CN117347492A - Method for detecting quality of welding seam of high-chromium alloy steel pipeline - Google Patents
Method for detecting quality of welding seam of high-chromium alloy steel pipeline Download PDFInfo
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- CN117347492A CN117347492A CN202311303664.0A CN202311303664A CN117347492A CN 117347492 A CN117347492 A CN 117347492A CN 202311303664 A CN202311303664 A CN 202311303664A CN 117347492 A CN117347492 A CN 117347492A
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- 230000035945 sensitivity Effects 0.000 claims description 62
- 238000012360 testing method Methods 0.000 claims description 57
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Classifications
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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
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
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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
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
- G01N29/265—Arrangements for orientation or scanning by relative movement of the head and the sensor by moving the sensor relative to a stationary material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
Abstract
The invention relates to the technical field of weld quality detection, in particular to a method for detecting weld quality of a high-chromium alloy steel pipeline. The method comprises the following steps: s1: selecting a phased array detector; selecting a phased array probe and a wedge block according to the specification of the workpiece; s2: calibrating the phased array detector according to the specification of the workpiece; s3: preparing and scanning a weld detection area before scanning; s4: after the detection is finished, storing detection data in an instrument, importing the detection data into a computer, and analyzing images by using analysis equipment to obtain detection quantity, positioning and quantitative information of the defects; s5: and (5) defect assessment and acceptance. According to the method, the rapid and effective detection of the weld defects of the thick-wall pipelines of the P91/P36 high-chromium alloy steel is realized by adopting a mode that the phased array probe scans the single-sided bilateral direct waves for multiple times and scans the primary reflected waves simultaneously, so that the construction period is greatly shortened, the labor intensity is reduced, the personnel radiation risk is avoided, and the problem that the traditional ray detection is difficult is effectively solved.
Description
Technical Field
The invention relates to the technical field of weld quality detection, in particular to a method for detecting weld quality of a high-chromium alloy steel pipeline.
Background
The P91/P36 high-chromium alloy steel thick-wall pipeline is a main component of a nuclear energy demonstration fast reactor main steam system of the fourth generation of 'Charpy nuclear power', and an operation medium is high-temperature high-pressure steam, so that the high-temperature high-pressure high-chromium alloy steel thick-wall pipeline plays an important role in a fast reactor nuclear power unit. The welding process parameters (heat treatment parameters and heat treatment times) of the welding line are strict, and the defects of cracks, unfused and tiny inclusions (slag) and the like are easy to occur during welding. Because the main steam pipeline and the main water supply pipeline are made of high-chromium steel and have large wall thickness, the design file has definite limit on the heat treatment times of the welding seams, and therefore the central transillumination cannot be realized without designing a radial inspection plug for central exposure of the welding seams of the pipelines; when the Ir192 radiation source double-wall single-image transillumination is adopted, the exposure time is too long due to the fact that the penetration is impossible or the penetration thickness is too large, the haze of the negative film is increased, and the detection rate of the tiny defects is reduced sharply; if the Co60 radioactive source is adopted for inspection, the problems of difficult radiation protection, long construction period, high time pressure and the like exist.
The ultrasonic welding seam detection technology has been primarily applied in the welding seam detection field at present due to the characteristics of convenient operation, high detection speed, high sensitivity and good reliability; the existing ultrasonic detection technology is difficult to carry out nondestructive detection on the welding line of the thick-wall pipeline of the P91/P36 high-chromium alloy steel, and the detection standard is difficult to be achieved. Therefore, how to perform nondestructive testing on the weld quality of the thick-wall pipeline of the P91/P36 high-chromium alloy steel is a technical problem which needs to be solved by the technicians in the field.
Disclosure of Invention
The invention aims to provide a method for detecting the quality of a welding line of a high-chromium alloy steel pipeline, which aims to solve the problem that the quality of the welding line of the high-chromium alloy steel pipeline is difficult to detect in the prior art.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
a method for detecting the quality of a welding line of a high-chromium alloy steel pipeline comprises the following steps:
s1: selecting a phased array detector; selecting a phased array probe and a wedge block according to the specification of the workpiece;
s2: calibrating the phased array detector according to the specification of the workpiece;
s3: preparing and scanning a weld detection area before scanning;
when the weld joint detection area is scanned, a coding scanning mode of scanning single-sided double-sided direct waves or single-sided direct waves for multiple times and scanning primary reflected waves simultaneously is adopted;
s4: after the detection is finished, storing detection data in an instrument, importing the detection data into a computer, and analyzing images by using analysis equipment to obtain detection quantity, positioning and quantitative information of the defects;
s5: defect assessment and acceptance;
disqualification conditions for planar defects include cracks, unfused, and incomplete penetration;
assessing disqualification conditions for non-planar defects includes:
the amplitude is greater than or equal to phi 2-4dB;
the amplitude is less than phi 2-4dB and greater than phi 2-18dB, indicating that the length is greater than or equal to t/3;
in the adjacent display with the minimum distance less than or equal to 6L, the indication length is less than t/3 and the defect accumulation length is greater than t within the length of 12t, wherein L is the maximum indication length and t is the nominal thickness.
Further, step S2 includes sound speed calibration, delay calibration, angle gain compensation calibration, scan sensitivity setting, TCG curve setting, scan sensitivity setting, acoustic energy transmission loss calibration, and encoder calibration;
the step of scanning sensitivity setting comprises the following steps: setting a sensitivity test block and a sensitivity verification test block; simulating a small-size volume type defect through the sensitivity test block to be used as a reference for the amplitude gain of the small-size volume type defect; verifying sensitivity simulation through a sensitivity verification test block, testing the amplitude of a ball hole on the sensitivity verification test block, and comparing the result with actual measurement; and (3) setting an evaluation line to be phi 2-30dB, setting a quantitative line to be phi 2-18dB, and setting a waste line to be phi 2-10dB according to the verification result.
Further, in step S2, sound velocity calibration, wedge delay calibration and sensitivity calibration are performed using semicircular arcs on the reference block and the ISO19675 block, and a transverse through hole with a diameter of 2mm is used as a base sensitivity;
the coupling loss and the material attenuation of the surface of the workpiece are the same as those of the test block, otherwise, the measurement of the acoustic energy transmission loss difference is performed, the scanning sensitivity is compensated according to the actual measurement result, and the compensation quantity is calculated into a distance/amplitude curve; no compensation is performed when the maximum transmission loss difference in the span-prone sound path is less than or equal to 2dB.
The encoder is calibrated before first use or every month in the following way: moving the encoder by at least 300mm, requiring an error of less than 1% or 10mm, subject to a smaller value; the encoder scan step is less than 2mm.
Further, in step S3, when scanning is performed on the weld detection area, a scanning mode of combining mechanical scanning and electronic scanning of axial and circumferential sector scanning/0-degree line scanning and line scanning is adopted; and adsorbing a magnetic stripe or drawing a straight line on the test piece to serve as a reference line for fixing the distance between the front edge of the probe and the center of the welding line.
Further, in step S3, when single-sided single-side direct wave scanning is adopted, the remaining height of the welded joint is flattened, one fan scanning and longitudinal vertical scanning are added at the center line of the welded joint, and the whole detection area is scanned by adopting zigzag scanning in at least one direction;
if the defect is found during zigzag scanning, fan scanning and longitudinal vertical scanning are adopted at the defect position to acquire and record data.
Further, in step S3, the pre-scan preparation includes: grinding the surplus height of the weld seam to be level, grinding the surplus height to be level with the adjacent parent metal, and detecting the surface roughness Ra of the surface to be less than or equal to 6.3 mu m; the temperature difference between the detection temperature and the reference block temperature in the calibration process is not more than 14 ℃.
Further, in step S3, the weld detection area is characterized by a weld detection area width and a weld detection area thickness; the width of the welding line detection area is the width of the welding line itself plus the heat affected areas at the two sides of the welding line;
the relationship between the width of the welding line and the width of the heat affected zones at two sides of the welding line is as follows:
when T is less than or equal to 30mm, the heat affected zone is more than or equal to 5mm;
when T is more than or equal to 30mm, the heat affected zone is more than or equal to 10mm.
Further, in step S3, when scanning the weld detection area, the suspicious part is detected by adopting a fan scanning and vertical line scanning mode and combining with a first scanning mode or a plurality of scanning modes of saw teeth, front and back, left and right, rotation and surrounding;
each movement of the probe and the last time have partial overlap, and the range of the probe is at least 15% of the size of the transducer perpendicular to the scanning direction;
when the workpiece is scanned in a segmented mode in the length direction, the overlapping range of each segment of scanning area is larger than or equal to 20mm; for annular workpieces, the range of the scan stop position beyond the start position is greater than or equal to 20mm.
Further, in step S5, the assessment of the defect includes quantifying depth, amplitude, indicated length, height of the defect; the depth is quantified by taking the position of the maximum reflection amplitude of the defect as the defect depth, and the maximum amplitude obtained by saw-tooth scanning is taken as the defect amplitude.
Further, in step S5, when the amplitude is larger than phi 2-30dB and smaller than phi 2-4dB and the distance between any two defects is smaller than 20mm, increasing RT test to judge; when the defect interval is measured, measuring is carried out at the position of the highest value of the defects;
for abnormal reflection with questionable defect quality, one or more of the traditional UT, manual phased array ultrasonic detection technology, TOFD detection technology and ray detection technology are selected for further judgment.
The invention has the beneficial effects that:
the invention provides a method for detecting the quality of a welding line of a high-chromium alloy steel pipeline, which comprises the following steps: s1: selecting a phased array detector; selecting a phased array probe and a wedge block according to the specification of the workpiece; s2: calibrating the phased array detector according to the specification of the workpiece; s3: preparing and scanning a weld detection area before scanning; s4: after the detection is finished, storing detection data in an instrument, importing the detection data into a computer, and analyzing images by using analysis equipment to obtain detection quantity, positioning and quantitative information of the defects; s5: and (5) defect assessment and acceptance. According to the method, the rapid and effective detection of the weld defects of the thick-wall pipelines of the P91/P36 high-chromium alloy steel is realized by adopting a mode that the phased array probe scans the single-sided bilateral direct waves for multiple times and scans the primary reflected waves simultaneously, so that the construction period is greatly shortened, the labor intensity is reduced, the personnel radiation risk is avoided, and the problem that the traditional ray detection is difficult is effectively solved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are needed in the description of the embodiments or the prior art will be briefly described, and it is obvious that the drawings in the description below are some embodiments of the present invention, and other drawings can be obtained according to the drawings without inventive effort for a person skilled in the art.
FIG. 1 is a process flow diagram of a method for detecting quality of a high-chromium alloy steel pipeline provided by an embodiment of the invention;
FIG. 2 is a three-view of a PRB-C reference block for a pipe specification of Φ323×28.58;
FIG. 3 is a three-view of a PRB-L reference block for a pipe specification of Φ323×28.58;
FIG. 4 is a three-view of a PRB-C reference block for a pipe specification of Φ406.4X36.53;
FIG. 5 is a three-view of a PRB-L reference block for a pipe specification of Φ406.4X136.53;
FIG. 6 is a three-view of a PRB-C reference block for a pipe specification of Φ406.4X140.49;
FIG. 7 is a three-view of a PRB-L reference block for a pipe specification of Φ406.4X140.49;
FIG. 8 is a three view of a PRB-C reference block for a pipe specification of Φ559×53.98;
FIG. 9 is a three view of a PRB-L reference block for a pipe specification of Φ559×53.98;
FIG. 10 is a schematic diagram of the structure of an ISO19675 phased array calibration block;
FIG. 11 is a schematic diagram showing a crack defect provided by an embodiment of the present invention;
FIG. 12 is a schematic diagram showing an unfused defect according to an embodiment of the present invention;
FIG. 13 is a schematic illustration showing an incomplete penetration defect provided by an embodiment of the present invention;
FIG. 14 is a schematic diagram showing a stripe defect according to an embodiment of the present invention;
FIG. 15 is a schematic diagram showing dense defect display according to an embodiment of the present invention;
FIG. 16 is a schematic diagram showing defects of pores and slag inclusions provided by the embodiment of the invention;
FIG. 17 is a schematic diagram of a sensitivity block according to an embodiment of the present invention;
FIG. 18 is a schematic diagram showing a defect evaluation step according to an embodiment of the present invention.
Icon:
1-a phased array oblique probe; 2-welding seams.
Detailed Description
The technical solutions of the present invention will be clearly and completely described in connection with the embodiments, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, the invention provides a method for detecting the quality of a weld joint of a high-chromium alloy steel pipeline, which comprises the following steps:
s1: selecting a phased array detector; selecting a phased array probe and a wedge block according to the specification of the workpiece;
s2: calibrating the phased array detector according to the workpiece specification, wherein step S2 comprises the following steps:
1. sound velocity calibration
According to the workpiece specification and the reference standard, the adjusting instrument enters a sound velocity calibration guide interface, and the sound velocity calibration is carried out by using semicircular arcs on the reference block and the ISO19675 test block; fig. 2 to 10 show the structures of the reference blocks corresponding to different pipeline specifications in the present application.
2. Delay calibration
And according to instrument performance and reference standards, adjusting the instrument to enter a wedge delay calibration guide interface, and performing wedge delay calibration by using semicircular arcs on a reference block and an ISO19675 block.
3. Angular gain compensation calibration
According to the performance of the instrument and a reference standard, the instrument is regulated to enter a sensitivity calibration guide interface, and a reference block is used for carrying out sensitivity calibration; the reference block is used for detecting and calibrating, the specification and the welding process of the reference block are the same as those of a field weld joint, the reference block is made of the same P91/P22 alloy material as that of a pipeline, and the welding is carried out by adopting the same process as that of the field weld joint.
4. TCG Curve setup
Nondestructive testing of nuclear island mechanical equipment of nuclear power plant according to NB/T20003.3-2010, section 3: the TCG curve is set according to acceptance level of ray detection and technical procedure of phased array ultrasonic detection of welding joint of DL/T1718-2017 thermal power plant, and a transverse through hole with phi 2mm is used as basic sensitivity.
5. Scanning sensitivity setting
Setting a sensitivity test block and a sensitivity verification test block; simulating a small-size volume type defect through the sensitivity test block to be used as a reference for the amplitude gain of the small-size volume type defect; testing the amplitude of the ball hole on the sensitivity verification test block, comparing the result with the actual measurement, and verifying sensitivity simulation through the sensitivity verification test block; through test and verification results, the evaluation line is set to be phi 2-30dB, the quantitative line is set to be phi 2-18dB, and the waste line is set to be phi 2-4dB.
Specifically, in order to set proper scanning sensitivity, the invention sets a special sensitivity test block, as shown in fig. 17, and tests are carried out by utilizing a plurality of ball holes with different sizes processed on the test block, so as to test and analyze the reflected signal amplitudes of the ball holes with different sizes, thereby taking the reflected signal amplitudes as the reference of sensitivity setting.
The sensitivity test block is in a partial annular column shape, the diameter of an outer ring of the sensitivity test block is 559mm, the thickness of the sensitivity test block is 54.98mm, and a simulation weld joint is arranged at the middle part of the sensitivity test block; the inclination angle between the two end faces of the sensitivity test block and the axis of the sensitivity test block is 60 degrees, 4 groups of ball hole groups which are arranged in parallel are arranged on each end face, and each group of ball hole groups comprises 5 ball holes which have the same diameter and are arranged in parallel; in this embodiment, the diameters of the ball holes in the 4 ball hole groups are 3mm, 2mm, 1mm and 0.7mm respectively, the depths of the ball holes are 15mm, and the volume type defects with different diameters are simulated through a plurality of ball holes.
The sensitivity test block is used for carrying out sensitivity simulation, and reflected signal amplitudes of ball holes with different sizes are tested and analyzed.
The test method of the sensitivity test block comprises the following steps:
the same detection method and focusing mode as in the actual detection are adopted, and the scanning line is fixed to be 60 degrees, at the moment, the scanning line and the ball hole processing direction are the same, and the projection in the scanning line direction is punctiform;
moving the probe to obtain the maximum wave height of each reflector on the 60-degree scanning line; the gain is adjusted to control the reflected wave height to 80%, and the gain value of the defect reflected wave is measured;
counting gain values when the reflection waves of reflector defects with different depths and different sizes are adjusted to 80%; the results obtained after a normal TCG calibration procedure for the 60 ° test were: phi 3 spherical holes with 60-degree reflection average gain of phi 2-0.9dB; phi 2 spherical hole reflection gain is phi 2-5.5dB in average gain; phi 1 spherical hole 60 DEG reflection average gain is phi 2-17.9dB; the average gain of the spherical hole reflection phi 0.7 is phi 2-23.1dB, and the maximum gain phi 2-25.9dB;
by analyzing the results, as the noise of the P91/P36 high-chromium alloy steel material is low, the gain required for detection is high for small-size (phi 1.0mm and phi 0.7 mm) spherical hole reflectors, but the detection can still be obviously distinguished from the background wave height; the signal-to-noise ratio near the defect wave is higher than 12dB.
The method for setting the evaluation line, the quantitative limit and the waste line judgment is as follows:
designing and manufacturing a sensitivity verification test block, wherein the diameter of the outer ring of the sensitivity verification test block is 559mm, the thickness of the outer ring of the sensitivity verification test block is 53.98mm (the maximum specification of a workpiece), and ball holes with different diameters (3 mm, 2mm, 1mm and 0.7 mm) are formed in the outer ring of the sensitivity verification test block;
the test sensitivity verifies the ball hole on the test block and the ball hole on the actual machined piece, the simulation result and the actual measurement result are compared, the ball Kong Fuzhi with the diameter of 0.7mm (53.98 mm deep) in the simulation is phi 2-30dB, the amplitude of the ball hole with the diameter of 0.7mm (50 mm deep) in the actual measurement is phi 2-26dB, and the amplitude of the ball hole and the ball hole are different by 4dB; taking the hole machining deviation and the position difference into consideration, and performing actual measurement and simulation to basically coincide;
when the light is incident vertically, the average gain of the spherical hole reflection phi of 0.7 (50 mm deep) is phi 2-23.1dB, the maximum gain phi is 2-26dB, and the defect signal-to-noise ratio can reach 12dB;
combining sensitivity simulation, verification test and standard analysis, setting the sensitivity as follows according to test results of ball holes with different sizes in a sensitivity test block: the evaluation line is phi 2-30dB (phi 0.7 spherical hole is used as a reference), the quantitative line is phi 2-18dB (phi 1 spherical hole is used as a reference), and the waste line is phi 2-4dB (phi 2 spherical hole is used as a reference).
6. Acoustic energy transmission loss calibration
The coupling loss and the material attenuation of the surface of the workpiece are the same as those of the test block, otherwise, the measurement of the acoustic energy transmission loss difference is performed, the scanning sensitivity is compensated according to the actual measurement result, and the compensation quantity is calculated into a distance/amplitude curve; no compensation is performed when the maximum transmission loss difference in the span-prone sound path is less than or equal to 2dB.
7. Encoder calibration
The encoder is calibrated before first use or every month in the following way: moving the encoder by at least 300mm, requiring an error of less than 1% or 10mm, subject to a smaller value; the encoder scan step is less than 2mm.
S3: preparing and scanning a weld detection area before scanning;
when the weld joint detection area is scanned, a coding scanning mode of scanning single-sided double-sided direct waves or single-sided direct waves for multiple times and scanning primary reflected waves simultaneously is adopted;
s4: after the detection is finished, storing detection data in an instrument, importing the detection data into a computer, and analyzing images by using analysis equipment to obtain detection quantity, positioning and quantitative information of the defects; in this embodiment, after detection is completed, the detection data is stored in the instrument, and after being exported by the SD card, image analysis can be performed by the suparup V2.01.00 software;
s5: defect assessment and acceptance;
disqualification conditions for planar defects include cracks, unfused, and incomplete penetration;
assessing disqualification conditions for non-planar defects includes:
the amplitude is greater than or equal to phi 2-4dB;
the amplitude is less than phi 2-4dB and greater than phi 2-18dB, indicating that the length is greater than or equal to t/3;
in the adjacent display with the minimum distance less than or equal to 6L, the indication length is less than t/3, the defect accumulation length is greater than t, wherein L is the maximum indication length, and t is the nominal thickness.
In step S1, the device used in the method is a portable phased array detector of SyncScan model, and performance evaluation is performed according to the performance and inspection of the phased array ultrasonic detection system of the GBT 29302-2012 nondestructive detection instrument, and the instrument meets the requirements of phased array detection.
In step S1, when the phased array probe and the wedge are selected, the frequency, the number of wafers, the wafer pitch, the wafer size, the shape, the wedge specification, and the like of the phased array probe are selected according to the thickness, the material, the inspection position, the inspection surface shape, and the type of the acoustic beam used for inspection. The selection and main parameters of the phased array probe and the wedge block in the method are shown in the following table 1:
table 1 selection of probes and wedges
In step S3, the pre-scan preparation includes:
the method comprises the steps of setting a detection area, wherein the weld detection area is characterized by the width of the weld detection area and the thickness of the weld detection area, and the width of the weld detection area is equal to the width of the weld and the width of heat affected areas at two sides of a weld fusion line. The relationship between the width of the welding line and the width of the heat affected zones at two sides of the welding line is as follows: when T is less than or equal to 30mm, the heat affected zone is more than or equal to 5mm; when T is more than or equal to 30mm, the heat affected zone is more than or equal to 10mm;
the surplus height of the weld seam is ground to be level, the surplus height is ground to be level with the adjacent parent metal, welding spatter, scrap iron, oil dirt and other impurities are removed from a probe moving area, and the surface roughness Ra of a detection surface is less than or equal to 6.3 mu m;
the temperature difference between the detection temperature and the reference block temperature in the calibration process is not more than 14 ℃.
In step S3, when the welded seam detection area is scanned, the first scanning mode of the welded joint is combined with a manual scanning mode, wherein the manual scanning mode comprises a line scanning mode, a fan scanning mode, a vertical line scanning mode, a grid scanning mode, a fan scanning mode and a vertical line scanning mode, and the manual scanning mode adopts a detection mode of axial and circumferential direction 40-70 degrees fan scanning and 0 degree vertical line scanning.
When in semiautomatic scanning, the suspicious part can be detected by adopting a fan scanning mode and a vertical line scanning mode and combining various scanning modes such as sawtooth scanning, front-back scanning, left-right scanning, rotation scanning, encircling scanning and the like. The inspection area should be scanned completely by the probe, and in order to scan the whole area to be inspected, the oblique wave inspection should scan the outer surface in the circumferential direction and the axial direction perpendicular to each other, and each movement of the probe should be partially overlapped with the last time, and the area should be at least 15% of the size of the transducer perpendicular to the scanning direction. If the workpiece is required to be scanned in a segmented mode in the length direction, the overlapping range of each segment of scanning area is at least 20mm. For annular workpieces (e.g., girth welds), the sweep stop position should be at least 20mm beyond the start position.
The speed of probe movement should not exceed 60mm/s during manual scanning.
In the application, the butt joint adopts sector scanning, the display mode can select sound path display imaging or geometric structure display imaging, and primary waves and secondary waves are respectively arranged for detection. According to the actual situation, the detection can be performed by being divided into different channels, and the detection can also be performed by using one channel. And a longitudinal wave straight probe is added to test the welding line and the heat affected zone, and a proper focusing mode is selected to detect the layering defect of the welding line.
In step S3, during scanning, in order to ensure the full coverage of the sound field, a scanning mode of combining mechanical scanning and electronic scanning of axial and circumferential sector scanning/0-degree line scanning and line scanning is adopted, and in order to ensure the coverage and no omission of the scanning area, single-sided bilateral direct wave and primary reflected wave can be adopted for simultaneous scanning; if the method is limited by conditions, when single-sided single-side direct wave scanning is adopted, the residual height of the welding joint is ground flat, one fan scanning and longitudinal vertical scanning are added at the central line of the welding joint, and the whole detection area is scanned by zigzag scanning in at least one direction; if the defect is found during zigzag scanning, fan scanning and longitudinal vertical scanning are adopted at the defect position to acquire and record data.
In this embodiment, the weld parameters corresponding to each workpiece specification are shown in table 2 below:
TABLE 2 work piece and weld parameter set table
For the above pipe specifications, the recommended scan parameters for the weld are shown in table 3 below:
table 3 sound field coverage setting table
In step S3, in order to ensure that the distance between the front edge of the probe and the center of the weld is consistent during the detection process, a magnetic stripe is adsorbed on the test piece or a straight line is drawn as a reference line for fixing the distance between the front edge of the probe and the center of the weld. Optionally, the suspicious part is detected by adopting a fan scanning mode and a vertical line scanning mode and combining a first scanning mode or a plurality of scanning modes of saw teeth, front and back, left and right, rotation and surrounding.
In step S5, the defect needs to be qualified; specifically, defects are classified into area type defects, which are mainly classified into cracks, unfused, and incomplete penetration, and non-area type defects (bulk type defects), which are mainly classified into pinholes, slag inclusions, stripe type defects, and dense defects.
In the method provided by the application, when the defect display amplitude is greater than or equal to phi 2-30dB, the defect is required to be qualified; when the defect display amplitude is greater than or equal to phi 2-18dB and less than phi 2-4dB, the defect is measured for the indicated length. According to the method, the defects are qualitatively determined by adding manual zigzag scanning and observing the positions of the defects, displaying images and the dynamic echo signal characteristics of the defects; the echo signal characteristics of the defect are as follows:
1) Characteristics of crack echo signals
Referring to fig. 11, the crack echo signal is typically relatively directional, and may be found on both sides of the weld when detected, with the other side having a lower defect-free echo signal or echo signal. Crack echo roots often have an extra small peak. Sometimes, the rough texture surface of the crack will have scattered echo signals. Moving a scanning cursor along the length direction of the defect, wherein the wave crest of the crack echo signal often fluctuates in a sawtooth shape;
2) Characteristics of unfused echo signals
Referring to fig. 12, the appearance that the groove is not fused in the S-type display has better coincidence with the weld groove, and the visible defect echo signals in the D-type display are characterized by a straight line on one side, and the amplitude difference of the peer echo signals on two sides of the weld is larger. Moving along the length direction of the defect, enabling the amplitude of the defect echo signal to be smooth, enabling the defect echo signal to ascend linearly and then to be stable, and then descending, wherein no redundant small peak exists at the root of the waveform;
3) Characteristics of unwelded echo signals
Referring to fig. 13, the single-sided welding penetration is located at the root of the weld in the S-type display, and when detecting both sides of the weld, the amplitude of the echo signal of the defect can be found at both sides is high, and the echo signal of the secondary wave appears, and both side images have the opening defect characteristic. The position of the defect echo signal is seen in the D-type display to be lower than the echo signal of the weld seam residue height. Moving along the length direction of the defect, wherein the echo signal amplitude of the defect is smooth, the echo signal is stable after the straight line rises, then the echo signal descends, and the root of the waveform has no redundant small peak;
4) Strip defect determination
Referring to fig. 14, the display screen shows a single sharp echo waveform whose amplitude smoothly rises from zero to a maximum value as the probe moves back and forth and side to side, and fluctuates slightly at a high level by a small distance, and then smoothly falls back to zero. When the amplitude of the scanning defect with different angles has obvious change, the defect can be considered to be a strip defect;
5) Dense defect determination
Referring to fig. 15, the phased array oblique probe 1 is used to scan the weld 2 and perform image analysis on the detected data, and when the image is displayed as a dense and large number of defects on a fan-scan image or any other two-dimensional image display (B/C/D type display), the image should be defined as a dense defect; the evaluation area of the bulk dense defect is a 10X 20mm area in the top view, and if similar defect reflection is found, the detection area is subjected to a recheck by using a ray detection technology;
6) Characteristics of air holes and slag inclusion type defect echo signals
Referring to fig. 16, the air holes and slag inclusions are generated at any position of the weld joint, the ultrasonic signals of the air holes and slag inclusions are difficult to distinguish, and the defect safety evaluation does not distinguish the types of the two defects. The echo signals of a single wave crest and a single wave form without redundant wave crests are generally taken as air holes, the air holes move along the length direction of the defects, the echo signals of the air holes are generally gradually displayed and disappeared in background signals, the heights of the defects of the air holes and slag inclusion type are generally not higher than the heights of a single pass weld bead, the two sides of the weld bead can be provided with defective echoes generally, and the amplitude of the defect echo signals is not high generally.
In step S5, after the defect is qualified, the defect may be measured; the determination of the defects comprises depth quantification, amplitude quantification, indication length quantification and height quantification of the defects; the depth is quantified by taking the position of the maximum reflection amplitude of the defect as the defect depth, and the maximum amplitude obtained by saw-tooth scanning is taken as the defect amplitude. The determination of defects includes:
1. determination of defect amplitude
The probe should be moved to find the maximum echo amplitude, and record and judge are carried out;
2. determination of defect size
When the defect reflected wave has only one high point, measuring the indication length by adopting a-6 dB method;
when the defect reflection peak value fluctuates, a plurality of high points exist, and the indication length is measured by an endpoint-6 dB method;
the actual length I of the defect should be calculated as follows:
I＝Lx(R-H)/R
wherein:
l-measured defect indication length, mm;
r is the outer diameter of the tube, mm;
h-depth of defect from outer surface, mm.
Through the steps, the amplitude and the indication length of the defect can be measured; fig. 18 is a step of evaluating defects, and referring to fig. 18, step S5 includes:
1) Judging whether the amplitude of the defect is greater than or equal toIf yes, the defect is qualified;
2) Judging the planar defects such as cracks, unfused and incomplete penetration;
for non-planar defects, a further evaluation is required;
3) For non-planar defects, determining whether the amplitude of the defect is greater than or equal toIf yes, judging the defect to be useless;
4) For non-planar defects, the amplitude of the defect is less thanAnd greater than or equal to->Judging whether the indication length of the defect is greater than or equal to t/3, wherein t is the nominal thickness; if yes, judging the defect to be useless;
5) For non-planar defects, the amplitude of the defect is less thanAnd greater than or equal to->The indication length is less than t/3, judging whether the accumulated length of the defects is greater than t (except for adjacent display with the minimum distance exceeding 6L) within the length of 12 t; if yes, the defect is judged to be useless.
In summary, in step S5, after the defect is measured, the defect is assessed according to the measurement result; the following drawbacks are not acceptable:
1. planar defects such as cracks, unfused and incomplete penetration;
2. for non-planar defects:
the amplitude is greater than or equal to phi 2-4dB;
the amplitude is less than phi 2-4dB and greater than phi 2-18dB, indicating that the length is greater than or equal to t/3;
in the adjacent display with the minimum distance less than or equal to 6L, the indication length is less than t/3 and the defect accumulation length is greater than t in the length of 12t, wherein L is the maximum indication length and t is the nominal thickness;
3. for amplitude exceedingAnd is less than->When the distance between any two defects is smaller than 20mm, increasing RT test to judge; when the defect interval is measured, measuring is carried out at the position of the highest value of the defects;
4. for abnormal reflection with questionable defect quality, one or more of the traditional UT, manual phased array ultrasonic detection technology, TOFD detection technology and ray detection technology are selected for further judgment.
The volumetric defect acceptance criteria (set by the step scan sensitivity setting) are shown in table 4 below:
TABLE 4 volume defect acceptance criteria
| Evaluation line | Quantitative line | Waste judging line |
| Φ2-30dB | Φ2-18dB | Φ2-4dB |
The detection method provided by the application has the following advantages:
1. the method has the advantages that a phased array probe scanning mode is adopted, different layering principles are adopted through multidirectional scanning, and the detection position is determined by utilizing an encoder, so that the rapid and effective detection of the weld defects of the thick-wall pipelines of the P91/P36 high-chromium alloy steel is realized, the construction period is greatly shortened, the labor intensity is reduced, the personnel radiation risk is avoided, and the problem of difficult traditional ray detection is effectively solved;
2. in the scanning mode, a coding scanning mode of single-sided double-side direct wave multiple scanning and primary reflection wave simultaneous scanning is adopted, so that coverage and non-omission of scanning areas are ensured;
3. in the aspect of defect detection, the detection capability equivalent to rays is realized in the aspect of volume defect by comparing with the traditional ray detection acceptance technical conditions and taking the ray acceptance conditions as the reference;
4. according to the method for ultrasonically detecting the weld quality of the P91/P36 high-chromium alloy steel thick-wall pipeline by using the phased array, in the aspect of sensitivity setting, a special sensitivity test block and a special sensitivity verification test block are arranged by comparing with the acceptance technical conditions of traditional rays, and reflected signal amplitudes of ball holes with different sizes are analyzed by testing and used as references for sensitivity setting;
5. the reference block is welded by adopting the same P91/P36 alloy material as the pipeline and adopting the same process as the field welding seam; the structure of the reference block is provided with an internal boring size, which is different from the traditional plane reference block, and meanwhile, the curvature of the reference block is the same as that of the field weld joint, so that the detection result is more accurate and reliable;
6. in the aspect of defect positioning and quantification, the positioning and quantification precision is improved by manually rechecking and increasing TOFD detection;
7. in the aspect of defect qualitative, the defect position, the display image and the dynamic echo signal characteristics of the defect are observed to be qualitative by adding manual zigzag scanning, so that the qualitative accuracy is improved.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.
Claims (10)
1. The method for detecting the quality of the welding line of the high-chromium alloy steel pipeline is characterized by comprising the following steps of:
s1: selecting a phased array detector; selecting a phased array probe and a wedge block according to the specification of the workpiece;
s2: calibrating the phased array detector according to the specification of the workpiece;
s3: preparing and scanning a weld detection area before scanning;
when the weld joint detection area is scanned, a coding scanning mode of scanning single-sided double-sided direct waves or single-sided direct waves for multiple times and scanning primary reflected waves simultaneously is adopted;
s4: after the detection is finished, storing detection data in an instrument, importing the detection data into a computer, and analyzing images by using analysis equipment to obtain detection quantity, positioning and quantitative information of the defects;
s5: defect assessment and acceptance;
disqualification conditions for planar defects include cracks, unfused, and incomplete penetration;
assessing disqualification conditions for non-planar defects includes:
the amplitude is greater than or equal to phi 2-4dB;
the amplitude is less than phi 2-4dB and greater than phi 2-18dB, indicating that the length is greater than or equal to t/3;
in the adjacent display with the minimum distance less than or equal to 6L, the indication length is less than t/3 and the defect accumulation length is greater than t within the length of 12t, wherein L is the maximum indication length and t is the nominal thickness.
2. The method for detecting the quality of a weld joint of a high-chromium alloy steel pipeline according to claim 1, wherein the step S2 comprises sound velocity calibration, delay calibration, angle gain compensation calibration, scanning sensitivity setting, TCG curve setting, scanning sensitivity setting, acoustic energy transmission loss calibration and encoder calibration;
the step of scanning sensitivity setting comprises the following steps: setting a sensitivity test block and a sensitivity verification test block; simulating a small-size volume type defect through the sensitivity test block to be used as a reference for the amplitude gain of the small-size volume type defect; testing the amplitude of the ball hole on the sensitivity verification test block, comparing the result with the actual measurement, and verifying sensitivity simulation through the sensitivity verification test block; through test and verification results, the evaluation line is set to be phi 2-30dB, the quantitative line is set to be phi 2-18dB, and the waste line is set to be phi 2-4dB.
3. The method for detecting the quality of the welded seam of the high-chromium alloy steel pipeline according to claim 2, wherein in the step S2, sound velocity calibration, wedge delay calibration and sensitivity calibration are performed by using semicircular arcs on a reference block and an ISO19675 test block, and a phi 2mm transverse through hole is used as a basic sensitivity;
the coupling loss and the material attenuation of the surface of the workpiece are the same as those of the test block, otherwise, the measurement of the acoustic energy transmission loss difference is performed, the scanning sensitivity is compensated according to the actual measurement result, and the compensation quantity is calculated into a distance/amplitude curve; no compensation is performed when the maximum transmission loss difference in the span-prone sound path is less than or equal to 2dB;
the encoder is calibrated before first use or every month in the following way: moving the encoder by at least 300mm, requiring an error of less than 1% or 10mm; the encoder scan step is less than 2mm.
4. The method for detecting the quality of the welded seam of the high-chromium alloy steel pipeline according to claim 1, wherein in the step S3, a scanning mode of combining mechanical scanning and electronic scanning of axial and circumferential sector scanning/0-degree line scanning and line scanning is adopted when a welded seam detection area is scanned; and adsorbing a magnetic stripe or drawing a straight line on the test piece to serve as a reference line for fixing the distance between the front edge of the probe and the center of the welding line.
5. The method for detecting the quality of the welded seam of the high-chromium alloy steel pipeline according to claim 4, wherein in the step S3, when single-sided single-side direct wave scanning is adopted, the residual height of the welded joint is ground flat, one fan scanning and longitudinal vertical scanning are added at the central line of the welded seam, and the whole detection area is scanned by adopting zigzag scanning in at least one direction;
if the defect is found during zigzag scanning, fan scanning and longitudinal vertical scanning are adopted at the defect position to acquire and record data.
6. The method for detecting the quality of a weld joint of a high-chromium alloy steel pipe according to claim 1, wherein in step S3, the preparation before the scanning includes: grinding the surplus height of the weld seam to be level, grinding the surplus height to be level with the adjacent parent metal, and detecting the surface roughness Ra of the surface to be less than or equal to 6.3 mu m; the temperature difference between the detection temperature and the reference block temperature in the calibration process is not more than 14 ℃.
7. The method for detecting the quality of a weld joint of a high-chromium alloy steel pipe according to claim 1, wherein in step S3, the weld joint detection area is characterized by a weld joint detection area width and a weld joint detection area thickness; the width of the welding line detection area is the width of the welding line itself plus the heat affected areas at the two sides of the welding line;
the relationship between the width of the welding line and the width of the heat affected zones at two sides of the welding line is as follows:
when T is less than or equal to 30mm, the heat affected zone is more than or equal to 5mm;
when T is more than or equal to 30mm, the heat affected zone is more than or equal to 10mm.
8. The method for detecting the quality of the welded seam of the high-chromium alloy steel pipeline according to claim 1, wherein in the step S3, when a welded seam detection area is scanned, a suspicious part is detected by adopting a sector scanning mode and a vertical line scanning mode and combining one or more scanning modes of saw teeth, front and back, left and right, rotation and surrounding;
each movement of the probe and the last time have partial overlap, and the range of the probe is at least 15% of the size of the transducer perpendicular to the scanning direction;
when the workpiece is scanned in a segmented mode in the length direction, the overlapping range of each segment of scanning area is larger than or equal to 20mm; for annular workpieces, the range of the scan stop position beyond the start position is greater than or equal to 20mm.
9. The method for detecting the quality of a weld joint of a high-chromium alloy steel pipe according to claim 1, wherein in step S5, the assessment of the defect includes quantifying the depth, the amplitude, the indicated length, and the height of the defect; the depth is quantified by taking the position of the maximum reflection amplitude of the defect as the defect depth, and the maximum amplitude obtained by saw-tooth scanning is taken as the defect amplitude.
10. The method for detecting the quality of the welding seam of the high-chromium alloy steel pipeline according to claim 1, wherein in the step S5, the RT test is added for judgment when the amplitude is more than phi 2-30dB and less than phi 2-4dB and the distance between any two defects is less than 20mm; when the defect interval is measured, measuring is carried out at the position of the highest value of the defects;
for abnormal reflection with questionable defect quality, one or more of traditional UT, manual phased array ultrasonic detection technology, TOFD detection technology and ray detection technology are selected.
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