RU2625985C1 - Method of manufacture of flanged plug for inline inspection tool functionality test in pipeline testing ground - Google Patents

Abstract

FIELD: test equipment.

SUBSTANCE: coils of pipe spools with natural defects from operating pipelines and coils of pipe spools with artificial defects applied on them are used.

EFFECT: providing the possibility of creating a method of manufacturing a flange plug for inline inspection tool functionality test in pipeline testing ground.

2 dwg, 1 tbl

Description

The invention relates to tests of in-line inspection devices used for in-line diagnostics of oil pipelines and oil products pipelines, in particular to methods for certification and verification of in-line inspection devices (hereinafter VIP).

A known sample for ultrasonic testing (options) (RU 2186383 C2, IPC G01N 29/04, priority of 04/13/1999), made in the form of a body of controlled material with at least one cavity in which an artificial defect is placed, and the rest part of the cavity is welded, characterized in that the artificial defect is made in the form of a defect-forming element, in one of the surfaces of which a recess is made, and with this surface the defect-forming element is inseparably connected to one of the planes of the body cavity, while the dimensions and geometric shape The recesses are identical to the real defect, and the defect-forming element is made of controlled material and can be made in the form of a lining, two overlays or half washers, and a fixing recess is made to fix the defect-forming element on the plane of the body cavity. The invention relates to ultrasonic testing and is intended for certification of equipment for ultrasonic testing.

A known sample for non-destructive testing (RU 2235987 C1, IPC G01N 3/00, G01N 29/00, priority 25.03.2005), made in the form of a body of controlled material containing an artificial defect and at least one stepped groove with blunting which is brewed, characterized in that the sample is made in the form of a pipe, the artificial defect is made in a step on the reverse side of the cutting for welding in the form of a defect-forming groove simulating a real defect on the back side of the weld of the product, while the width of the groove is equal to the sum of the shrink Tull after welding and width simulating real defect in the product, and the depth and the groove, and the cutting is made variable on the end face of the sample opposite to the changing relative blunting, which remains constant. The invention relates to ultrasonic testing of welded joints of various metals and alloys.

A device for applying artificial defects to the inner surface of pipes (SU 1004865 A1, IPC G01N 29/04, priority 06/08/1980), comprising a rod, a cylinder with a tool located in the cavity of the pipe with the possibility of rotation around the longitudinal axis and longitudinal movement, the fitting and hose for the supply of working fluid. The invention relates to non-destructive testing and can be used for pipe inspection.

A device for applying artificial defects (RU 34746 U1, IPC G01N 29/04, priority since 07/15/2002), including a base, guides, a fixed and movable beam, a striker with a front edge of a wedge-shaped cutting edge inclined to the direction of introduction, a reference sample, characterized the fact that the reference sample is mounted obliquely at right angles to the front face of the cutting edge of the striker. The utility model relates to means of ultrasonic flaw detection and can be used both for the manufacture of standards by which flaw detectors are calibrated and for the application of artificial defects in a production environment.

A known control sample for magnetic flaw detection (RU 2002251 C1, IPC G01N 27/85, priority since 06/21/1991), containing strips connected by a weld seam and an artificial defect in the root of the seam.

A known method of monitoring the health of uncertified equipment for measuring residual stresses using test samples (RU 2354929 C1, IPC G01B 5/30, priority from 12/18/2007), in which on non-certified equipment in accordance with a given scale of the depth of residual stresses, measures the residual stresses for each test sample of a batch made with a regulated distribution of residual stress values, the distribution of residual stress values of test samples is recorded s depending on the depth of residual stresses.

A known method of manufacturing samples for non-destructive testing (RU 2346268 C1, IPC G01N 9/04, priority since 05/14/2007), including the joining of two workpieces from a controlled material by welding with the placement of an artificial defect in a previously obtained groove, followed by welding, characterized in that the defect-forming element is made of a wire of refractory material, the melting temperature (° C) of which exceeds the melting temperature (° C) of the welded material is not less than 2 times.

A known method of verifying the performance of an ultrasonic flaw detector (RU 2262101 C1, IPC G01N 29/04, priority from 09/07/2004), which consists in the fact that the radiation of ultrasonic vibrations by the acoustic unit of the flaw detector is carried out in a controlled product, these vibrations are received by an exemplary transducer from the back of the controlled products, the radiation of secondary ultrasonic vibrations into the product is carried out in the same direction as the direction of reception, the flaw detector is checked for operability without interrupting the process to ntrolya product at a scanning speed V _c.max, not exceeding

V _c.max ≤H [tg (a ₀ + ϕ _p ) -tg (a ₀ + ϕ _p )] / k _min T,

where H is the thickness (height) of the controlled product;

α ₀ and ϕ _p are the input angle and half the opening angle of the radiation pattern of the flaw detector transducer;

T is the period following the probe pulses of the flaw detector;

k _min - the minimum number of echo pulses at which a decision is made to detect a defect.

A device and method for monitoring the performance of an ultrasonic flaw detector (RU 2104519 C1, IPC G01N 29/04, priority since 12/26/2004), which consists in the fact that the acoustic unit is installed on the working surface of the sample, provides acoustic contact between the sample and the acoustic unit, emits acoustic pulsed ultrasonic vibrations into the sample with a block, receive ultrasonic vibrations from the sample with the same acoustic block, amplify it with a flaw detector, select by the time of their passage and by the operation of the flaw detector indicators they are concerned about its performance, characterized in that before receiving ultrasonic vibrations by the acoustic unit of the flaw detector, the vibrations emitted by it are received by the exemplary piezoelectric transducer from the back of the sample, the fact of this admission is indicated by the exemplary indicator, and after a predetermined time the ultrasonic vibrations are periodically emitted by the same piezoelectric transducer into the sample with an amplitude greater than the threshold level of the flaw detector, the specified delay time is selected taking into account the working time range of the flaw detector, but Flaw detector properties are judged together by flaw detector indicators and a model indicator. The device also contains a sample of sound-conducting material with a working and rear surfaces, while it is equipped with an exemplary piezoelectric transducer for periodically receiving and emitting ultrasonic vibrations mounted on the rear surface of the sample, and an electric path made of a waiting multivibrator, a reference indicator, and connected in series with the reference piezoelectric transducer of on-off switch, amplifier, pulse normalizer, adjustable delay line, defect switch c, a control method switch and a pulse generator with an amplitude regulator, in which the output of the normalizer is connected to an exemplary indicator and the input of the standby multivibrator connected to the control input of the on-off switch.

A known sample for monitoring two-beam piezoelectric transducers (RU 114373 U1, IPC G01N 29/30, priority from 09/01/2011), made in the form of a three-dimensional body having a measuring plane with marks for mounting the piezoelectric transducer and holes located so as to mirror ultrasound rays of the piezoelectric transducer mounted on the marks, characterized by the presence on the measuring plane of the mounting space for the stationary placement of the piezoelectric transducer with the possibility Because of its rotation around the axis of symmetry and two holes directed towards the required axes of the ultrasonic rays of the piezoelectric transducer, which are blind, the ends of the holes have different distances from the piezoelectric transducer.

A known control lash for checking the performance of flaw detectors (RU 159890 U1, IPC B61K 9/10, priority since 07/15/2015), including a rail segment made with the possibility of installing non-destructive testing means on it based on a flaw detector and made artificial defects formed by reflectors in it with the possibility of the identity of their reflective properties to the reflective properties of natural defects, while the reflectors are made in the form of models of natural defects, including models of defects in welded joints, models of defects native cracks in rails, models of defects of transverse cracks in rails and models of defects of interrelated longitudinal and transverse cracks in rails, characterized in that it has additional models of natural defects, including models of defects of vertical bundles of the rail head, models of defects of horizontal bundles of the rail head, models of defects corrosion and fatigue corrosion cracks of the rail sole, models of defects in quenching cracks in the hardened layer of metal of the rail head and models of defects in punctures in the sole of the rail Yelsa.

A known test rail section for testing the performance of flaw detectors (RU 131133 U1, IPC B61K 9/10, priority since 07/05/2013), the essence of which is that artificial defects are formed by reflectors to ensure that their reflective properties are identical to the reflective properties of natural defects, while reflectors are made in the form of natural defects models, including models of defects in welded joints, models of defects in longitudinal cracks in rails, models of defects in transverse cracks in rails and models of defects in interrelated longitudinal and transverse cracks in rails.

A known test sample for non-destructive testing (RU 2243548 C1, IPC G01N 29/04, priority since 02.25.2003), consisting in the fact that the test sample is made in the form of a product or its most critical part from the same material and for the same technologies as the product, with the test sample containing one or more groups of three groups of defects: defects whose sizes lie in the range from the sizes of defects admissible during operation to the dimensions critical for the product during operation of defects; defects, the sizes of which lie in the range from the dimensions allowed during the manufacture of defects to the sizes of defects allowed during operation; defects, the sizes of which lie in the range from the minimum sizes available for detecting defects to the sizes of defects acceptable during manufacturing (it is permissible that the upper boundary of the interval exceed the dimensions of defects acceptable during manufacturing), while the first two types of defects mimic defects of an operational nature, and the third type is technological.

A known method of manufacturing a specimen with a crack (RU 2009462 C1, IPC G01N 3/00, priority 05.06.1990), which is applied to the prismatic surface of the prismatic specimen, load the specimen until a crack forms and grows from the top of the notch into the interior of the specimen, and then the material is removed in the zone of crack propagation, characterized in that, in order to produce a specimen with a crack of constant length, a prismatic specimen with longitudinal rectangular protrusions on opposite faces perpendicular to the notch line is used, the specimen is loaded ski before germination cracks on entire thickness of the projections, the projections and then removed.

Known test sample for ultrasonic testing (RU 2324172 C1, IPC G01N 29/04, priority from 05/17/2006), made in the form of a prism or in the form of an article or its part or in any form of an optically transparent material, containing one defect or a set of defects located in a predetermined and / or random manner and introduced using laser technology for volumetric internal processing of transparent media, as a standard for tuning and evaluating control systems, when modeling defects such as discontinuities and heterogeneities and structural noise of structural materials, evaluating the technical parameters of equipment Hovhan and skill level personnel to carry it out, determining the probability characteristics of the ultrasonic flaw detection system.

The disadvantage of the above technical solutions is the impossibility of their use at a test pipeline test site to verify the operability of in-line inspection devices (VIP).

The technical result of the present invention is the creation of a method of manufacturing a flange insert for testing the performance of in-line inspection devices at a test site, such as: ultrasonic, magnetic, magneto-ultrasonic inspection devices used for in-line non-destructive testing of the pipeline, as well as inspection devices used for profilometry, thickness measurement and determination of the spatial position of the pipeline.

A method of manufacturing a flange insert to test the performance of in-line inspection devices at a test site is that they use coil tubes with natural defects from existing pipelines and coil tubes with artificial defects applied to them, while the coil of the tube section with natural defects from the current the pipeline is cut so that the distance in the longitudinal direction from the edges of the defect to the edges of the coil is some given distance, and the deviation of the recess of the end of the coil from the perpendicular was no more than a predetermined size, the outer surface of the coil is completely cleaned of all types of insulation, such as film or bitumen, and prepared for defectoscopic inspection; the inner surface of the coil is cleaned of oil, oil products and asphalt-resin-paraffin deposits, and the location of each defect present on the cut out coil is circled with indelible paint by a closed line on the outer surface of the coil corresponding to the contour of the defect, then on the outer surface of the coil is marked with indelible paint "POLIGON" ( to indicate that the coil is intended for use at a test site), zero position in the pipeline (“0 °”), flow direction a fluid conduit name; the name of the pipeline section, the number of the defect, while the marking of the number of the defect is carried out in the immediate vicinity of the marked defect contour, while natural and artificial defects are classified according to the following types:

1. Defects in the geometry of the pipe - defects associated with a change in the shape of the pipeline:

- a dent

- corrugation,

- narrowing (ovality);

2. Defects in the pipe wall - defects in the main metal of the pipeline:

- loss of metal,

- decrease in wall thickness,

- increase in wall thickness,

- crack

- bundle,

- inclusion,

- surface defect;

- mechanical damage to the surface of the pipeline wall - risk and scoring;

3. Weld defects - these are defects in the weld itself or in the heat affected zone:

- discontinuity of the planar type of transverse, longitudinal, spiral weld - crack, lack of penetration, non-fusion;

- anomaly of the transverse, longitudinal, spiral weld - pores, slag inclusions, elongation, undercut, penetration excess, influx, scale, slag inclusions, deviation of the weld size from the requirements of regulatory documents, fistula in the weld;

- displacement of the transverse, longitudinal, spiral weld; displacement of the edges - mismatch between the levels of the internal and external surfaces of the walls of the welded (welded) pipes (for the transverse weld) or sheets (for spiral and longitudinal seams) in the butt welds;

- oblique joint - a welded butt joint of a pipe with a pipe (with a coil, with a connecting part), in which the longitudinal axis of the pipes are located at an angle to each other;

- deviation of the size of the weld from the requirements of normative documentation, the deepening (sinking) between the rollers of the weld, excess reinforcement of the weld, insufficient reinforcement of the weld, poor renewal of the weld;

4. Other defects and features of the pipeline:

- foreign object

- deposit

- a metal object,

- anomaly of the pipe material,

- an invalid feature;

at the same time, all defects have a certain geometry and dimensions, and artificial defects are made to a given size with a given accuracy;

flange inserts are assembled at a length of less than 16 m on a special slipway, and at a length of more than 16 m, flanged inserts are assembled directly at the test site, and the flange insert is assembled by welding coils of pipe sections, while the flange inserts have flanges, which are provided with holes for mounting the flange insert with connecting pins with pipe elements of the test pipeline test site, the holes are aligned with the holes rugih elements of the test pipeline landfill to ensure interchangeability of the flange insert.

The flanged insert made by the above method is an element of the test pipeline test site, which is used in testing and verifying the performance of the VIP in terms of defect determination, the types of which are shown in Table 1. At the same time, the elements as flange inserts, if necessary, are reused after cutting to the specified dimensions.

In FIG. 1 shows a flange insert.

In FIG. 1 adopted the following notation:

1. Flange;

2. The coil of the pipe section;

3. Weld ring;

4. Longitudinal weld.

In FIG. 2 shows a slipway for assembling a flange insert.

In FIG. 2 adopted the following notation:

5. Flange insert;

6. The slipway.

Claims (8)

A method of manufacturing a flange insert to test the performance of in-line inspection devices at a test site is that they use coil tubes with natural defects from existing pipelines and coil tubes with artificial defects applied to them, while the coil of the tube section with natural defects from the current the pipeline is cut so that the distance in the longitudinal direction from the edges of the defect to the edges of the coil is some given distance, and the deviation of the recess of the end of the coil from the perpendicular was no more than a predetermined size, the outer surface of the coil is completely cleaned of all types of insulation, such as film or bitumen, and prepared for defectoscopic inspection; the inner surface of the coil is cleaned of oil, oil products and asphalt-resin-paraffin deposits, and the location of each defect present on the cut out coil is circled with indelible paint by a closed line on the outer surface of the coil corresponding to the contour of the defect, then on the outer surface of the coil is marked with indelible paint "POLIGON" ( to indicate that the coil is intended for use at a test site), zero position in the pipeline (“0 °”), flow direction a fluid conduit name, the name of the pipeline section, the defect number, wherein the number of defect marking operate in close proximity to the marked contour of the defect, the natural and artificial defects are classified into the following types: - defects in the geometry of the pipe - defects associated with a change in the shape of the pipeline: a dent, corrugation, narrowing (ovality); - pipe wall defects - defects in the main metal of the pipeline: metal loss, decrease in wall thickness, increase in wall thickness, crack, delamination, inclusion, surface defect; - mechanical damage to the surface of the pipeline wall: risk and scoring; - defects of the weld are defects in the weld itself or in the near-weld zone: discontinuity of the planar type of the transverse, longitudinal, spiral weld - crack, lack of penetration, non-fusion; anomaly of the transverse, longitudinal, spiral weld - pores, slag inclusions, elongation, undercut, excess melt, influx, scale, slag inclusions, deviation of the weld size from the requirements of regulatory documents, fistula in the weld; displacement of the transverse, longitudinal, spiral weld; displacement of the edges - mismatch of the levels of the internal and external surfaces of the walls of the welded (welded) pipes (for the transverse weld) or sheets (for spiral and longitudinal seams) in butt welds; oblique joint - a welded butt joint of a pipe with a pipe (with a coil, with a connecting part), in which the longitudinal axes of the pipes are located at an angle to each other; deviation of the weld dimensions from the requirements of normative documentation, deepening (dropping) between the weld beads, exceeding the weld reinforcement, insufficient reinforcement of the weld, poor renewal of the weld; - other defects and features of the pipeline: foreign object, deposit, metal object, anomaly of the pipe material, an unacceptable structural element; in this case, all defects have a certain geometry and dimensions, and artificial defects are made to a given size; flange inserts are assembled at a length of less than 16 m on a special slipway, and at a length of more than 16 m, flanged inserts are assembled directly at the test site, and the flange insert is assembled by welding coils of pipe sections, while the flange inserts have flanges, which are provided with holes for mounting the flange insert with connecting pins with pipe elements of the test pipeline test site, the holes are aligned with the holes rugih elements of the test pipeline landfill to ensure interchangeability of the flange insert.

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