Background
The oil gas pipeline is used as an important carrier for national energy transmission, and in order to ensure the normal operation of the pipeline, the safety maintenance and the periodic investigation of the pipeline are very important. Electromagnetic nondestructive testing technology belongs to an important branch of nondestructive testing, and utilizes the change of electrical or magnetic properties of a tested material under the action of an electromagnetic field, and utilizes a detection unit to capture electromagnetic information, so as to detect and effectively evaluate structural damage such as defects, fatigue, residual stress and the like of the tested material.
At present, electromagnetic technology adopted in pipeline detection mainly comprises detection methods such as magnetic flux leakage detection, eddy current detection, alternating current magnetic field detection, magnetic powder detection and the like. Because the long-time oil gas transportation of the pipeline is carried out, the defect types of the pipeline structure are different, the pipeline structure is mainly damaged by structures such as corrosion, pits, cracks and scratches, the single pipeline internal detection method has limited evaluation capability on the safety of the pipeline structure, and the pipeline can be evaluated in all directions to a certain extent by adopting the combination of multiple detection methods. The leakage magnetic detection principle is shown in fig. 1, two permanent magnets are used as a two-pole magnetizing device, the two permanent magnets are connected through a high-permeability material, the two permanent magnets transmit magnetic force lines to a ferromagnetic pipeline through pole shoes, an induced magnetic field can be generated in the pipeline after the ferromagnetic pipeline is magnetized, if the pipeline has volumetric defects such as corrosion, mechanical damage and the like, the magnetic force lines can leak to the outside of a plate, so that a leakage magnetic field is formed on the surface of the plate, and the defects parallel to the magnetization direction can not leak the magnetic field, so that the method can not detect the defects parallel to the magnetization direction, and is only suitable for the structural health evaluation of the ferromagnetic material. The eddy current detection technology is difficult to detect the subsurface defects of the pipeline, the full-scale evaluation of the health condition of the pipeline cannot be realized, and meanwhile, the power consumption is high. The alternating electromagnetic field detection principle is shown in fig. 2, and can only be applied to detection of surface defects, subsurface defects cannot be detected due to the influence of skin effect, when an exciting coil for supplying alternating current is close to a conductor, the alternating current generates an alternating magnetic field in a surrounding space, and induced current on the surface of a detected pipeline (conductor) is gathered on the surface of the conductor due to the skin effect. When the pipeline is defect-free, induction electric lines are parallel to each other, and the magnetic field on the surface of the pipeline is uniformly distributed; if a defect occurs in the pipeline, the electromagnetic field distribution is affected due to the change of resistivity, the magnetic induction line deflects near the defect, and the magnetic field on the surface of the pipeline is distorted. The magnetic powder detection can detect surface and subsurface defects, but has low detection efficiency and is not easy to apply to detection in a pipeline.
Meanwhile, the technology for detecting the small-diameter pipeline applied at home and abroad is always limited by factors such as pipeline size, energy consumption and the like, and the conventional magnetic leakage technology is difficult to control due to the fact that the excitation structure is large in size and the magnetizing capacity is limited in small-diameter pipeline passability.
Disclosure of Invention
The invention aims to solve the technical problem of providing a defect detection probe, a device and a system which are applicable to a small-diameter pipeline by combining two detection technologies of magnetic leakage and alternating electromagnetic fields.
The invention adopts the technical scheme that the oil and gas pipeline defect detection probe based on the electromagnetic sensing technology comprises a magnetic ring made of soft magnetic materials, a winding coil, a magnetic sensor circuit board and a steel brush;
The two ends of the magnetic ring are fixed with steel brushes to form a complete pole shoe structure, and the geometric parameters of the diameters of the steel brushes are matched with the inner diameter of the pipeline and are clung to the pipe wall;
The area between the two ends of the magnetic ring is uniformly provided with cross beams which are axially protruded, and the coils supported by the cross beams are uniformly wound on the area between the two ends of the magnetic ring to form winding coils; the outer diameter of the winding coil is smaller than that of the steel brush, and the winding coil is excited by low-frequency alternating current;
The magnetic sensor circuit board is fixed in the vertical direction of the circumferential center of the magnetic ring at the central position of the groove area between the cross beams of the magnetic ring and is positioned in the winding coil;
the magnetic sensor circuit board is integrated with a magnetic field induction module and an amplifying and filtering circuit.
When the probe detects a pipeline, an alternating magnetic field generated after the winding coil is excited by low-frequency alternating current acts on the inner wall of the pipeline, so that the inner wall of the pipeline induces a circumferential vortex field, and an alternating electromagnetic field is formed on the surface of the pipeline; at this time, because the pipeline belongs to ferromagnetic material, the low-frequency magnetization field generated by the exciting coil is transmitted to the pole shoe and the pipeline to form a magnetic loop through the magnetic conduction material, the axial magnetization is generated in the local area of the pipeline to form a leakage magnetic field, and the magnetic field induction module positioned in the winding coil can simultaneously receive the information of the alternating electromagnetic field and the leakage magnetic field, thereby creatively realizing the mode of generating two detection technologies by the same excitation.
In addition, the invention also provides a detection device using the probe, which comprises a support plate, a detector cabin body and the probe, wherein the support plate is arranged in front of the detector cabin body, and the probe is arranged at the tail part of the detector cabin body.
The invention also provides a system using the detection device, which comprises an upper computer and the detection device;
the upper computer is connected with the detection device through the network port and used for controlling the operation and stop of the detection device, setting and adjusting parameters in the detection device, downloading data information stored in a signal storage module of the device, processing and analyzing the data, and further judging defect information and positions in the test piece.
Compared with the traditional magnetic leakage internal detector consisting of a permanent magnet or coil direct current excitation structure, the magnetic leakage and alternating electromagnetic fusion sensing detection technology provided by the invention adopts a low-frequency alternating current excitation structure to fuse two detection technologies at the same time, and improves the detection capability of the probe to defects on the basis of not additionally increasing the excitation structure. The traditional permanent magnetic flux leakage technology is sensitive to detection in a single detection direction and easy to leak detection. The present invention reduces power consumption compared to probes using two detection techniques alone, which require the allocation of 2 stimuli. Compared with the detection probes which are arranged outside the coils in most of the prior schemes, the integral magnetic ring probe structure improves the distance between the magnetic field induction module and the pipe wall, thereby improving the passing capacity of the small-diameter pipe at the bent pipe and having a larger application range.
The beneficial effects of the invention are as follows:
(1) Based on the prior art, the traditional magnetic leakage and alternating electromagnetic field excitation structure is improved, and the two technologies are fused, namely, the electromagnetic technology structure coupling method is adopted, and the respective advantages of the magnetic leakage and alternating electromagnetic field technology are combined, so that the limitation of a single technology is broken through. The defect detection method has the advantages that the sensitivity of magnetic leakage to the defect direction and the disadvantage of difficult detection of alternating electromagnetic field to subsurface defects are easy to generate the detection omission in the pipeline detection process, meanwhile, the special identification capability of the two technologies to the defects is utilized to distinguish the detected surface defects from subsurface defects, and the capability of pipeline health assessment is further improved.
(2) The two detection technologies are fused, only one exciting coil is used for realizing effective evaluation of pipeline structure detection, power consumption is reduced, and the detection range basically covers the whole circumferential area of the pipeline. Because the coil is used for excitation, the magnetizing energy is controllable, the magnetizing capacity is adjustable, the pipeline diameter detection expansion capacity is good, the detection of the 4-inch small pipe diameter is realized, the detection method is applicable to the detection of the pipeline with smaller pipe diameter, and the problem that the pipeline trafficability is influenced by the overlarge volume of a system is solved.
Detailed Description
Example 1
The oil gas pipeline defect detection probe based on the electromagnetic sensing technology is of an excitation-receiving structure, and comprises a silicon steel magnetic ring 1, a winding coil, two steel brushes, 18 magnetic sensor circuit boards 4 and a magnetic sensor circuit board fixing piece 5 as shown in fig. 6;
Silicon steel is a preferred material for the magnetic ring, and other materials with high magnetic permeability and toughness can be applied to the invention, and the structure of the magnetic ring is shown in fig. 3.
The two ends 1 of the magnetic ring are fixed with steel brushes to form pole shoes 6, and the circular outer edges of the steel brushes are matched with the inner diameter of the oil gas pipeline; the structure of the steel brush in the embodiment is shown in fig. 4, and consists of 2 rows of steel brush bristles, and a person skilled in the art can replace and adjust the structure according to the requirement, namely, the steel brush can contact the inner wall of a pipeline and can smoothly run in the pipeline according to the actual inner diameter size of the pipeline.
The area between the two ends 1 of the magnetic ring is uniformly provided with a cross beam 2 which is axially protruded, and the coil supported by the cross beam is uniformly wound on the area between the two ends of the magnetic ring to form a winding coil, namely the coil is wound on the middle part of the magnetic ring; the outer diameter of the wound coil is smaller than the outer diameter of the steel brush as shown in fig. 7;
6 identical groove areas 3 are arranged between the cross beams 2 of the magnetic ring; the number of the beams can be adjusted by a person skilled in the art according to the number of the magnetic sensor circuit boards 4 required to be arranged, so long as the beams are uniformly distributed on the magnetic rings;
The magnetic sensor circuit board 4 is fixed in the vertical direction of the circumferential center of the magnetic ring at the central position of the groove area 3 between the cross beams of the magnetic ring and is positioned in the winding coil; specifically, in the embodiment, the magnetic sensor circuit board is fixed on the magnetic ring through a detachable fixing piece 5, as shown in fig. 5, in order to facilitate assembly, the fixing piece 5 is divided into two pieces, and on one hand, the fixing piece provides a fixing clamping position for the magnetic sensor circuit board 4, and on the other hand, the fixing piece is matched with the magnetic ring in structure.
In each groove region 3,3 magnetic sensor circuit boards 4 are provided, and 18 magnetic sensor circuit boards are provided in total. Only 1 magnetic sensor circuit board 4 may be provided per groove area, and placed in the middle of the groove area. The magnetic sensor circuit board is fixed at the unified position of each groove area through the fixing piece, so that the consistency of signals of each sensor is ensured. The magnetic sensor circuit boards in the 6 groove areas are matched with the pole shoes and the external coils to form 6 electromagnetic structure coupling units, the detection range can cover the detection area of 81.2% of the whole circumference of the pipeline, and the high-permeability silicon steel material is adopted to ensure the high-magnetic-flux transmission function, and meanwhile, the magnetic sensor circuit boards have good mechanical toughness and good shock resistance, and are not easy to damage through the pipeline.
The winding length of the coil on the magnetic ring is 30mm, different coil lengths have different advantages for electromagnetic excitation, and the optimal length can be selected according to the size of the magnetic ring. The magnetic ring coincides with the geometric center axis of the wound coil.
The magnetic sensor circuit board is integrated with an axial magnetic field induction module and an amplification filter circuit in two directions.
The sensor circuit board is used for receiving electromagnetic information caused by defects, and the fixing piece ensures the structural stability of information acquisition and the information reliability.
The special steel brush structure designed for the pipeline can improve the magnetic flux transmission capability, so that the magnetic ring detection capability of the structure is not affected, the distance between the magnetic ring structure and the inner wall surface of the pipeline is improved, and the trafficability of the magnetic ring probe in the pipeline is facilitated.
For a pipeline made of ferromagnetic materials, the probe combines the unique advantages of two technologies of magnetic leakage and alternating electromagnetic field detection, breaks through the limitations of defect type limitation, low detection efficiency, complex detection structure and the like of a single detection method, and improves the detection capability of a detector in the pipeline; for a pipeline made of non-ferromagnetic materials, the probe can still detect by an alternating electromagnetic field detection mode.
The probe adopts the same excitation based on magnetization and electromagnetic induction mechanisms to reasonably design an excitation structure, simultaneously generates excitation modes of two detection technologies, utilizes a magnetic sensor to collect disturbance signals, and can greatly improve the detection capability and efficiency of the system by separating and processing defect information to obtain the defect information of a pipeline.
Example 2
The structure of the oil gas pipeline defect detection device based on the electromagnetic sensing technology, namely the inner detector, is shown in fig. 8, and the oil gas pipeline defect detection device comprises a supporting plate, a detector cabin body and a probe of the embodiment 1, wherein the supporting plate is arranged in front of the detector cabin body, and the probe is arranged at the tail part of the detector cabin body.
The detector cabin comprises a shell, a battery cabin, an electronic hardware part and an ADC module unit;
The electronic hardware part comprises a signal excitation module, a signal acquisition module, a signal conditioning module and a signal storage module; the output end of the signal excitation module is connected with the winding coil of the probe, the input end of the signal acquisition module is connected with the input end of the ADC module unit, the output end of the signal acquisition module is connected with the input end of the signal conditioning module, the output end of the signal conditioning module is connected with the signal storage module end, and the signal storage module end is connected with the network port at the same time.
The shell is used for guaranteeing the mechanical structure safety of the electronic hardware part, the battery bin, the ADC module unit and the probe, and reducing the external interference influence in the pipeline internal detection process.
Specifically, the power module in the battery compartment adopts a 29.6V battery to supply power to the whole hardware, so that the safe operation of the detection device is ensured.
Specifically, the excitation module comprises a signal generator and a power amplifier, and a low-frequency signal of the signal generator is output to a winding coil of the probe after passing through the power amplifier.
Specifically, the signal acquisition module, the signal conditioning module and the signal storage module can be realized by being integrated on the FPAG. The ADC module unit is used for converting an analog electromagnetic signal of the magnetic sensor circuit board into a digital signal and transmitting the digital signal to the FPAG for data processing and storage. Or uses the arm unit as a signal storage module for separate data storage.
The ADC module units included ADC units corresponding to the number of magnetic sensor circuit boards, and 18 ADC units were also provided for the case of 18 magnetic sensor circuit boards in example 1. In order to achieve placement of 18 blocks in a limited space, in the 2 cavities of fig. 8, each cavity is stacked to place 9 ADC units one above the other in a bottom-up manner.
The signal excitation acts on the winding coil to generate an alternating magnetic field, and the magnetic field induction module receives disturbance signals generated by the external excitation on the test piece; the ADC module unit is used for carrying out analog-to-digital conversion on the signals, so that the FPGA is convenient to identify, and the FPAG is used for processing and storing the signals.
Example 3
An oil gas pipeline defect detection system based on an electromagnetic sensing technology comprises an upper computer and a detection device of the embodiment 2;
The upper computer is connected with the detection device through the network port and is used for controlling the running and stopping of the device, setting and adjusting parameters in the device, downloading data information stored in a signal storage module of the device, processing and analyzing the data, and further judging defect information and positions in a test piece. The upper computer analyzes and processes the corresponding amplitude and phase change of the obtained magnetic signal, and accurately detects and evaluates the corresponding defect position and size. Further, the temperature sensor is also used for monitoring the temperature change of the electronic hardware part of the device.
Specifically, the in-device parameters include excitation frequency, excitation voltage, ADC sampling frequency.
When the electromagnetic nondestructive detection system detects a pipeline, the detection device is horizontally placed at the position of an inlet of the pipeline, a traction rope controlled by a traction machine is fixed on a traction ring of the detection device, then the working state of the detection device is controlled by an upper computer, a net opening is pulled out, a traction machine switch is opened, the detection device moves at a uniform speed in the pipeline, at the moment, low-frequency alternating current generated by an excitation module of the detection device acts on a winding coil of a probe, an alternating magnetic field generated by the coil acts on the inner wall of the pipeline, a uniform circumferential vortex field is induced, and the principle is consistent with the alternating electromagnetic field detection technology; meanwhile, because the exciting coil acts on the silicon steel magnetic ring, magnetic flux passes through the steel brush to form a closed magnetic loop with the pipeline, the pipeline is locally magnetized, and the defect and position information of the pipeline surface and subsurface are judged by capturing the abnormal magnetic field information leaked in the air, and the principle is consistent with the magnetic leakage detection principle.
Detection test
When the system scans the defects of the test piece, the mechanical arm controls the probe structure to move at a certain speed according to the scanning direction. Firstly, a signal generator in an excitation module outputs a low-frequency signal, and is connected with a power amplifier to drive a winding coil of a probe, and meanwhile, data acquisition work is carried out through an upper computer; the probe structure is controlled to move a certain distance (lifting) above the test piece through the mechanical arm handle, alternating excitation current generated by excitation equipment respectively generates a uniform vortex field and a magnetization field in a local area of the test piece through the coil and the magnetic yoke, when a defect passes through, if the defect direction is vertical to the vortex field, vortex can pass around two ends of the defect, and at the moment, the vortex disturbance is maximum; if the defect direction is perpendicular to the magnetization direction, part of the magnetic field leaks into the air at the defect position because the test piece is magnetized locally by an external magnetic field generated by the magnetic yoke; therefore, when the probe passes the defect, corresponding eddy current disturbance or magnetic leakage signals are generated, the electromagnetic information of response is received by the magnetic sensor, and the defect position and the size information of the tested test piece are judged, so that the purpose of nondestructive testing is achieved once.
The ferromagnetic material test piece with the artificial defects at different angles, subsurface and surface artificial defects is made of 45# steel, the detection result of scanning by using an electromagnetic coupling probe structure is shown in fig. 10, and crack angle inclination information and subsurface defect buried depth information are marked in the diagram. It can be seen that the 45-degree inclined defect signal has the smallest amplitude, and is positioned in the insensitive direction of the magnetic leakage and alternating electromagnetic field detection technology, and the magnetic leakage information and the eddy current disturbance are not obvious; 30 degrees and 60 degrees of inclination defects, namely the leakage magnetic field and the vortex field simultaneously play roles at the moment, and the defect signal amplitude is large and easy to detect; aiming at subsurface defect detection, mainly using a magnetic leakage technology, the signal characteristics can be found that as the defect burial depth is reduced, the signal amplitude is increased, and according to the semi-magnetization detection principle, the magnetization capacity is reduced along with the deep penetration into the test piece, and the leakage magnetic leakage information in the air is reduced, so that the deeper the defect burial is, the less easy to detect, the signal characteristics conform to the magnetic leakage detection principle, and the probe and the device using the probe have better detection effect on a ferromagnetic material test piece.
FIG. 9 is a diagram of the magnetic ring pair 4 inch x80 pipeline external defect real object and corresponding detection result from an ADC unit, wherein the external defect has the dimension parameters of 34mm long, 13mm wide and 4mm deep pipeline external wall defects, the channel information corresponding to the defect pair pipeline clock position is selected, and the external defect can be detected through repeated experiment verification, so that the functional requirement of the invention is verified.
While the foregoing describes the embodiments of the present invention so as to facilitate the understanding of the present invention by those skilled in the art, it should be apparent that the present invention is not limited to the scope of the embodiments, but is to be construed as being protected by the accompanying claims insofar as various changes are within the spirit and scope of the present invention as defined and defined by the appended claims.