Ultra-high-speed automatic detection technology for large diameter pipes
The probes are arranged on both sides of the weld together, and the probe is scanned by the external rotation mechanism of the tube to detect the weld seam. When the defect is found, the alarm is marked, and the automatic detection device is suitable for carbon steel with diameter greater than 529 mm and thickness of 7-40 nm. Low alloy steel is a long-distance pipeline for materials. Compared with labor, it can improve work efficiency and greatly reduce the labor intensity of workers. It can realize 100% inspection of the weld cross section and realize the functions of recording, storing and printing related data of defect waveform.
Key words pipeline ultrasonic flaw detector automatic detection welding micro-computer long-distance pipeline welding quality inspection work requirements iro% ultrasonic testing method for quality analysis. At present, most of the ultrasonic testing in China adopts manual operation. In order to improve efficiency, reduce labor intensity and meet the needs of production and construction, an ultrasonic automatic detecting device has been developed.
KSD-8 Ultrasonic Flaw Detector is a type A pulse multi-channel digital flaw detector. It is an ultrasonic flaw detection equipment used in conjunction with industrial control computers. The device is suitable for long-distance pipelines made of carbon steel and low-alloy steel with a diameter of more than 529mm and a wall thickness of 7~40mm. It uses an 8-channel ultrasonic flaw detector to arrange six probes together on both sides of the weld. The external rotation mechanism of the tube drives the probe to scan the weld seam, and when the defect is found, the alarm prints the mark.
1. Composition of detection device The ultrasonic automatic detection device for large-diameter pipe is an automatic detection device for high-efficiency pipe circumferential weld quality of the pipeline. It mainly includes two parts, namely the external crawling mechanism and multi-channel digital ultrasonic flaw detection. instrument.
1.1.1 Design of the outer crawling mechanism The outer crawling mechanism is an important component to ensure the normal operation of the detecting device. It is used to replace the manual operation, and the probe holding device, the defect printing marking device, the coupling agent spraying mechanism and the like are uploaded. In order to quickly install and debug the external crawling mechanism on the large-diameter pipe, the flaw detection time is reduced as much as possible, and it is easy to install and disassemble. The magnetic crawling trolley is used as the carrier. The machine is adsorbed outside the steel pipe and moves in a circular motion along the direction of the weld bead, and the movement speed is adjustable.
The probe holder is made of a light plastic material to reduce the weight of the carrier. The device can ensure the left and right, up and down and steering movement of the probe, and the probe can be adapted to the pipe joint detection requirements of different pipe diameters and different curvature radii. The small spring is installed inside, and the probe can be used to detect the sliding surface when sliding under the action of the spring thrust. Adhering to the outer wall of the pipe, the height deviation generated for the outer surface of the pipe while the crawling trolley is walking can be controlled between 15.
The defective print marking device is fixed on the creeper, screwed, and adjustable up and down. When a weld defect is detected, the computer issues an instruction to open the solenoid valve on the device, print a mark, and specify the defect location.
The couplant spraying mechanism enables the probe to slide over the outer wall surface of the steel pipe while spraying a layer of couplant film on the bottom surface of the probe to prevent voids. In order to achieve automatic flaw detection, the pump is used to supply the couplant from the ground, and a soft hose is sprayed to the spray pipe connected to the front of the probe. The probe immediately squeezes the oil agent to fill the probe with the outer wall of the tube without a gap.
1.2 When the operation mode and work process are working, the flexible track is first pressed on the test bead in the direction of the bead to be tested, and is fastened with a wire rope. Mount the magnetic wheel crawler on the track. Adjust the probe clamping device so that the probe detection surface is pressed against the outer wall surface of the tube, and a certain amount of probe adjustment margin is left and left, and the top wire is tightened. Turn on the creeper and the fuel pump power switch, and the automatic detection starts.
1.1.3 Technical indicators Adapt to the pipe diameter: *529 ~ 2000mm circumferential walking speed: 0 forward, backward direction convertible flaw detection auxiliary preparation time: 2min magnetic wheel adsorption force: <50kg linear deviation along the track: <8 channel digital ultrasonic flaw detection The working sequence of each channel of KSD is determined by programming. Each channel has a maximum frequency of 8 kHz. Each channel has an alarm gate. Each channel can be set with an over-threshold value of multiple channels. The gate status can be set in the main menu for adjustment.
The scan depth and delay for each channel can be set individually.
The specific operation can be adjusted in the main menu interface, and can be used for multiple flaw detection of different sound paths.
The panel adopts a full GUI interface, and the desired function key is clicked with a touch button, and the operation is flexible and reliable.
In addition to the main menu settings of the machine, you can also call the saved process file to directly change the original parameters.
Strong anti-interference performance, high signal-to-noise ratio, using average and related advanced information processing technology.
The software alarm directly outputs the driving signal, drives the external marking device, and realizes real-time marking on the surface of the pipe to be probed.
Frequency range: 0.5~1CMHz attenuation: 119, 0.5dB step (small), 5dB step (large) dynamic range: >26dB vertical linear: <4% 1mm pulse delay: 0 2 ultrasonic flaw detection system principle ultrasonic flaw detection The system principle is as shown. Under the control of the microcomputer program, the flaw detector emits high-voltage electric pulses in each flaw detection channel, and is excited by the probe line to the 6-channel probe array. At the same time, the probe array is pressed onto the surface of the detected steel pipe, and the mechanical device is placed on the probe. A layer of eutectic oil of about 1 mm thick is produced between the array and the steel tube, so that the probe array and the object are well-fitted. The probe array emits ultrasonic waves into the steel pipe, and the quality inspection information echoes are transmitted to the probe, converted into electric pulses, and the information is transmitted to the computer for display and recording by giving the sound and light alarm detection results. The instrument also controls the simultaneous automatic flaw detection and marking signals of the electromechanical system. The power supply is mainly a strong electric power source, which is responsible for the operation requirements of the electromechanical system. The instrument power supply guarantees the supply of various DC voltages of the flaw detection instrument. At the same time, the S104/386BX industrial control microcomputer is used inside the computer tester. The display adopts the EL display system, the operation platform adopts the membrane switch type touch button, and the UPS power supply adopts 3 The road output switching power supply, the flaw detection device uses an 8-channel flaw detection system. The instrument system is mainly composed of a main computer, a multi-channel flaw detector, a printer, an electromechanical control box and related input and output devices. The flaw detection instrument and the micro industrial computer are installed in the portable case. There are 4 external interfaces on the outside of the chassis. The probe interface can be connected with 8 sets of probes. The communication interface can be connected to the serial port of the portable computer through the communication line for data communication. It can be connected to the electromechanical control box through the 7-core wire to control the external electromechanical action, and the power interface directly inputs 220V AC. The generation, emission and amplification of ultrasonic waves are all performed by the KSD-8 digital ultrasonic flaw detector. It has a complete dedicated computer communication port and control alarm port. The instrument itself can be connected to the probe. It collects data and communicates with the industrial computer. The industrial computer and the flaw detection system software process the data in real time to generate the flaw detection waveform and make defects. Call the police.
The operation of the electromechanical control part is realized by the four buttons of forward rotation, reverse rotation, marking and stopping on the operation platform, wherein the marking button is used for marking system installation and debugging, in the actual flaw detection process, the microcomputer The direct output signal drives the marking system for automatic marking. The internal control system of the flaw detector is connected to an external relay through a 9-pin row plug to control the external circuit.
3. Conclusion The whole set of equipment is stable in operation and easy to operate. Compared with manual flaw detection, it can improve work efficiency. The larger the diameter of the probe, the more obvious the effect.
The realization of flaw detection automation has greatly reduced the labor intensity of workers and reduced the rate of false detection caused by humans.
It can realize 100% of the weld cross section and realize the functions of related data recording, storage and printing.
(200-06-21 Editing Yang Jun) Oil and Gas Field Surface Engineering (GnEc
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