CN114778687A - Method for quickly identifying and evaluating welding defects of pressure pipeline - Google Patents
Method for quickly identifying and evaluating welding defects of pressure pipeline Download PDFInfo
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- CN114778687A CN114778687A CN202111595884.6A CN202111595884A CN114778687A CN 114778687 A CN114778687 A CN 114778687A CN 202111595884 A CN202111595884 A CN 202111595884A CN 114778687 A CN114778687 A CN 114778687A
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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
- G01N29/06—Visualisation of the interior, e.g. acoustic microscopy
- G01N29/0654—Imaging
- G01N29/069—Defect imaging, localisation and sizing using, e.g. time of flight diffraction [TOFD], synthetic aperture focusing technique [SAFT], Amplituden-Laufzeit-Ortskurven [ALOK] technique
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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
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/4409—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison
- G01N29/4418—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison with a model, e.g. best-fit, regression analysis
Abstract
The invention discloses a method for quickly identifying and evaluating welding defects of a pressure pipeline, which organically combines an ultrasonic phased array technology with a three-dimensional visual imaging technology, scanning defects at the welding position of the pressure pipeline by adopting an ultrasonic phased array method, directly introducing defect influences into a pressure pipeline mechanical model based on a representative unit method of a material containing the defects on the basis of obtaining three-dimensional shape data of the defects, establishing a three-dimensional finite element model of a structure containing the defects, analyzing and predicting the influence of the defects on the service performance of the pressure pipeline by a finite element analysis method, automatically combining industrial standards and professional analysis knowledge to perform 'fit-to-use' safety evaluation on the pipeline containing the defects, automatically forming an evaluation report, therefore, the reliability and the identifiability of the detection result are improved, detection personnel can carry out all-dimensional observation on the model after three-dimensional display, and the detection efficiency and the detection accuracy are greatly improved.
Description
Technical Field
The invention belongs to the technical field of welding quality detection, and particularly relates to a detection technology of pipeline welding quality.
Background
The pressure pipeline is used as equipment for continuously conveying fluid media, is widely applied to production and public engineering systems in petrochemical, electric power, environmental protection and other industries, such as oil refining devices, chemical devices, power station boilers and the like, and plays an important role in national economic construction. Most of the pipelines convey flammable, explosive, high-temperature, toxic and corrosive gaseous or liquid media with certain pressure, once explosion or leakage occurs, disastrous accidents such as fire and poisoning can be caused, and serious life and property loss is caused, so that the safety of the pressure pipelines is highly concerned by researchers at home and abroad.
The pressure pipelines are mostly assembled by field welding, defects of different types are often formed in the welding process due to the fact that the welding process is not tightly controlled or field operation is improper, the welding defects refer to defects formed in the welding process of a welding joint part and mainly comprise air holes, slag inclusions, incomplete penetration, incomplete fusion, cracks, pits, undercuts, welding beading and the like. The existence of the defects reduces the actual bearing capacity of the pipeline on one hand, and on the other hand, more dangerous crack defects can be generated due to factors such as load, medium and the like in the using process, so that great hidden danger is generated for the operation safety of the pipeline. For example, a large number of old liquid ammonia refrigeration system pipelines are not provided with grooves during welding, so that the weld joint has incomplete penetration defect, and the leakage and the fracture of the weld joint of the pipeline are easily caused under the action of bending stress and fatigue stress. How to accurately detect the defects of the pipelines and evaluate and process the detected defects in the process of periodic inspection is a problem which always troubles the management departments and the use units of the industrial pipelines.
At present, ultrasonic nondestructive testing is an important means for welding quality detection, and compared with traditional ultrasonic testing, phased arrays are a new technology for ultrasonic testing. The phased array detection technology adopts a probe array formed by combining multiple wafers to transmit and receive ultrasonic waves, controls time delay of each wafer in the wafer array through computer software, and controls pulse transmission to enable a wave beam to be focused to a specific depth and spread at a certain angle. The sound beam angle, the focal column position and the focal point position are dynamically and continuously adjustable within a certain range through electronic control. The array can produce focused shear and longitudinal waves. The phased array can realize functions of linear scanning, fan-shaped scanning, dynamic depth focusing and the like, and has a larger coverage area under the condition that the probe is not moved. The phased array ultrasonic detection technology has the advantages of high detection precision, high detection speed, strong repeatability, high defect detection rate, low detection cost and the like, is suitable for detecting welding seams in various groove forms, and gradually becomes the first-choice technology of welding seam detection.
The ultrasonic phased array technology performs imaging display in different dimensions and modes in the aspect of signal display, and compared with the traditional ultrasonic single waveform display mode, the defect display mode is improved, and two-dimensional appearances such as the position, the length and the like of a defect relative to a welding seam can be observed.
The ultimate goal of defect detection is to give an adaptive evaluation of the pressure bearing properties of a pipe containing defects. The method is suitable for nondestructive testing technology, and a large number of researches on the safety evaluation technology of the pressure pipeline with defects in service are carried out from the last 80 th century at home and abroad, such as 'degraded pipe research plan' of the American Nuclear regulatory Commission, 'pipeline reliability experimental research plan' of the Japan atomic energy institute, 'German pressure pipeline research plan' of the national institute of materials, MPA of the Germany Stuttgart university, 'nine five' national key scientific and technological issues 'research on the safety evaluation technology of the pressure pipeline with defects in service', and a series of safety evaluation standards of the pipelines with defects are formed on the basis of the research plans, wherein the outstanding safety evaluation standards of the pipelines with defects are IWB-3640 and appendix C 'austenitic steel pipeline defect evaluation regulation and acceptance criterion', IWB-3650 and appendix H 'ferritic steel pipeline defect evaluation regulation and acceptance criterion' of the fifth XI in American ASME specifications, and ASME B31G 'handbook for residual strength measurement of corrosion pipelines', CEGB R6 of British Central Power Bureau of China (assessment of structural integrity including defects), GB/T19624-2004 safety assessment of pressure vessels including defects in use, and the like.
However, most of the domestic and foreign applicability evaluation technologies provide evaluation methods with certain application ranges based on standards and specifications, and each standard and specification has certain limitations. The standard specifications relate to comprehensive theoretical knowledge and empirical knowledge in multiple aspects such as materials, mechanics, failure analytics and the like, the evaluation process is complex, and common engineering technicians are difficult to master.
Disclosure of Invention
The invention aims to solve the technical problem of providing a method for quickly identifying and evaluating the welding defects of the pressure pipeline, and improving the reliability and identifiability of the detection result.
In order to solve the technical problem, the invention adopts the following technical scheme:
a method for quickly identifying and evaluating welding defects of a pressure pipeline comprises the following steps:
s1: scanning defects of the welding part of the pressure pipeline by adopting an ultrasonic phased array method to form a three-dimensional imaging map;
s2: extracting key points, lines and planes from the point cloud information of the three-dimensional imaging map to generate a three-dimensional entity pipeline model, and realizing the parameterization of pipeline entity modeling, material performance, load, boundary condition application and grid density;
s3: importing the three-dimensional model obtained in the step S2 into finite element mechanical analysis software, and carrying out mechanical calculation to obtain a stress variation range of the pressure pipeline defect;
s4: and analyzing the influence of the defects on the safety performance of the pressure pipeline and generating an evaluation report.
Preferably, in step S1, the shape, the vertex position, and the relationship of the vertex position of the 3D graph are determined according to the appearance vertex data of the pipeline welding part, so as to establish the skeleton of the 3D graph; then scanning defects of the pipeline welding joint by adopting an ultrasonic phased array method, acquiring data information of each position point through the detection waveform data acquired in real time, and generating a group of detection point cloud information; according to the position of the scanning sensor, obtaining detection and positioning information of a welding object where the point cloud information is located, and putting the point cloud data on a welding seam model to obtain two-dimensional slice data on the current position; in the detection process, the scanner is moved, and after the slice data are collected by the mechanical scanning device for S-scan detection of a section of ultrasonic phased array, each frame of slice data are extracted, namely two-dimensional layered information is superposed, so that a complete 3D image of the welding seam is generated.
Preferably, the defects include cracks, lack of fusion, lack of penetration, porosity, slag inclusions, and local thinning.
Preferably, the flaw evaluation of the cracks, the non-fusion and the non-penetration welding adopts a U factor evaluation rule of GB/T19624-2019 appendix G 'pressure pipeline straight pipe section plane flaw safety evaluation method'.
Preferably, the evaluation of the defects of air holes, slag inclusion, local thinning and specific incomplete penetration adopts the plastic limit load evaluation rule of GB/T19624-2019 appendix H 'pressure pipeline straight pipe section volume defect safety evaluation method'.
The invention organically combines an ultrasonic phased array technology with a three-dimensional visual imaging technology on the basis of ultrasonic phased array detection, scans the defects of the welding part of the pressure pipeline by adopting the ultrasonic phased array method, obtains the three-dimensional shape data of the defects, directly introduces the defect influence into a pressure pipeline mechanical model on the basis of a representative unit method of a material containing the defects, establishes a three-dimensional finite element model containing a defect structure, analyzes and predicts the influence of the defects on the service performance of the pressure pipeline by a finite element analysis method, automatically combines industrial standards and professional analysis knowledge to carry out 'fit use' safety evaluation on the pipeline containing the defects, automatically forms an evaluation report, can better reflect the length, depth, position, trend and other information of the real defects by detection, thereby improving the reliability and identifiability of a detection result, and leading a detector to carry out omnibearing observation on the model after three-dimensional display, the efficiency and the accuracy of detection are greatly improved; an intelligent evaluation tool is provided for engineering technicians of the first-line detection, and the safety condition and the scientific management level of the pressure pipeline in service in China are effectively improved.
The following detailed description of the present invention and the advantages thereof will be described with reference to the accompanying drawings.
Drawings
The invention is further described with reference to the accompanying drawings and the detailed description below:
FIG. 1 is a flow chart of defect identification and evaluation according to the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, a method for quickly identifying and evaluating a welding defect of a pressure pipe includes the following steps:
s1: scanning defects of the welding part of the pressure pipeline by adopting an ultrasonic phased array method to form a three-dimensional imaging map;
s2: extracting key points, lines and planes from the point cloud information of the three-dimensional imaging map to generate a three-dimensional entity pipeline model, and realizing the parameterization of pipeline entity modeling, material performance, load, boundary condition application and grid density;
s3: importing the three-dimensional model obtained in the step S2 into finite element mechanical analysis software, and carrying out mechanical calculation to obtain a stress variation range of the pressure pipeline defect;
s4: and analyzing the influence of the defects on the safety performance of the pressure pipeline and generating an evaluation report.
In the three-dimensional imaging technique in step S1, the existing phased array detection may be referred to implement 3D. 3D refers to a representation about all shapes in 3D space, and its position can be calculated using a coordinate system. A defect (object) in 3D is composed of and represented by each point in a coordinate system. The properties of the object are represented by color. The position coordinates of each point are indicated by (x, y, z), and the color is represented by (R, G, B).
Conventional ultrasound detection has the X-axis representing distance (time) and the Y-axis representing amplitude values. The phased array uses a linear arrangement probe and is matched with a focusing algorithm to realize scanning of a two-dimensional image. The 3-dimensional direction recording can be realized by adding an encoder for recording the distance.
In 3D detection and analysis of phased arrays: the x axis is a distance coordinate of coding walking records, the y axis is the arrangement of the phased array one-dimensional linear array probes, the z axis is a distance (time) unit corresponding to a wave scanning line of detection data A of the phased array, and the color of each point is the color in a color level corresponding to the phased array detection data. The specific implementation steps are as follows: 1. initializing a 3D drawing environment by using an open source 3D drawing tool;
2. in the drawing environment, according to the actual sizes of the workpiece and the weld bead model, 1: 1, drawing a three-dimensional workpiece graph; 3. starting to collect waveform data by interacting with hardware;
4. calculating single imaging, calculating the imaging position (Z axis) of the current single image according to the reading value of the encoder, and turning and cutting the image beyond the boundary;
5. loading the imaging calculated in the step 4 into a preset 3D buffer area;
6. the imaging data of the most buffer area adaptively adjusts the transparency of the imaging pixel, thereby achieving the purposes of highlighting the defect type and weakening the noise signal, and ensuring that the imaging is more vivid;
7. and finally, drawing and rendering the whole graph.
The three-dimensional imaging map enables a three-dimensional image of the defect to present a good outline, a good trend and the like, so that rich information is provided for defect positioning, quantification, grading and judgment.
Firstly, determining the shape, the vertex position and the mutual relation of a 3D graph according to the appearance vertex data of a pipeline welding part, and establishing a skeleton of the 3D graph, namely a welding model three-dimensional frame diagram. And then scanning defects of the pipeline welding joint by adopting an ultrasonic phased array method, acquiring data information of each position point through real-time acquired detection waveform data, and generating a group of detection point cloud information. And acquiring detection positioning information of a welding object where the point cloud information is located according to the position of the scanning sensor, and putting the point cloud data on a welding seam model to obtain two-dimensional slice data at the current position. In the detection process, the scanner is moved, the slice data are collected by the mechanical scanning device for S scanning detection of a section of ultrasonic phased array, each frame of slice data is extracted, two-dimensional layered information is superposed, and then a complete welding seam 3D model and a detection result are generated.
As shown in fig. 1, the model is imported into finite element mechanical analysis software ANSYS, a pipeline-dedicated intelligent analysis program is established based on a secondary development tool APDL, and key points, lines and planes are extracted from the point cloud information to generate a three-dimensional entity pipeline model. The method comprises the steps of inputting parameters including the inner diameter, the length and the wall thickness of a pipeline, the volume and the direction of defects and the working pressure of the pipeline, generating a defect-containing pipeline entity model according to the pipeline model and the defect model, setting pressure and boundary conditions according to the pressure of the pipeline, realizing the parameterization of pipeline entity modeling, material performance, load, boundary condition application and grid density, and quickly finishing the mechanical analysis of the defect-containing pipeline.
On the basis of finite element analysis, parameters required by fatigue evaluation of the welding defects are obtained, including stress variation ranges of the defects of the pressure pipeline, fatigue evaluation is carried out on the welding defects according to 'safety evaluation of pressure containers containing defects in use', and finally, an evaluation report of the pressure pipeline is automatically generated.
The pressure pipeline welding defects mainly refer to plane defects such as cracks, incomplete fusion, incomplete penetration and the like, and air holes, slag inclusion, local thinning and specific incomplete penetration defects. The influence of the defects on the safety performance of the pressure pipeline can be referred to the standards of national standard GB/T19624-2019 safety evaluation of pressure vessels containing defects in use and the like.
(1) The plane defects of cracks, unfused, incomplete penetration and the like adopt a U factor evaluation rule of GB/T19624-2019 appendix G 'pressure pipeline straight pipe section plane defect safety evaluation method': if the criterion expressed by the formula is established, the assessment result is safe or acceptable; otherwise, it is not guaranteed to be safe or acceptable.
Wherein σmIs film stress, σBFor bending stress, σsIs the material yield strength, σbIs the tensile strength of the material.
For allowable rheology stress ratio, U is the ratio of plastic limit load to crack initiation load, npThe safety factor is taken according to the load.
(2) The defects of air holes, slag inclusion, local thinning and specific incomplete penetration are evaluated by a plasticity limit load evaluation rule of 'pressure pipeline straight pipe section volume defect safety evaluation method' in appendix H of GB/T19624-2019: if the formula holds, the defect is safe or acceptable; otherwise, it is considered to be not guaranteed safe or acceptable.
Wherein P, M represents the internal pressure, bending moment load and PLSIs the plastic limit internal pressure, M, of a defect-containing pipe at pure internal pressureLSThe bending moment is the plastic limit bending moment of the pipeline containing defects under pure bending moment.
While the invention has been described with reference to specific embodiments, it will be understood by those skilled in the art that the invention is not limited thereto, and may be embodied in other forms without departing from the spirit or essential characteristics thereof. Any modifications which do not depart from the functional and structural principles of the present invention are intended to be included within the scope of the claims.
Claims (5)
1. A method for quickly identifying and evaluating welding defects of a pressure pipeline is characterized by comprising the following steps:
s1: scanning defects of the welding part of the pressure pipeline by adopting an ultrasonic phased array method to form a three-dimensional imaging map;
s2: extracting key points, lines and surfaces from the point cloud information of the three-dimensional imaging map to generate a three-dimensional entity pipeline model, and realizing the parameterization of pipeline entity modeling, material performance, load, boundary condition application and grid density;
s3: importing the three-dimensional model obtained in the step S2 into finite element mechanical analysis software, and carrying out mechanical calculation to obtain a stress variation range of the pressure pipeline defect;
s4: and analyzing the influence of the defects on the safety performance of the pressure pipeline and generating an evaluation report.
2. The method as claimed in claim 1, wherein the step S1 is implemented by determining the shape, vertex position and their relationship of a 3D graph according to the appearance vertex data of the pipeline welding part, and building the skeleton of the 3D graph; then scanning defects of the pipeline welding joint by adopting an ultrasonic phased array method, acquiring data information of each position point through the detection waveform data acquired in real time, and generating a group of detection point cloud information; according to the position of the scanning sensor, obtaining detection and positioning information of a welding object where the point cloud information is located, and putting the point cloud data on a welding seam model to obtain two-dimensional slice data on the current position; in the detection process, the scanner is moved, and after the slice data are collected by the mechanical scanning device for S-scan detection of a section of ultrasonic phased array, each frame of slice data are extracted, namely two-dimensional layered information is superposed, so that a complete 3D image of the welding seam is generated.
3. The pressure pipeline welding defect rapid identification and evaluation method according to claim 1, characterized in that: the defects comprise cracks, incomplete fusion, incomplete penetration, air holes, slag inclusion and local thinning.
4. The pressure pipeline welding defect rapid identification and evaluation method according to claim 3, characterized in that: the flaw evaluation of the cracks, the incomplete fusion and the incomplete penetration adopts a U factor evaluation rule of GB/T19624-2019 appendix G 'pressure pipeline straight pipe section plane flaw safety evaluation method'.
5. The pressure pipeline welding defect rapid identification and evaluation method according to claim 3, characterized in that: and evaluating the defects of air holes, slag inclusion, local thinning and specific incomplete penetration by adopting a plastic limit load evaluation rule of GB/T19624-2019 appendix H 'pressure pipeline straight pipe section volume defect safety evaluation method'.
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| CN115330094A (en) * | 2022-10-14 | 2022-11-11 | 成都秦川物联网科技股份有限公司 | Intelligent gas pipeline service life prediction method, internet of things system, device and medium |
| CN116465969A (en) * | 2023-06-09 | 2023-07-21 | 曲阜市龙祥冶铸辅料有限公司 | Method for analyzing influence of using amount of molding sand powder on casting quality based on image processing |
| CN116663190A (en) * | 2023-06-06 | 2023-08-29 | 嘉丰盛精密电子科技(孝感)有限公司 | Method for identifying splicing strength of stamping parts in shielding cover |
| CN117056686A (en) * | 2023-08-14 | 2023-11-14 | 嘉兴市安得特种设备科技有限公司 | Alarming method and system for detecting surface defects of pressure container |
| CN117058145A (en) * | 2023-10-12 | 2023-11-14 | 中特检深燃安全技术服务(深圳)有限公司 | Intelligent detection system based on oil and gas pipeline operation and maintenance |
| CN117589889A (en) * | 2024-01-19 | 2024-02-23 | 江苏省特种设备安全监督检验研究院 | Ultrasonic phased array microcrack detection method and system based on finite element model |
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| CN115330094A (en) * | 2022-10-14 | 2022-11-11 | 成都秦川物联网科技股份有限公司 | Intelligent gas pipeline service life prediction method, internet of things system, device and medium |
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| CN116663190B (en) * | 2023-06-06 | 2023-11-07 | 嘉丰盛精密电子科技(孝感)有限公司 | Method for identifying splicing strength of stamping parts in shielding cover |
| CN116465969A (en) * | 2023-06-09 | 2023-07-21 | 曲阜市龙祥冶铸辅料有限公司 | Method for analyzing influence of using amount of molding sand powder on casting quality based on image processing |
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| CN117058145A (en) * | 2023-10-12 | 2023-11-14 | 中特检深燃安全技术服务(深圳)有限公司 | Intelligent detection system based on oil and gas pipeline operation and maintenance |
| CN117058145B (en) * | 2023-10-12 | 2023-12-22 | 中特检深燃安全技术服务(深圳)有限公司 | Intelligent detection system based on oil and gas pipeline operation and maintenance |
| CN117589889A (en) * | 2024-01-19 | 2024-02-23 | 江苏省特种设备安全监督检验研究院 | Ultrasonic phased array microcrack detection method and system based on finite element model |
| CN117589889B (en) * | 2024-01-19 | 2024-04-02 | 江苏省特种设备安全监督检验研究院 | Ultrasonic phased array microcrack detection method and system based on finite element model |
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