is arranged on the Ip curve, and the Ip curve changes.
(3) Test acquisition of the detection curve and verification data of the detected pipe: testing and obtaining a ray intensity curve of the pipe with corresponding specification size and material according to a specific detection object; during the test, the error between the actual advancing speed and the set value is determined according to the set detection advancing speed v, the point sampling timing of the curve, the actual wall thickness of the pipe, the outer diameter of the pipe and the inner diameter of the pipe, and the error is adjusted to be the minimum value.
The specific way of acquiring the ray intensity curve is as follows: the sampling frequency of the system recording the intensity value Ip is 50-100 times/second, the detection device and the pipe move at a constant speed at a v relative speed, and the system obtains a ray intensity value Ip curve 4. According to the instrument configuration, a proper sampling frequency is adopted. The frequency is too high, the operation speed of the instrument is slow, and the detection speed is slow.
The specific way of adjusting the error is as follows:
setting O as the starting position of the ray emitter and the receiver, and A, B, C as the position of the ray emitter and the receiver;
starting from 0, it is denoted t0(ii) a The time of the ray emitter and receiver going to point A is recorded as tAThe time from the line to the point B is denoted as tBThe time from the line to the point C is denoted as tC；
The actual pipe has an outside diameter D, and the data measured by the test is 0C-v x tC；
The actual internal diameter of the pipe is Di, and the measured data AB is v x (t)B-tA)；
The actual wall thickness of the tube is δ, and the test measurement data 0A BC v × tA＝v×(tC-tB)。
The set value v of the detected traveling speed is adjusted to v' according to the error of the test data and the actual pipe size data, and the calculation formula of the error adjustment is as follows:
v′＝v×D÷(0C)＝v×Di÷(AB)＝v×δ÷(0A)＝v×δ÷(BC)
(4) and (4) carrying out test detection by using the sample tube, and checking the accuracy and reliability of the detection result according to the actual accumulated height of the oxide skin or the foreign matter inside the tube.
As shown in fig. 1 a, the method for determining the scale or foreign matter deposition height is: when no oxide skin or foreign matter and water exist in the pipe, the whole Ip curve 4 is divided into three sections of smooth curves, wherein two obvious turning points are arranged; as shown in the b diagram in fig. 1, when the oxide scale or foreign matter is present in the tube, the smooth curve in the middle section breaks the smooth state, and the Ip curve 4 has an inflection point h, which is the corresponding position of the height of the accumulated oxide scale or solid foreign matter; the height of the oxide skin accumulation or foreign bodies is recorded as h, and the system calculation formula is as follows:
h＝v′×(th-tA)
in the formula, h is the stacking height of oxide skin in the tube;
v' — the travel speed set by the instrument after error calibration;
ththe instrument starts timing from point 0 to point h;
tAthe instrument starts timing from point 0 to point a.
And converting the size or the proportion of the inner section of the pipe according to the relation between the accumulated height of the oxide skin or the solid foreign matters and the inner section of the pipe, or converting the mass equivalent of the oxide skin accumulated in the pipe through test comparison data.
Adopting a micro gamma-ray source or a micro x-ray source automatic detection device and a data processing system; the receiver transmits the received ray intensity to a data processing system, the data processing system comprises a program setting module, a data receiving module, an analysis module and a processing module, the advancing speed v is the synchronous uniform advancing speed when the ray emitter and the receiver which are set in the data processing system in advance detect, the processing program and the data verification formula for processing an Ip curve obtained by test detection are set in advance through the program setting module, and A, B, C and the test values of h points are input into the data processing system to calibrate the detection device.
During detection, the ray emitter 2 and the ray receiver 3 are vertically arranged on two sides of the pipe to be tested, the clear distance between the ray emitter and the ray receiver is larger than the outer diameter of the pipe to be tested, the pipe is kept not to be touched, and the ray emitter and the ray receiver synchronously move at a constant speed during testing.
Example one
The high temperature superheater tubes for the HG-1913/25.4-YM3 model boilers were tested. The boiler is supercritical, the outlet temperature of the final superheater is 571 ℃, the steam pressure is 25.4MPa, the operation is carried out in 10 months in 2008, and the accumulated operation time is 72876.5 h; the specification of the superheater tube is phi 50 multiplied by 8mm, and the grade of the austenitic steel used is SA213-TP 347H.
The detection instrument used was CH-Ir 6. The detection steps are as follows:
1. mounting tool to boiler tube panel to be detected
According to the situations of the site of the boiler pipe to be detected, the maximum height position of the scale deposit in the boiler pipe to be detected and the like, the tool is correctly installed, the clear distance between the ray transmitter and the ray receiver is about 60mm, and the ray transmitter and the ray receiver are installed and connected with an operation control circuit and a receiver to receive a data circuit.
2. Personnel evacuate the tool installation position and reach the safe position of the instrument control position, and the personnel are prevented from being injured by ionizing radiation.
3. And (5) checking the instrument. The control system is turned on to move the radiation emitter and receiver to below the tube so that the receiver receives the radiation without interference from the tube. When the computer display is stable, the closed window of the miniature ray source is opened, and the ray intensity I received by the receiver displayed in the display is checked0Roughly judge I empirically or according to distance, radiation source activity, etc0Whether the value is normal.
4. Detection of
And (4) synchronously lifting the ray emitter and the ray receiver, detecting all bent pipes in the detected pipe screen, recording detection data by an instrument, automatically finishing judgment of a detection result, and displaying a detection curve for manual check.
Example two
The high-temperature superheater tubes of B & WB-2082/28.0-M type boilers are detected. The boiler has ultra-supercritical parameters, the outlet temperature of the superheater is 605 ℃, the steam pressure is 28.0MPa, the boiler is put into production in 2013 in 1 month, and the accumulated running time is 43625.7 h; the specification of the superheater tube is phi 41.3 multiplied by 7mm, and the grade of the used austenitic steel is Super304 HSB.
The same instrument system as in example 1 was used.
The instrument was calibrated and tested as in example 1.
EXAMPLE III
The final reheater tube of a boiler model DG3000/27.46-II1 was tested. The boiler is an ultra-supercritical parameter, the outlet temperature of a final-stage reheater is 603 ℃, the pressure is 5.94MPa, the boiler is put into production in 12 months in 2008, and the accumulated running time is 86736.5 h; the specification of the reheater pipe is phi 57 multiplied by 4mm, and the steel mark is T92.
The same instrument system as in example 1 was used.
The instrument was calibrated and tested as in example 1.
It is to be understood that the above description is not intended to limit the present invention, and the present invention is not limited to the above examples, and those skilled in the art may make modifications, alterations, additions or substitutions within the spirit and scope of the present invention.
Claims (10)
1. A method for intelligently quantifying an oxide skin in a pipe according to a ray intensity curve is characterized by comprising the following steps:
(1) according to the theory of interaction between rays and substances, calculating the ray intensity curve of the rays after passing through the tubes according to the specification and the material of the tubes of the high-temperature heating surface of the common boiler;
(2) presetting detection process program parameters and a detection program;
(3) testing to obtain a detection curve and verification data of the detected pipe;
(4) and (4) carrying out test detection by using the sample tube, and checking the accuracy and reliability of the detection result according to the actual accumulated height of the oxide skin or the foreign matter inside the tube.
2. The method for intelligently quantifying the oxide skin in the tube according to the ray intensity curve as claimed in claim 1, wherein in the step (1), the ray intensity curve obtained by calculation is a theoretical curve; the calculated theoretical curve forms of the ray intensities of the pipes with different specifications and materials are the same, the calculated theoretical curve forms are three-section curves, and the maximum intensity value I is at the position without the pipe0The shape is a straight line; the curvature of each section of the curve is different when the specification and the material of the pipe are different.
3. The method for intelligently quantifying the oxide skin in the tube according to the ray intensity curve as claimed in claim 1, wherein in the step (2), the traveling speed v of the automatic detection system is set; setting the intensity of the ray received by the receiver as I0(ii) a The intensity of the ray received by the receiver after the ray passes through the tube wall is Ip, and an Ip curve is formed in the process that the ray emitter and the receiver synchronously pass through the detected tube; the sensitivity of the radiation receiver is adjusted according to the detection test condition or the emission intensity of the radiation emitting device is adjusted according to the sensitivity of the receiver.
4. The method of claim 3, wherein the Ip curve has a fixed shape, and in the fixed shape, the instrument system can calculate and confirm that there is no foreign object inside the tube according to the curve shape and neglect the Ip value; when the oxide skin or foreign matter is accumulated in the tube, the oxide skin or foreign matter attenuates the ray, a certain strength attenuation area is arranged on the Ip curve, and the Ip curve changes.
5. The method for intelligently quantifying the oxide skin in the tube according to the radiation intensity curve as claimed in claim 1, wherein in the step (3), according to the specific detection object, the radiation intensity curve of the tube with the corresponding specification size and material is obtained through testing; during the test, the error between the actual advancing speed and the set value is determined according to the set detection advancing speed v and curve point sampling timing, and the data of the actual wall thickness, the inner diameter and the outer diameter of the pipe, and the error is adjusted to be the minimum value.
6. The method for intelligently quantifying the oxide skin in the tube according to the radiation intensity curve as claimed in claim 5, wherein the radiation intensity curve is obtained by: the system records that the sampling frequency of the intensity value Ip is 50-100 times/second, the detection device and the pipe move at a constant speed at a v relative speed, and the system obtains a curve of the ray intensity value Ip.
7. The method for intelligently quantifying the scale in the tube according to the ray intensity curve as claimed in claim 5, wherein the error is adjusted in a specific manner as follows:
setting O as the starting position of the ray emitter and the receiver, and A, B, C as the position of the ray emitter and the receiver;
starting from 0, it is denoted t0(ii) a The time of the ray emitter and receiver going to point A is recorded as tAThe time from the line to the point B is denoted as tBThe time from the line to the point C is denoted as tC；
The actual pipe has an outside diameter D, and the data measured by the test is 0C-v x tC；
The actual internal diameter of the pipe is Di, and the measured data AB is v x (t)B-tA)；
The actual wall thickness of the tube is δ, and the test measurement data 0A BC v × tA＝v×(tC-tB)。
The set value v of the detected traveling speed is adjusted to v' according to the error of the test data and the actual pipe size data, and the calculation formula of the error adjustment is as follows:
v′＝v×D÷(0C)＝v×Di÷(AB)＝v×δ÷(0A)＝v×δ÷(BC)
8. the method for intelligently quantifying the oxide scale in the tube according to the ray intensity curve as claimed in claim 1, wherein in the step (4), the accumulated height of the oxide scale or foreign matter is determined by: when no oxide skin or foreign matter and water exist in the pipe, the whole curve is divided into three sections of smooth curves, wherein two obvious turning points are arranged; when oxide scale or foreign matters exist in the pipe, the smooth curve of the middle section breaks the smooth state, and an inflection point h appears, wherein the inflection point h is the height corresponding position of accumulated oxide scale or solid foreign matters; the height of the oxide skin accumulation or foreign bodies is recorded as h, and the system calculation formula is as follows:
h＝v′×(th-tA)
in the formula, h is the stacking height of oxide skin in the tube;
v' — the travel speed set by the instrument after error calibration;
ththe instrument starts timing from point 0 to point h;
tAthe instrument starts timing from point 0 to point a.
9. The method for intelligently quantifying the oxide scale in the pipe according to the ray intensity curve as claimed in claim 8, wherein the size or the proportion of the inner section of the pipe is calculated according to the relation between the accumulated height of the oxide scale or the solid foreign matters and the inner section of the pipe, or the mass equivalent of the oxide scale accumulated in the pipe is calculated according to experimental comparison data.
10. The method for intelligently quantifying the oxide skin in the tube according to the ray intensity curve is characterized in that a miniature gamma-ray source or a miniature x-ray source automatic detection device and a data processing system are adopted; the receiver transmits the received ray intensity to a data processing system, the data processing system comprises a program setting module, a data receiving module, an analysis module and a processing module, the advancing speed v is the synchronous uniform advancing speed when the ray emitter and the receiver which are set in the data processing system in advance detect, the processing program and the data verification formula for processing an Ip curve obtained by test detection are set in advance through the program setting module, and A, B, C and the test values of h points are input into the data processing system to calibrate the detection device.
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| CN202111487579.5A CN114166157B (en) | 2021-12-08 | 2021-12-08 | Intelligent quantitative method for oxide skin in tube according to ray intensity curve |
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| CN114166157B (en) | 2023-10-20 |
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