RU164509U1 - DEVICE FOR AUTOMATED ULTRASONIC CONTROL OF RING WELDED PIPE CONNECTIONS - Google Patents

Abstract

1. Device for automated ultrasonic testing of annular pipe welded joints, including a supporting frame, on which are fixed: an electronic unit with contact liquid supply units mounted on it and connected by electric cables to the battery compartment, a seam position monitoring sensor, acoustic units, a movement drive control unit and a wireless data transmission module; an arm with a rotary lever, on which a seam position monitoring sensor and a movement drive are installed; suspensions of acoustic blocks on which acoustic blocks are fixed; driven wheels with track sensor; wherein the contact fluid supply units are located symmetrically with respect to the longitudinal axial line of the carrier frame and are configured to supply contact fluid directly to the contact area of the working surfaces of the acoustic units with the ultrasound object; wherein the sensor for controlling the position of the inductive-type seam is moved forward in front of the movement drive, and its position is determined by the geometry of the axis and bracket screws with a rotary lever; while the suspension of the acoustic unit provides the swing of the acoustic blocks with three degrees of freedom and the adjustment of the distance between the acoustic blocks; wherein the acoustic units consist of two acoustic transducers located symmetrically relative to the longitudinal axial line of the carrier frame; wherein the electronic unit 6 is configured to use sounding schemes for the entire section of the weld and the heat-affected zone based on pulse echo and diffraction

Description

The inventive utility model relates to the field of ultrasonic testing and is intended for automated non-destructive ultrasonic testing of ring welded joints of pipelines with a diameter of 530 to 1220 mm and a wall thickness of 8 to 40 mm, performed by all types of automatic, semi-automatic, manual fusion welding and flash butt welding with construction, repair and reconstruction of oil pipelines.

Of the currently known ultrasonic control devices, the closest to the useful model are automated ultrasonic control devices: Pipe WIZARD (electronic resource: http://www.olympus-ims.com/ru/ - accessed 11.28.2015, manufacturer Olympus, country: Japan, Canada), Rotoscan (electronic resource: http://www.applus.com/en/-flaTa of circulation November 28, 2015 producer - Applus, country: Netherlands), Argovision (electronic resource: http: // www. mnpo-spektr.ru/; http://www.sonotronndt.com/-flaTa of circulation November 28, 2015 producer - Applus, country: Russia, Israel), TVP128 (electronic resource: http: //www.eclipsescientific.c om /; http://www.sonotronndt.com/-flaTa of circulation November 28, 2015, manufacturer - Eclipse Scientific, country: Canada), WeldStar (electronic resource: http://www.ge.com/uk/-flaTa of circulation 11.28.2015, manufacturer - General Electric, country: USA).

Existing devices have the following disadvantages:

- the need to bind the device settings to specific geometric parameters of the joint;

- the need to manufacture a special calibration block of complex design, individual for each project and each type of weld;

- high requirements for the accuracy of the position of the blocks of ultrasonic sensors relative to the center line of the seam (regardless of the correct position of the cushion roller relative to the center line).

Due to these shortcomings, the above-mentioned automated ultrasonic control devices are used with special guiding bandages (usually from welding machines) with preliminary marking of their installation (before welding).

The use of bandages reduces labor productivity and increases the likelihood of incorrect interpretation of the control results, which largely depends on the accuracy of the installation of bandages. This feature reduces the reliability of detecting defects in the weld section.

The problem solved by the claimed utility model is the creation of an automated device for ultrasonic testing of ring welded pipe joints without the use of a bandage in the construction and repair of pipelines.

The technical result consists in increasing the reliability of ultrasonic testing of annular welded pipe joints.

The specified technical result is achieved, and the problem is solved due to the fact that on the supporting frame 1 are fixed:

an electronic unit with contact fluid supply units mounted on it and connected by electric cables to the battery compartment, a seam position monitoring sensor, acoustic units, a movement drive control unit and a wireless data transmission module;

an arm with a rotary lever, on which a seam position monitoring sensor and a movement drive are installed;

suspensions of acoustic blocks on which acoustic blocks are fixed;

driven wheels with track sensor,

wherein the contact fluid supply units are located symmetrically with respect to the longitudinal axial line of the carrier frame and are configured to supply contact fluid directly to the contact area of the working surfaces of the acoustic units with the ultrasound object;

wherein the sensor for controlling the position of the inductive-type seam is moved forward in front of the movement drive, and its position is determined by the geometry of the axis and screws of the bracket of the carrier frame;

while the suspension of the acoustic unit provides the swing of the acoustic blocks with three degrees of freedom and the adjustment of the distance between the acoustic blocks;

wherein the acoustic units consist of two acoustic transducers located symmetrically relative to the longitudinal axial line of the carrier frame;

wherein the electronic unit 6 is configured to use sounding schemes for the entire section of the weld and the heat-affected zone based on pulse echo and diffraction amplitude-time methods;

while the movement drive provides magnetic pressing and holding the device to the surface of the pipe using magnetic wheels symmetrically located relative to the weld;

wherein the electronic unit generates electrical signals, excites vibrations in the acoustic units, receives and performs analog-to-digital conversion of signals received from the acoustic units, and transmits information over the air through the wireless data transmission module to an external personal computer for subsequent processing;

while the power supply provides offline power to the electrical circuit of the device.

Additional technical result is achieved by the fact that:

- the movement drive consists of a pivot beam with magnetic wheels mounted on it, connected to electric motors through a gearbox and ensures uniform movement without jerking and slipping, along the axis of the weld with an average speed of at least 2 m / min and smooth passage through longitudinal welds seams

- acoustic blocks contain built-in magnets, ensuring the pressing of acoustic transducers to the surface of the ring welded joints in all spatial positions;

- acoustic blocks contain acoustic transducers, implemented on the basis of a phased array with 16 elements in the array, operating at the operating frequency of the transducer to implement an echo-pulse monitoring method of at least 4 MHz and at least 6 MHz with the diffraction amplitude-time sounding method in the sector scanning in the range of angles from 40 ° to 75 °;

- the gap between the inductance coils of the sensor for monitoring the position of the seam 8 and the reinforcement roller of the weld, at which the adjustment of the balance of the speed of rotation of the wheels of the drive of movement is maintained is 5–8 mm;

- driven wheels with a path sensor based on an optical encoder provide measurement of the coordinate of scanning along the axis of the pipe at a length of not less than 12000 mm with an error of not more than ± 2 mm;

- automatic tracking of the weld provides an error in the measurement of coordinates of defects ± 2 mm;

- the time of continuous operation from the battery at a temperature of minus 40 ± 5 ° C is at least 6 hours, and the average charging time of the battery is not more than 2.5 hours.

The inventive utility model is illustrated by the following graphic materials: FIG. 1 - a device for automated ultrasonic testing of ring welded pipe joints in the control position of the ring weld; FIG. 2 is a top view of the device, where:

1. The supporting frame.

2. The acoustic unit.

3 Suspension of the acoustic unit.

4. Drive wheel with track sensor.

5. Drive movement.

6. The electronic unit.

7. The drive control unit.

8. Sensor monitoring the position of the seam.

9. The power supply.

10. Contact fluid supply unit.

11. Wireless data transmission module.

Structurally, the device is a self-propelled multi-channel flaw detector with the function of automated control of the scanning device. Providing scanning along the necessary path occurs due to the basing of the device relative to the weld using the drive 5 on the signals of the sensor for monitoring the position of the weld 8 through the control unit drive 7.

On the supporting frame 1 are fixed: an electronic unit 6, a battery compartment 9 for autonomous power supply, driven wheels with a path sensor 4, suspensions of acoustic blocks 3, an arm with a pivot arm (not shown in Fig. 1, 2), a drive control unit 7 and wireless data transmission module 11.

The electronic unit 6 is connected by electric cables to the battery compartment 9, a seam position monitoring sensor 8, acoustic units 2, a motion drive control unit 7 and a wireless data transmission module 11. The insulation resistance of electric cables must be at least 1 MΩ to prevent a breakdown during charging battery from an external electrical network.

The drive of movement 5 and the sensor for monitoring the position of the seam 8 are fixed on the rotary lever. The rotary lever with the help of a spring presses the wheels of the drive of movement 5 to the pipe surface, ensuring the normal operation of the sensor for monitoring the position of the seam 8.

The movement drive 5 consists of a pivot beam (not shown in Fig. 1, 2), on which magnetic wheels are mounted, connected to the electric motor through a gearbox. During control, magnetic wheels are installed symmetrically with respect to the controlled weld. The movement drive 5 provides magnetic pressing and holding the device to the pipe surface, uniform (without jerking and slipping) movement along the axis of the weld with an average speed of at least 2 m / min and smooth passage through longitudinal welds. A pivot beam allows the wheel axis to rotate in the plane of motion and track the position of the weld.

An inductive type sensor is used as a sensor for monitoring the position of the seam 8, which does not have acoustic and mechanical contact with the test object, is not subject to wear and does not require installation on the seam for adjustment. Studies have shown that the most necessary accuracy for detecting defects is provided by the seam position control sensor, which is moved forward in front of the movement drive 5. The seam position control sensor 8 is mounted on an axis with two wheels, which is connected to the bracket with a rotary lever.

The position of the sensor for monitoring the position of the seam 8 is determined by the geometry of the axis and screws of the bracket with a rotary lever, which allows you to set the gap between the inductors of the sensor for monitoring the position of the seam 8 and the reinforcement roller of the weld in the range of 5 ÷ 18 mm. This ensures that the adjustment of the balance of the speed of rotation of the wheels of the drive movement 5 for the normal operation of the device.

Acoustic blocks 2 contain two acoustic transducers based on a phased array, the characteristics of which satisfy the following requirements:

- the number of phased array elements: not less than 16;

- type of excited wave: longitudinal, transverse;

- sector scanning in the range of angles: from 40 ° to 75 °;

- operating frequency of the converter for implementing the echo-pulse control method: at least 4 MHz;

- operating frequency for the implementation of the diffraction amplitude-time control method: at least 6 MHz.

The acoustic blocks 2 are fixed symmetrically relative to the center of the axes of the suspensions of the acoustic blocks 3 and contain built-in magnets, ensuring their constant pressing to the surface of the ring welded joints to the surface of the test object (ring welded joints) in all spatial positions.

The suspension design of the acoustic unit 3 provides the swing of the acoustic blocks 2 with three degrees of freedom and the adjustment of the distance between the acoustic blocks 2.

Between the acoustic blocks 2 there are driven wheels with a path sensor 4. The wheels themselves are magnetic, which ensures guaranteed magnetic pressing of the device to the pipe surface at any location. The path sensor is an optical encoder that measures the coordinate of scanning along the axis of the pipe at a length of at least 12,000 mm with an error of not more than ± 2 mm.

Automatic tracking of the seam, implemented using the sensor to control the position of the seam 8, the movement drive 5 and the control unit of the movement drive 7 provide the necessary lateral accuracy regardless of the height of the reinforcement roller and its width. When the device is in operation, the acoustic blocks 3 are quickly returned to the middle of the seam in the event of accidental failures, when moving through a longitudinal weld and inaccurate installation of the scanning mechanism on the seam by the operator. Automatic tracking of the weld provides an error in measuring the coordinates of defects ± 2 mm.

On the electronic unit 6, which carries out the collection, registration, processing and storage of information, guides are located in which the contact liquid supply units 3 and 4 are fixed with screws.

The electronic unit 6 is designed to generate electrical signals and excite oscillations in the acoustic units 2, receive, analog-to-digital conversion of signals received from the acoustic units and transmit information to an external personal computer for subsequent processing. The electronic unit includes a signal converter, a central processor, a voltage stabilizer, a probe pulse generator, non-volatile memory (not shown in Figs. 1, 2) that implement sounding schemes for the weld section and a heat-affected zone based on echo-pulse and diffraction amplitude-time methods.

Through the wireless data transmission module 11, containing a Wi-Fi adapter for wireless transmission of information over the air, the monitoring results can be transmitted to an external personal computer (not shown in Fig. 1, 2) for further processing.

The control unit 7 controls the electric motors of the drive 5 according to the signals of the sensor for monitoring the position of the seam 8.

The control unit 7 also serves to configure the sensor for monitoring the position of the seam 8, setting operating modes and turning on / off the electrical power of the device.

The power supply 9 provides offline power to the electrical circuit of the device. It consists of four batteries. Two batteries through the cable provide power to the acoustic unit 2. Two other batteries provide power to the electric motors of the drive 5 through the cable. Each of the batteries is connected to its own connector located on the housing of the battery compartment. These connectors can be used to independently charge batteries using chargers. The time of continuous operation of the battery at a temperature of minus 40 ± 5 ° C is at least 6 hours, and the average charging time of the battery is no more than 2.5 hours.

The contact liquid supply units 10 are located symmetrically with respect to the longitudinal axial line of the supporting frame 1 and are mechanical spring pumps for supplying the contact liquid directly to the contact area of the working surfaces of the acoustic units 2 with an ultrasonic object. Symmetrical arrangement is necessary for the stability of the device when moving along a controlled seam.

The claimed utility model works as follows.

The device is installed on the weld so that the wheels of the drive movement 5 and the driven wheels with a path sensor 4 are located between the weld. Using the control unit 7 enter the parameters of the control and the controlled product, open the taps to start supplying the contact fluid (not shown in Fig. 1, 2) and start the device for control. In the process of automatic scanning, the contact fluid is supplied from the contact fluid supply blocks 10 under the acoustic blocks 2.

The movement drive 5 according to the signals of the sensor for monitoring the position of the seam 8 through the control unit 7 provides the necessary scanning path, while the automation of the device provides the necessary lateral accuracy regardless of the height of the reinforcement roller of the weld and its width, quickly returning the acoustic blocks 2 to the middle of the seam in case of accidental failures when moving through a longitudinal weld and inaccurate installation of the scanning mechanism on the seam by the operator.

According to the signal from the path sensor, which is part of the driven wheel with the path sensor 4, the central processor of the electronic unit alternately starts the probe pulse generator of all control circuits. Ultrasonic vibrations propagate in the weld of the controlled product, are reflected from defects and are accepted by the acoustic unit 2.

The received signals are digitized and processed by the processor of the electronic unit 6. As a result of processing, the quality of the acoustic contact is determined. After that, the amplitude and propagation time of the received signals are determined. The received data is processed according to a specific algorithm. In the process of checking an annular weld, the processor fixes all the coordinates of the defects. The control protocol is stored in non-volatile memory. After completion of the control, all its results can be viewed on the screen of a personal computer after transmitting information through the wireless data transmission module 11.

Processing of the data is carried out on a personal computer.

Based on the results of the control, a file is generated containing the following information:

- name of the controlled object (date of control, name of the control section, number of welded joint, information about the operator);

- geometric parameters of the controlled object (thickness and diameter of the welded joint, steel grade);

- “A” - scan of the controlled compound;

- “B” - scan of the controlled compound;

- “C” - channel-by-channel scan of a controlled connection, indicating defective areas and areas with loss of acoustic contact;

- information on the status of the object (valid, repair, cutting, not determined - if there is a loss of acoustic contact for more than 1% on the perimeter of the weld).

Adjustment of a device for automated ultrasonic testing of annular welded pipe joints for various diameters is carried out by changing the position of the lever in the bracket. To do this, combine the required hole of the lever with the corresponding hole of the bracket and fix the position with a hairpin.

The hole indices “12”, “10”, “8”, “7” correspond to adjusting the device to control the annular weld of the pipe with a diameter of 1220, 1020, 820, 720 mm, respectively. In the case of commissioning to control the ring weld on pipes with a diameter of 530 mm, the brackets of the drive 5 and the driven wheels with a path sensor 4 are attached to the supporting frame 1 through special spacers (hole index - "7").

The inventive utility model, which represents an autonomous automated device, increases the reliability of ultrasonic testing of ring welded pipe joints and is used in the construction, repair and reconstruction of oil pipelines.

Claims (8)

1. Device for automated ultrasonic testing of annular pipe welded joints, including a supporting frame, on which are fixed: an electronic unit with contact liquid supply units mounted on it and connected by electric cables to the battery compartment, a seam position monitoring sensor, acoustic units, a movement drive control unit and a wireless data transmission module; an arm with a rotary lever, on which a seam position monitoring sensor and a movement drive are installed; suspensions of acoustic blocks on which acoustic blocks are fixed; driven wheels with track sensor; wherein the contact fluid supply units are located symmetrically with respect to the longitudinal axial line of the carrier frame and are configured to supply contact fluid directly to the contact area of the working surfaces of the acoustic units with the ultrasound object; wherein the sensor for controlling the position of the inductive-type seam is moved forward in front of the movement drive, and its position is determined by the geometry of the axis and bracket screws with a rotary lever; while the suspension of the acoustic unit provides the swing of the acoustic blocks with three degrees of freedom and the adjustment of the distance between the acoustic blocks; wherein the acoustic units consist of two acoustic transducers located symmetrically relative to the longitudinal axial line of the carrier frame; wherein the electronic unit 6 is configured to use sounding schemes for the entire section of the weld and the heat-affected zone based on pulse echo and diffraction amplitude-time methods; while the movement drive provides magnetic pressing and holding the device to the surface of the pipe using magnetic wheels symmetrically located relative to the weld; wherein the electronic unit generates electrical signals, excites vibrations in the acoustic units, receives and performs analog-to-digital conversion of signals received from the acoustic units, and transmits information over the air through the wireless data transmission module to an external personal computer for subsequent processing; while the power supply provides offline power to the electrical circuit of the device. 2. The device according to claim 1, characterized in that the movement drive consists of a pivot beam, with magnetic wheels mounted on it and connected to electric motors through a gearbox, and ensures uniform movement without jerking and slippage along the axis of the weld at an average speed of less than 2 m / min and smooth passage through longitudinal welds. 3. The device according to p. 1, characterized in that the acoustic blocks contain built-in magnets, ensuring the pressing of acoustic transducers to the surface of the ring welded joints in all spatial positions. 4. The device according to p. 1, characterized in that the acoustic blocks contain acoustic transducers implemented on the basis of a phased array with 16 elements in the array, operating at a working frequency of the transducer for implementing an echo-pulse monitoring method of at least 4 MHz and at least 6 MHz with the diffraction amplitude-time sound method for sector scanning in the range of angles from 40 ° to 75 °. 5. The device according to claim 1, characterized in that the gap between the inductance coils of the seam position monitoring sensor and the weld reinforcement roller, at which the adjustment of the balance of rotation speed of the drive wheels 5 is maintained, is 5-18 mm. 6. The device according to claim 1, characterized in that the driven wheels with a path sensor based on an optical encoder provide measurement of the scan coordinate along the axis of the pipe at a length of at least 12,000 mm with an error of not more than ± 2 mm. 7. The device according to p. 1, characterized in that the automatic tracking of the weld provides an error in measuring the coordinates of defects ± 2 mm. 8. The device according to p. 1, characterized in that the time of continuous operation of the battery at a temperature of minus 40 ± 5 ° C is at least 6 hours, and the average charging time of the battery is not more than 2.5 hours.

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