CN112798687A - Ultrasonic transmission in-situ detection method for creep cracks in inner wall of hydrogen furnace tube - Google Patents
Ultrasonic transmission in-situ detection method for creep cracks in inner wall of hydrogen furnace tube Download PDFInfo
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- 238000001514 detection method Methods 0.000 title claims abstract description 119
- 239000001257 hydrogen Substances 0.000 title claims abstract description 39
- 229910052739 hydrogen Inorganic materials 0.000 title claims abstract description 39
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 title claims abstract description 38
- 230000005540 biological transmission Effects 0.000 title claims abstract description 18
- 238000011065 in-situ storage Methods 0.000 title claims abstract description 17
- 238000004519 manufacturing process Methods 0.000 claims abstract description 36
- 238000000034 method Methods 0.000 claims abstract description 20
- 230000007547 defect Effects 0.000 claims abstract description 9
- 238000009792 diffusion process Methods 0.000 claims abstract 2
- 230000005284 excitation Effects 0.000 claims description 24
- 230000009194 climbing Effects 0.000 claims description 17
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 10
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- 239000000523 sample Substances 0.000 claims description 8
- 238000012545 processing Methods 0.000 claims description 7
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- 238000003384 imaging method Methods 0.000 claims description 4
- 238000004891 communication Methods 0.000 claims description 3
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- 238000002592 echocardiography Methods 0.000 claims description 3
- 238000012360 testing method Methods 0.000 claims description 3
- 238000007654 immersion Methods 0.000 claims 2
- 238000012790 confirmation Methods 0.000 claims 1
- 230000005611 electricity Effects 0.000 claims 1
- 150000002431 hydrogen Chemical class 0.000 claims 1
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- 230000008901 benefit Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 239000007822 coupling agent Substances 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000011160 research Methods 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 101001055216 Homo sapiens Interleukin-9 Proteins 0.000 description 1
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 description 1
- 102100026871 Interleukin-9 Human genes 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000001174 ascending effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000009933 burial Methods 0.000 description 1
- 238000009750 centrifugal casting Methods 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000007903 penetration ability Effects 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
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- 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
- G01N29/07—Analysing solids by measuring propagation velocity or propagation time of acoustic waves
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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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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/10—Number of transducers
- G01N2291/104—Number of transducers two or more emitters, one receiver
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/10—Number of transducers
- G01N2291/105—Number of transducers two or more emitters, two or more receivers
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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
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/30—Hydrogen technology
- Y02E60/36—Hydrogen production from non-carbon containing sources, e.g. by water electrolysis
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Abstract
本发明公开了一种制氢炉管内壁蠕变裂纹超声透射原位检测方法，将两压电换能器按特定角度设置成一激一收方式构成一组，周向设置三组并固定于距制氢炉管外壁一定位置处，利用压电换能器扩散角内的声束及检测环的旋转实现制氢炉管检测区域内管道内壁全覆盖；采用电子扫查方式同时激励每组检测结构中发射压电换能器，使其向耦合剂中辐射超声波并以一定的角度进入管道内壁，在穿过检测区域后回波信号同样以一定角度辐射出管道，进入耦合剂被接收换能器接收，通过对回波信号特征的识别，从而定量管道蠕变裂纹。本发明通过三组一激一收检测环旋转方式对制氢炉管进行检测，实现了非人工扫查方式的风机主轴表面缺陷的原位检测。
The invention discloses an ultrasonic transmission in-situ detection method for creep cracks in the inner wall of a hydrogen-producing furnace tube. At a certain position on the outer wall of the hydrogen production furnace tube, the sound beam in the diffusion angle of the piezoelectric transducer and the rotation of the detection ring are used to achieve full coverage of the inner wall of the pipeline in the detection area of the hydrogen production furnace tube; the electronic scanning method is used to simultaneously stimulate each group of detection structures The medium-emitting piezoelectric transducer makes it radiate ultrasonic waves into the couplant and enter the inner wall of the pipe at a certain angle. After passing through the detection area, the echo signal also radiates out of the pipe at a certain angle, and enters the couplant to be received by the transducer. Receive, and quantify the creep crack of the pipeline by identifying the characteristics of the echo signal. The invention detects the hydrogen-producing furnace tubes through three sets of one-exciting and one-retracting detection ring rotation modes, and realizes the in-situ detection of the surface defects of the main shaft of the fan in a non-manual scanning mode.
Description
Technical Field
The invention relates to an ultrasonic transmission in-situ detection method for creep cracks on the inner wall of a hydrogen production furnace pipe, and belongs to the field of nondestructive detection.
Background
Hydrogen energy has received increasing attention as a clean renewable energy source. With the large-scale application of the hydrogen production furnace in petrochemical oil refining enterprises, the operation states of the hydrogen production furnace tube and parts thereof are directly related to the production safety and benefits of national enterprises. A plurality of pipelines work in the hydrogen production furnace side by side, the furnace tube is a main pressure-bearing part, and the condition of generating cracks due to long-time high-temperature and high-pressure environment and hydrogen oxide corrosion is inevitable. Thus, the safety detection of the structure not only helps to prevent the occurrence of safety accidents, but also can replace the problem pipeline in time to avoid unnecessary economic loss.
The hydrogen production furnace tubes are fixed between two heating furnaces in a whole row and are in a high-temperature and high-pressure production state all the year round, the whole furnace needs to be stopped for 1-2 days in each detection, the enterprise benefit is greatly influenced, the starting and stopping of the heating furnaces seriously influence the growth of cracks of the pipelines, so that how to comprehensively detect the pipelines in the furnace in a short time is a main problem at present, a detector can only climb a scaffold in the furnace stopping state, the fire facing surface and the fire backing surface of the furnace tube are detected in a stepping mode by using a longitudinal wave probe or the pipeline is scanned twice by using a crawler, but the number of pipelines in the furnace is large, and the detection coverage area is small, the time and the labor are consumed, and the detection cost is very large by using the two modes in the stopping state. Therefore, the in-situ detection of the furnace tube, particularly the HP40 pipeline which is centrifugally cast, cannot be well implemented so far, and in order to ensure the safe use of the hydrogen production furnace and ensure the national production safety, the potential safety hazard is minimized, and a defect detection method which does not need personnel to approach the furnace tube for manual detection and has wide coverage is very necessary and urgent to research.
The hydrogen production furnace tube is mainly made of nickel, chromium and other metal elements through centrifugal casting, has larger grain size compared with common tubes on the market, has larger attenuation on the transmission of various energies, and is designed to be a thick-wall pipeline in order to ensure that the workpieces can be in a working state all the year round. For the detection thereof, the ultrasonic transmission method is undoubtedly the most suitable and most effective detection method. Compared with other nondestructive detection methods, the ultrasonic nondestructive detection technology has comprehensive advantages in determining the size, position, orientation, burial depth, property and other parameters of the internal defect, and mainly comprises the following steps: strong penetration ability, high signal integrity and no harm to human body, workpieces and surrounding environment.
The petrochemical facility pipe detection is relatively researched at home and abroad, but the research on hydrogen production furnace pipes is less, the failed pipeline is generally disassembled and then failure analysis is carried out, a pipe climbing robot is applied to scan the fire facing surface and the fire backing surface of the pipeline under the condition of no pipeline movement, and the detection method is nearly mature. Although the method is reasonable and feasible in design, the method cannot be directly and widely applied to in-situ detection of the hydrogen production furnace tube, and the main reasons are as follows: although creep cracks are mostly generated on the back fire surface due to the influence of temperature difference, the creep failure caused by cracks generated at the back fire surface is found to be more probable at the back fire surface boundary through the actual failure analysis result, and the creep failure is just the loophole of the current detection method. And the length of a single furnace tube is about 12m, the traditional detection method has low efficiency, and the method can be widely applied.
Disclosure of Invention
The invention provides a furnace tube creep circumferential detection method based on ultrasonic transmission longitudinal waves, which adopts a longitudinal wave piezoelectric transducer to realize furnace tube inner wall creep crack detection through electronic scanning, avoids the complicated process of manual scanning in the conventional detection process, and is more favorable for realizing the circumferential detection of the furnace tube inner wall creep crack compared with other methods of furnace tube in-situ detection.
In order to achieve the purpose, the technical scheme adopted by the invention is an ultrasonic transmission in-situ detection method for creep cracks on the inner wall of a hydrogen production furnace pipe, and a detection device for achieving the detection method comprises a computer 1, ultrasonic excitation receiving equipment 2, a micro water supply pump 3, a rotating motor 4, a detection ring 5, an excitation receiving transducer 6 and a furnace pipe 7. Wherein, computer 1 passes through wireless module with supersound excitation receiving equipment 2 and is connected, and supersound excitation receiving equipment 2 is connected with rotating electrical machines 4, and miniature water supply pump 3 links to each other with detecting ring 5, and rotating electrical machines 4 passes through gear structure with detecting ring 5 and is connected, and this method concrete implementation step includes:
step one, determining the diameter D and the wall thickness T of a furnace tube to be detected, determining the distance T between an acoustic wave path in the tube and the inner wall of the tube according to the material of the hydrogen production furnace tube and the size Q of the defect to be detected, and enabling the refraction angle in the tube to pass through
Calculating, according to the snell law, the incident angle of the sound wave passes through
Calculating, wherein: cL1Is the wave velocity of the coupling agent, CL2The longitudinal wave velocity of the hydrogen production furnace tube material;
step two, selecting a piezoelectric transducer with moderate central frequency F, diameter d and focusing distance F according to an ultrasonic detection principle, adjusting the clamping angle of the transducer of the sensing ring according to the incident angle alpha of the sound wave obtained by calculation in the step one and the propagation path of the sound wave in the tube, so that the transducer meets the incident and receiving conditions obtained by calculation in the step one and is fixed, and setting the other two groups of detection structures in the same way;
thirdly, fixing three groups of transducers according to the method in the second step, wherein the zero time position is a detection group with the number 1, the detection groups are numbered clockwise according to the numbers 2 and 3, leading-out wires of each piezoelectric transducer in the detection ring are respectively connected to channel interfaces corresponding to the ultrasonic excitation receiving equipment, and the position setting and the electrical crosslinking of the piezoelectric transducers are completed;
step four, turning on a water pump to adjust flow, turning on ultrasonic excitation receiving equipment after judging that a coupling condition is reached, detecting the wireless communication state of the computer and the equipment, sending a detection instruction through the computer to control the ultrasonic excitation receiving equipment to enable three channels to excite the piezoelectric transducer at the same time, collecting three groups of echoes to confirm whether the waveform is normal, and repeating the first step and the second step to finely adjust the position of the transducer if the waveform has a problem;
step five, sending an instruction again to test the running states of the pipe climbing motor and the rotating motor after the sensor ring runs correctly, adjusting the pipe climbing machine to the bottom end of the pipeline to be tested after all links of the system are confirmed, and sending an instruction by the computer to start the automatic detection of the whole pipe;
scanning the machine from bottom to top, continuously sending detection data to a computer through a wireless module for imaging and processing, stopping running until a pipe climbing motor at the top end of the pipeline stops running, driving a detection ring to rotate by a certain angle through a rotating motor, running the pipe climbing motor again, and running a detection system from top to bottom;
and seventhly, after the pipe climbing machine runs to the bottom end of the pipeline, the ultrasonic excitation receiving equipment completes transmission of detection data, and data arrangement is performed on uplink and downlink echo signals of each numbered detection group on the computer to complete the hydrogen production furnace pipe detection. The data arrangement mode arranges the waveforms in sequence according to the scanning sequence from bottom to top of the system, so that three-channel downlink data of the system need to be exchanged end to end after scanning is finished, and uniform arrangement and processing of the whole-pipe circumferential scanning data are realized.
And step eight, determining the corresponding position and the appearance height of the group number of the defect position according to the detection group number and the peak value reduction value of the piezoelectric transducer with the problematic echo.
Compared with the prior art, the invention has the beneficial effects.
1. The method utilizes the ultrasonic waves radiated by the three groups of piezoelectric transducers to realize the detection of the creep cracks of the inner wall of the furnace tube in the circumferential direction of the hydrogen production furnace tube, does not need to manually adjust the position of the detection ring in the detection process, realizes the in-situ detection of the circumferential full coverage of the inner wall of the furnace tube, and has obvious advantages in the aspects of implementation convenience and detection efficiency.
2. According to the invention, a manual scanning mode is replaced by an electronic scanning mode of the pipe climbing machine, so that a tester does not need to climb a scaffold to perform manual stepping scanning detection operation aiming at a problem area; aiming at the quality detection of the components, in particular to the long pipe and the project which needs large work load of circumferential detection of the whole pipe, the invention provides a new idea for solving the technical problem.
Drawings
FIG. 1 is a schematic structural diagram of an ultrasonic transmission in-situ detection system for creep cracks on the inner wall of a hydrogen production furnace tube, which is used in the invention;
FIG. 2 is a structural dimension of a furnace tube and a single set of transducer detection areas in an embodiment of the invention;
FIG. 3 is a schematic diagram of the positional arrangement of three sets of piezoelectric transducers in the detection ring of the present invention;
FIG. 4 is a schematic view of a rotating electric machine drive detection ring of the present invention;
FIG. 5 is a schematic diagram of the location and coverage area of upstream and downstream probes in an embodiment of the invention;
Detailed Description
The invention is described in detail below with reference to the drawings and the detailed description.
For the hydrogen production furnace tube, the quality detection is very critical when the safety production operation can be carried out in the service life approaching or even exceeding the design service life. Practice proves that the hydrogen production furnace tube is influenced by environment and corrosive gas in the long-term use process, creep cracks growing from the inner wall to the outer wall are easily generated on the tube wall of the hydrogen production furnace tube, and the service life and the production safety of the furnace tube are directly influenced by the cracks.
The hydrogen production furnace tube adopted in the embodiment is the furnace tube 7 to be tested in fig. 1, the material of the furnace tube is 45Ni35cr25nb, and the ultrasonic longitudinal wave sound velocity of the material is 5917 m/s. The structural size and the detection area are shown in fig. 2, and the detection surface is an area close to the inner wall of the pipe.
The detection system adopted by the embodiment comprises a computer, ultrasonic excitation receiving equipment, a miniature water pump and a pipe climbing machine comprising a detection ring, and the detection system comprises the following specific implementation steps:
step one, in this embodiment, the material of the hydrogen production furnace tube 7 is 45Ni35cr25nb, the diameter D is 138mm, the wall thickness is 14.5mm, and a creep defect with Q less than or equal to 4mm needs to be detected, then the distance t between the path of the sound wave in the tube and the inner wall of the tube is determined to be 7.25mm, and the sound wave refraction angle β is 63.49 ° (63.5 °), α is 12.93 ° (12.9 °), wherein the wave velocity of the coupling agent is 1480m/s, and the wave velocity of the longitudinal wave of the furnace tube is 5917m/s are obtained through calculation;
step two, selecting a piezoelectric transducer with the center frequency of 1MHz and the diameter of phi 20mm according to the general principle of ultrasonic detection by combining the attenuation capacity of the material to sound waves, selecting a line focusing probe with the focusing distance F of 25mm for excitation in order to ensure the concentration of sound beams, receiving by a flat probe with the same parameters, determining the positions of the two probes and manufacturing a special clamp for fixation according to the incidence angle alpha obtained by calculation in the step one and the propagation path of the sound waves in the tube by combining the focusing distances of the probes, and setting the rest two groups of detection structures in the same way as shown in figure 3;
adjusting the position of the whole detection ring after the probe is fixed, adjusting a channel to a detection group which is just opposite to the fire surface on one side of the furnace tube and is numbered as 1, numbering the other detection groups 2 and 3 clockwise, and respectively connecting the leading-out wire of each piezoelectric transducer in the detection ring to a channel interface corresponding to the ultrasonic excitation receiving equipment to complete the position setting and the electrical crosslinking of the piezoelectric transducers;
step four, turning on a water pump to adjust flow, turning on ultrasonic excitation receiving equipment after judging that a coupling condition is reached, detecting the wireless communication state of the computer and the equipment, sending a detection instruction through the computer to control the ultrasonic excitation receiving equipment to enable three channels to excite the piezoelectric transducer at the same time, collecting three groups of echoes to confirm whether the waveform is normal, and repeating the first step and the second step to finely adjust the position of the transducer if the waveform has a problem;
step five, after the sensor ring operates correctly, sending an instruction again to test the ascending and descending distances of the pipe climbing motor by 1m, rotating the motor to operate at 60 degrees clockwise and anticlockwise, adjusting the pipe climbing machine to the bottom end of the pipeline to be tested after each link of the system is confirmed, and sending an instruction by the computer to start the automatic detection of the whole pipe;
scanning the machine from bottom to top, continuously sending detection data to a computer through a wireless module for imaging and processing, stopping running until a pipe climbing motor at the top end of the pipeline stops running, driving a detection ring to rotate clockwise by 60 degrees through a rotating motor, running the pipe climbing motor again as shown in figure 4, and running the detection system from top to bottom;
and seventhly, after the pipe climbing machine runs to the bottom end of the pipeline, the ultrasonic excitation receiving equipment completes transmission of detection data, and data arrangement is performed on uplink and downlink echo signals of each numbered detection group on the computer to complete the hydrogen production furnace pipe detection. The data arrangement mode arranges the waveforms in sequence according to the scanning sequence from bottom to top of the system, so that the first exchange of the downlink data of the first, second and third channels is realized after the scanning is finished, the uniform arrangement and processing of the circumferential scanning data of the whole pipe are realized, and the positions of the uplink and downlink transducers of each channel and the area covering the pipe in the whole detection process are shown in fig. 5.
And step eight, determining the corresponding position and the appearance height of the group number of the defect position according to the detection group number and the peak value reduction value of the piezoelectric transducer with the problematic echo.
Claims (5)
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| CN114942267A (en) * | 2022-05-05 | 2022-08-26 | 华能核能技术研究院有限公司 | A parallel crack orientation ultrasonic measurement system, method and application |
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