CN102519969A - Method for completely checking pressure pipeline with heat preservation function without stopping running - Google Patents
Method for completely checking pressure pipeline with heat preservation function without stopping running Download PDFInfo
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Abstract
The invention provides a method for completely checking a pressure pipeline with a heat preservation function without stopping running. The method comprises the following steps of: (1) determining a key erosion detection measurement part of the pressure pipeline with the heat preservation function by using an infrared thermal imaging technology; and (2) detecting the part to be detected by using an x-ray real-time imaging technology. According to the method for completely checking the pressure pipeline with the heat preservation function without stopping running, the problem about detection for welding quality of a welded joint of the similar pipeline and selective examination and measurement for residual thickness of the pipeline is solved by using the infrared thermal imaging technology and the x-ray real-time imaging technology; therefore, the requirement of checking without stopping running can be met, and the work efficiency can be improved.
Description
Technical field
The present invention relates to be with the heat preservation pressure pipeline not shut down the complete examination method.
Background technology
" with industrial pipeline periodic inspection rules " (trying) requires in complete examination the carrying out Non-Destructive Testing and the selective examination that pipeline carries out residual thickness is measured of pipeline welded joint, and is the check difficult point for shutting down, measuring with the selective examination of undercut, misalignment inspection and the pipeline residual thickness of the ray detection of the pipeline welded joint of insulation and utilidor weld seam.
Conventional x ray is bigger for the pipe welding seam detection difficulty of band insulation, and reason is that the pipe welding seam position can't be judged.For some special media, like liquefied ammonia etc. the x ray is also had absorption, can't in time understand the quality of imaging after the detection, detection efficiency is low.
The widespread use in industry-by-industry of x radiographic real-time imaging technology.The mandatory appendix of ASME boilers and pressure vessel standard (01 and 02,03 [) V volume chapter 2 has also been made regulation to the application of RTR.China has set up GB17925-1999 " gas cylinder butt-weld X ray Real-time Imaging " standard, and JB/T4730.11x real-time radiography inspection standard is write.
Summary of the invention
The purpose of this invention is to provide a kind of band heat preservation pressure pipeline and do not shut down the complete examination method.
Band heat preservation pressure pipeline provided by the invention is not shut down the complete examination method and may further comprise the steps:
(1) utilize that infrared thermal imaging technique confirms that band heat preservation pressure corrosive pipeline detects the emphasis location;
(2) utilize x radiographic real-time imaging technology that the position that need detect is detected.
Below each section for can be respectively or unite the embodiment of employing.
The concrete operation method of step (1) is: utilize thermal infrared imager that the infrared energy distribution pattern of measured target is reflected in the photosensitive unit of infrared eye; Convert infrared energy to electric signal by detector; Show Infrared Thermogram through processing and amplifying, conversion or video standard signal through TV screen or monitor; This thermography is corresponding with the heat distribution field of body surface; The heat distribution field is relevant with the insulation quality of band heat preservation pressure pipeline, utilizes this association, through analyzing the emphasis location that thermography confirms that corrosion detects.
The detection that detects in the step (2) be selected from pipeline welded joint detection, weld metal crack depth survey, pipe thickness measuring, calibrate and corrosive pipeline depth detection and misalignment in detecting one or multinomial; Wherein, weld metal crack depth survey and corrosive pipeline depth detection are utilized the gray scale measuring method; The pipe thickness measuring, calibrate to detect with Survey Software and detect with misalignment, wherein the pipe thickness measuring, calibrate and adopt the dual energy exposure mode.
Detection focal length in the step (2) is greater than 500mm, and tube voltage is greater than 100kv.
Step (2) utilizes the continuous x ray source to detect, and utilizes filter band to filter the soft ray that sends in the radiographic source, and the selection of filter band is with reference to the regulation of European E2597-07E1.
Step (2) utilizes the pulsed radiographic source to detect, and aligns detection to radiographic source and workpiece, guarantees detector simultaneously, radiographic source, workpiece sight alignment.
Carry out in the step (2) with the next item down or multinomial detection: utilize of the measurement of the surveyors' staff of DR ray detection image the tubercular corrosion size; Change based on gray level, uniform corrosion test specimen wall thickness is measured; Use the line profile instrument to carry out the mensuration of corrosion depth; The built-in line profile function of using system is carried out wall thickness measuring; The weld defect degree of depth such as, undercut lack of penetration based on the gray level measure of the change.
The x radiographic real-time imaging technology of step (2) comprises carries out detector coupling noise reduction and/or initial pictures is carried out the step of relief sculpture treatment radiographic source.
Said band heat preservation pressure pipeline is the refrigerant pressure pipeline.It for example is the ammonia refrigeration pressure pipeline.
Band heat preservation pressure pipeline provided by the invention is not shut down the complete examination method and is utilized infrared thermal imaging technique and x radiographic real-time imaging technology to solve to the detection of this type of pipeline welded joint with to the selective examination of pipeline residual thickness to measure, and the detection of welding joint comprises that Non-Destructive Testing and undercut, misalignment check.At present, the check difficult point of ammonia refrigeration pressure pipeline is to shut down in the prior art, and heat-insulation layer can't be removed, so the position of butt welded seam can't judge that directly carry out conventional X ray and detect, workload is very big.If wherein for liquefied ammonia etc. has the medium of absorption to ray, can't in time understand the quality of imaging after the detection, detection efficiency is very low.The invention enables above problem to be readily solved, check is met the demands, can increase work efficiency again.This technology is fit to detect various metal pipe materials, tube head, weldquality, crackle, pipe thickness measuring, corrosion imaging, undercut, misalignment etc., and has following characteristics:
(1) portable strong, both be fit to fixed test and also be suitable for on-the-spot the detection.
(2) without film, 2-5 forms images second, and detection case can be understood in the scene.
(3) highly sensitive.
(4) need not remove protective layer, detection efficiency is high.
(5) can carry out high-acruracy survey to defective.
Description of drawings
Fig. 1 is the detected image of the pipeline welded joint that adopts x radiographic real-time imaging technology and obtain;
Fig. 2 is a weld metal crack measurement image of utilizing the gray scale measuring method to obtain;
Fig. 3-1 carries out the image of pipe thickness measuring for adopting the dual energy exposure mode;
Fig. 3-2 carries out the image that pipe is calibrated for adopting the dual energy exposure mode;
Fig. 4 is a corrosive pipeline detected image of utilizing the gray scale measuring method to obtain;
Fig. 5-1 is the structural representation of the preceding pipe of processing;
Fig. 5-2 is the A-A cross-sectional view of the pipe shown in Fig. 5-1;
Fig. 5-3 is the structural representation after the pipe processing shown in Fig. 5-1;
Fig. 5-301, Fig. 5-302 and Fig. 5-303 be the cross-sectional view of B-B, C-C and the D-D direction of the pipe shown in the presentation graphs 5-3 respectively;
Fig. 5-3001 is the enlarged drawing of the position I of the pipe shown in Fig. 5-3;
Fig. 5-3002 is the enlarged drawing of the position II of Fig. 5-3001;
Fig. 5-3003 is the enlarged drawing of the position III of the pipe shown in Fig. 5-3;
Fig. 6, Fig. 7 are not adding under the keeping warm mode for the 89mm pipe, the ray detection picture under water-filling and two kinds of conditions of water-filling not in pipe;
Fig. 8, Fig. 9 are not adding under the keeping warm mode for the 159mm pipe, the ray detection picture under water-filling and two kinds of conditions of water-filling not in pipe;
The defective that Figure 10,11,12 is respectively diameter 38mm, 89mm, three pipes of 159mm detects image;
Figure 13 is that diameter is the image of pipeline usefulness comparison impulse source (XRS-3) inspection of 89mm;
Figure 14 is to be the image of the pipeline of 89mm with continuous source (XYD-225) inspection with the diameter;
Figure 15, Figure 16 are that the defective of 219mm, 273mm two tubes detects image for diameter under the situation of band insulation, band liquid;
Figure 17 is a tubercular corrosion diameter dimension survey sheet;
Figure 18 is for to carry out instrumentation plan based on gray level;
Figure 19 carries out survey sheet for changing based on gray level to the test specimen wall thickness;
Figure 20 a is the tubercular corrosion image;
Figure 20 b carries out the application drawing that the tubercular corrosion degree of depth is measured for using the line profile instrument;
Figure 21 line profile function is to the pipeline wall thickness survey sheet;
Figure 22 is to 89mm * the 5mm pipeline is lack of penetration depth survey figure based on the gray level variation measuring method;
Figure 23 is to 159mm * the 6mm pipeline is lack of penetration depth survey figure based on the gray level variation measuring method;
Figure 24 is to 219mm * the 6mm pipeline is lack of penetration depth survey figure based on the gray level variation measuring method;
Figure 25 is to 273mm * the 8mm pipeline is lack of penetration depth survey figure based on the gray level variation measuring method;
Figure 26 is the infrared thermal imaging figure of elbow to be detected;
Figure 27 is a Xin Pulao Food Co., Ltd liquefied ammonia pipeline X-ray detected image;
Figure 28 is an image after the relief sculpture treatment of seized position;
Figure 29 is the corrosion depth survey sheet;
Figure 30 is lack of penetration depth survey figure;
Figure 31 is an elbow pipeline outside drawing to be detected;
Figure 32 a is the lack of penetration situation outside drawing of seized elbow weld seam;
Figure 32 b is the lack of penetration situation detection of seized elbow weld seam figure;
Figure 33 a is the detected image that pipeline does not contain integument;
Figure 33 b is the detected image that pipeline contains integument;
Figure 34 a and Figure 34 b are respectively the detection figure of rubber and plastic foam and two kinds of cold insulation materials of polyurethane foam;
Figure 35 is that digital imaging plate is proofreaied and correct the detection comparison diagram of front and back to same workpiece.
Embodiment
Band heat preservation pressure pipeline provided by the invention is not shut down the complete examination method and specifically may further comprise the steps:
1 utilizes infrared thermal imaging technique to confirm the emphasis location of residual thickness selective examination.
Thermal infrared imager is that the infrared energy distribution pattern that utilizes infrared eye, optical imagery object lens and optical mechaical scanning system (advanced at present focal plane technology has then been saved the optical mechaical scanning system) to accept measured target is reflected in the photosensitive unit of infrared eye; Convert infrared energy to electric signal by detector, show Infrared Thermogram through TV screen or monitor through processing and amplifying, conversion or video standard signal.This thermography is corresponding with the heat distribution field of body surface; Thermal infrared imager can generate infrared image or heat radiation image, and accurate contact-free measurement of temperature function can be provided.Nearly all thermal infrared imager can possess the digitized image memory function.At any time, can through install on computers infrared analysis software on the heat picture of the demarcation that generated separately picture element carry out thermometric.
With the liquefied ammonia pipeline is example: in general, liquefied ammonia does not have corrosion to tube metal.If cause race cold but layer breakage of pipeline cold insulation or construction quality are bad, will cause thermofin to freeze or the steam infiltration, pipeline outer wall is caused heavy corrosion.The difference of the heat insulation quality of ammonia refrigeration pressure pipeline can form the temperature contrast on pipeline external thermal insulation surface; Through the detection of thermal infrared imager to the pipeline external surface temperature; Analysis temperature difference, the quality of judgement anticorrosive coat quality is lower to temperature; Be that insulation is removed at the second-rate position of anticorrosive coat, inspection corrosive pipeline situation is the preferred plan of pipeline outward appearance selective examination.
2 utilize x radiographic real-time imaging technology that the welding joint and the residual thickness of band utilidor are detected.
Adopt the digital transmissive detection system that the pipeline residual thickness that reaches of pipeline welded joint is detected.X radiographic real-time imaging technology is to be converted into light signal through the X ray rays such as (energy are significantly less than ray used in everyday) that the scintillator on imaging plate surface will be more weak; Amorphous silicon layer is converted into electric signal with light signal, and electric signal detects picture through handling to generate in real time then.
Adopt x real-time radiography inspection method to implement following the detection to pipeline:
(1) to the detection of pipeline welded joint.Fig. 1 is the detected image of the pipeline welded joint that adopts x radiographic real-time imaging technology and obtain.
(2) weld metal crack is measured: utilize the gray scale measuring method, can the butt welded seam defective measure, MEASURING QUASI, precision height.Fig. 2 is a weld metal crack measurement image of utilizing the gray scale measuring method to obtain.
(3) the pipe thickness measuring, calibrate: adopt the dual energy exposure mode, be convenient to measure caliber, wall thickness and pipeline protection layer thickness.Fig. 3-1 carries out the image of pipe thickness measuring for adopting the dual energy exposure mode, and Fig. 3-2 carries out the image that pipe is calibrated for adopting the dual energy exposure mode.
(4) corrosive pipeline detects: utilize the gray scale measuring method, can detect the corrosive pipeline situation.Fig. 4 is a corrosive pipeline detected image of utilizing the gray scale measuring method to obtain.
Further illustrate below.
1 is the testing program that example is implemented the x real-time radiography inspection with the ammonia refrigeration pressure pipeline
In order to realize accurate measurement, find the degree of depth, uniform corrosion and the tubercular corrosion degree of depth situation of Flaw Image among the X ray real time imagery figure and the corresponding relation that blackness changes accurately to defective; Find out the ratio relation that liquefied ammonia thickness in the x ray detection is equivalent to steel plate thickness, for not ammonia excretion pressure pipeline being carried out choosing of x ray detection parameter provides foundation.The special standard specimen of doing known defect carries out the test of X ray Real-time Imaging.
1.1 the preparation of defective test specimen
(1) choose No. 20 steel seamless steel tubes of five long 300mm, specification is respectively
(2) with the machine work of pipe inside and outside wall, process following specification pipe, require the level and smooth zero defect of inwall, wall thickness accurate:
(3) make the groove of wide 2.0mm apart from every pipe end 200mm place inwall hoop, the pipe groove depth of
and
is that the pipe groove depth of 0.5mm,
and
is that the pipe groove depth of 1.0mm,
is 1.5mm.
(4) on the every long end of pipe 100mm is paralleling to the axis, bore three rounds, hole depth is respectively 0.5mm, 1.0mm, 1.5mm, 2.0mm, and the aperture is 2mm, 3mm, 4mm, and the hole is column, every round center distance 10mm entad.
(5) the 200mm end with the pipe shown in Fig. 5-1 and Fig. 5-2 is processed into the appearance shown in Fig. 5-3, Fig. 5-301, Fig. 5-302, Fig. 5-303, Fig. 5-3001, Fig. 5-3002 and Fig. 5-3003:
The degree of depth is respectively 0.5mm, 1.0mm, 1.5mm, 2.0mm, each degree of depth segment length 20mm, rounding off transition segment length 20mm between section and the section, transition arc radius 200.25mm.Fig. 5-1 is the structural representation of the preceding pipe of processing; Fig. 5-2 is the A-A cross-sectional view of the pipe shown in Fig. 5-1; Fig. 5-3 is the structural representation after the pipe processing shown in Fig. 5-1; Fig. 5-301, Fig. 5-302 and Fig. 5-303 be the cross-sectional view of B-B, C-C and the D-D direction of the pipe shown in the presentation graphs 5-3 respectively;
Fig. 5-3001 is the enlarged drawing of the position I of the pipe shown in Fig. 5-3; Fig. 5-3002 is the enlarged drawing of the position II of Fig. 5-3001;
Fig. 5-3003 is the enlarged drawing of the position III of the pipe shown in Fig. 5-3.
1.2 experiment content
(1) influence of intraluminal fluid ammonia to detecting during X ray detects.
Because liquefied ammonia has penetrating odor, test is inconvenient.The density of water and the density of liquefied ammonia are about the same, and is fool proof again, utilizes water to replace ammoniacal liquor to make an experiment.Be filled with water with plastic foil and pack in the test specimen, be full of the operating mode of liquefied ammonia in the simulation pipeline.To diameter be 89mm, 159mm pipeline respectively with liquid with do not detect with the X ray of liquid, and record relevant parameter.The influence of liquefied ammonia to detecting in the analyzer tube.
(2) the known defect test specimen is carried out the X ray digital imagery and detect test.
For diameter is that 38mm, 89mm, every test specimen of three test specimens of 159mm are with the cold insulation layer respectively, are not with the cold insulation layer, and the X ray digital imagery of full liquid, aneroid detects.To 219mm, two kinds of pipeline test specimens of 273mm respectively with the cold insulation layer, not with the detection of cold insulation layer.Piping jacket is the 1mm aluminium sheet, and the cold insulation layer is divided into two kinds: a kind of is three layers of thick rubber and plastic foam of 3cm, and a kind of is the thick polyurethane of 5cm watt shell.Analyze of the influence of these two kinds of cold insulation layers to detecting.Utilize device software that defective is measured, use the validity of the ability that detects of known defect being estimated this kind method.
1.3X the test findings that ray digital imaging detects
1.3.1X intraluminal fluid ammonia is to the test findings of the influence of detection in the ray detection
To diameter is that the pipe of 89mm, 159mm has carried out band liquid respectively and not with the x ray detection of liquid, and the record relevant parameter, and concrete parameter is seen table 1:
Table 1 is with liquid, is not with liquid test specimen X ray detected parameters contrast table
Fig. 6, Fig. 7 are not adding under the keeping warm mode for the 89mm pipe, the ray detection picture under water-filling and two kinds of conditions of water-filling not in pipe.Fig. 6 is the not situation of water-filling of 89mm pipe, and Lower Half can recognize the picture element silk at most No. 14 for first half image local amplifies back embossment images displayed; Fig. 7 is the situation of 89mm pipe water-filling, and Lower Half is that the first half amplifies back embossment images displayed, can only observe o.11 picture element silk.
Fig. 8, Fig. 9 are not adding under the keeping warm mode for the 159mm pipe, the ray detection picture under water-filling and two kinds of conditions of water-filling not in pipe.Fig. 8 is the not situation of water-filling of 159mm pipe, and Lower Half is amplified back embossment images displayed for first half image local, can clearly see the picture element silk No. 12, and No. 13 silk is comparatively fuzzy; Fig. 9 is the situation of 159mm pipe water-filling, and Lower Half is that the first half amplifies back embossment images displayed, because water layer is thicker, can't observe the picture element silk more greatly to ray scattering.
Can find out through above two picture group pictures, in pipe during water-filling, need to increase radiogenic tube voltage or increase time shutter to obtain suitable detected image, when pipeline contains liquid medium, mainly can produce the influence of two aspects:
(1) liquid medium can produce certain attenuation to ray, and the liquid medium of general ray standard with respect to the attenuation coefficient ratio of carbon steel is:
Water: about 9: 1 gasoline: about 6: 1 heavy oil: about 4: 1
The molecular weight of liquefied ammonia and attenuation coefficient all approach water, can be used in the experiment parameter that water is cooked in the actual detected.
(2) liquid medium also can produce certain scattering process to ray, influences the sharpness of final detected image.
The pipeline of 89mm * 5mm is behind water-filling, owing to increase the water layer thickness of 79mm, ray tube voltage rises to 180KV than water-filling state 160KV down not, tube voltage increase 20KV;
The pipeline of 159mm * 6mm is behind water-filling, owing to increase the water layer thickness of 147mm, ray tube voltage rises to 200KV than water-filling state 135KV down not, tube voltage increase 65KV;
Can find that through the contrast of top picture quality and detected parameters the tube voltage value that when detecting the pipeline of water-filling, needs is higher, the quality of water-filled pipe detected image has obvious decline, and outer diameter tube is big more, image quality decrease will be obvious more.Different along with tube voltage and water layer thickness when simultaneously ray penetrates water layer, penetration capacity is difference also, and water layer is a nonlinear relationship to the decay of ray energy, in practical application, need accumulate the detection experience through testing, and instructs daily detection.
For 159mm external diameter pipeline, when its inner full of liquid medium,, can improve from the following aspects as wanting to improve the picture element index:
(1) can adopt the x-ray source of littler focus;
Focal length when (2) increasing detection improves tube voltage simultaneously;
Increase the digital averaging quantity of imaging when (3) detecting.
Pipeline for 108mm and 133mm external diameter; When its inner full of liquid medium; When detecting, recommend to use little focus radiographic source to detect; Should increase imaging digital averaging quantity simultaneously,, still can guarantee on the digital radial image, to recognize ride on Bus No. 11 picture element silk even like this under the topping up state.
1.3.2 diameter is to 38mm, 89mm, three pipe fault detections of 159mm situation under the situation of band insulation, band liquid.
Under the situation of band insulation, band liquid, be that 38mm, 89mm, three pipe defectives of 159mm examine to diameter, parameter is seen table 2.
The insulation of table 2 band, band liquid test specimen X ray detected parameters record sheet
The defective that Figure 10,11,12 is respectively diameter 38mm, 89mm, three pipes of 159mm detects image.Can find out from Figure 10, Figure 11, Figure 12 under the situation of band insulation, band liquid that diameter is that 38mm, 89mm, three pipe defectives of 159mm can detect, and all can see the class corrosion type and the lack of penetration type defective of test specimen processing in three width of cloth images., do not use in 38mm external diameter pipeline stereotype to carry out the scattering shielding when being detected; Sharpness when its imaging effect will be lower than 89mm and 159mm and has the stereotype shielding, so when practical application DR detects, some portable stereotypes of recommendation making; Be used for shielding scattered ray, the Enhanced Imaging effect.
During in addition to 38mm external diameter and 89mm external diameter pipe detection; Can also use the pulsed radiographic source to detect; Even water-filling in the pipeline uses the pulsed radiographic source still can keep enough effects that penetrates, when detecting at the scene, impulse source mainly possesses following advantage:
(1) x radiation x dosage is little, just can realize distance protection for three meters behind.
(2) volume is little, and is in light weight, and containing battery weight only has 5 kilograms, can penetrate less than the thick steel plate of 20mm (behind 89mm * 5mm pipeline water-filling, the thickness that its inner water layer is amounted to into steel is about 7mm).
(3) it is battery-operated to cooperate the DR system to use, in continuous working under the situation that does not connect alternating current more than 3 hours.
(4) can use the DR system that it is carried out synchro control, the radiographic source opening and closing all can realize operation on the notebook computer of DR system.
Figure 13, Figure 14 are to be that the pipeline of 89mm is an example with the diameter, the actual detected effect of impulse source (XRS-3) and continuous source (XYD-225) relatively, and detected parameters is seen table 3:
Table 3 impulse source and continuous source are to same test specimen X ray detected parameters record sheet
Remarks: 6.53 seconds time shutter are amounted in impulse source 99 pulses, amount to tube voltage 270KV, no tube current parameter.
Figure 13 be diameter be the pipeline of 89mm with the image of impulse source (XRS-3) inspection relatively, amplify the back embossment and show, can recognize the picture element silk at most No. 13; Figure 14 is to be the image of the pipeline of 89mm with continuous source (XYD-225) inspection with the diameter, amplifies the back embossment and shows, can recognize the picture element silk at most No. 14.
Can find out that through top contrast it is fully feasible when detecting the pipeline of the following specification of 89mm * 5mm, using impulse source; But note that in detection the radiogenic energy field of pulsed distributes littler than continuous source, so when work, to align detection to radiographic source and workpiece; Should guarantee detector simultaneously; Radiographic source, the workpiece sight alignment can obtain desirable DR ray detection picture like this in detection.
1.3.3 band is incubated, is not with liquid test specimen fault detection situation.
In band insulation, not to be with under the liquid situation diameter be that 219mm, two kinds of pipe defectives of 273mm are tested.Figure 15, Figure 16 are that the defective of 219mm, 273mm two tubes detects image for diameter under the situation of band insulation, band liquid.Can find out that from Figure 15, Figure 16 diameter is that 219mm, 273mm two tubes defective can detect under the situation of being with insulation, band liquid, in two width of cloth images, all can see the class corrosion type and the lack of penetration type defective of test specimen processing.Detected parameters is seen table 4:
Table 4 diameter is 219mm, two kinds of pipe X ray of 273mm detected parameters record sheet
1.3.4 utilizing the surveyors' staff of DR ray detection image measures flaw size in the image
Utilize DR ray detection software that the flaw size in the image is measured, can measure the degree of depth of test specimen uniform corrosion, diameter and the degree of depth, the lack of penetration degree of depth, caliber, the wall thickness of tubercular corrosion from the measurement result Survey Software.The physical size of measured value and test specimen and defective is roughly suitable.For the accurate measurement of test specimen defective is to continue the problem studied from now on.
(1) surveyors' staff that utilizes DR ray detection image utilizes the surveyors' staff of DR ray detection image that the size of tubercular corrosion is measured to the measurement of tubercular corrosion size, and is shown in figure 17.
Utilize the surveyors' staff function on the DR software can carry out the flaw size measurement fast.Measurement can use scale directly to measure, also can using system software in subsidiary line profile function, Figure 18 is seen in measurement based on gray level.The physical size in aperture is respectively 2mm on the test specimen, 3mm and 4mm.Use survey instrument to measure the aperture and be of a size of 2.03mm as 2mm, the aperture is that the hole actual measurement of 3mm is of a size of 2.99mm, and the aperture is that the aperture actual measurement of 4mm is of a size of 3.65mm.Based on the line profile survey instrument of gray level, be fit to measure the size of tiny defect.
(2) change based on gray level, the test specimen wall thickness is measured
A kind thickness of pipe variation is watched in variation based on gray level, detects employed appearance pipe specifically and on wall thickness, has variation, in actual detected, can use gray level measurement curve to watch these variations, and is shown in figure 19.
Can significantly see the variation of three ladders on the gray level change curve in Figure 19, this grey scale change trend just in time matches with appearance thickness of pipe stepped change trend, utilizes grey scale change just can record the wall thickness value of each point.
(3) use the line profile instrument to carry out the mensuration of corrosion depth
Use the line profile instrument to carry out the tubercular corrosion degree of depth and measure, like Figure 20 a and Figure 20 b.Figure 20 a is the tubercular corrosion image; Figure 20 b carries out the application drawing that the tubercular corrosion degree of depth is measured for using the line profile instrument.
As want to measure the residual wall thickness after the assigned address corrosion; Can use the line profile function; Check the grey scale curve situation of change of specifying on the straight line; Under the online profiled interface, the position of mouse-pointing generation wall thickness change, the position below the online profile window will demonstrate the residual wall thickness number percent of hot spot.
(4) the built-in line profile function of using system is carried out wall thickness measuring.
The built-in line profile function of using system can be measured pipeline wall thickness, sees Figure 21.
(5) based on the lack of penetration degree of depth of gray level measure of the change
Use the measuring method that changes based on gray level that the lack of penetration degree of depth is measured.
1) Figure 22 is seen in 89mm * lack of penetration depth survey of 5mm pipeline.
Show that on the gray level curve residual wall thickness number percent is 91%, the promptly lack of penetration degree of depth is about 5mm * (1-91%)=0.45mm.
2) Figure 23 is seen in 159mm * lack of penetration depth survey of 6mm pipeline.
Show that on the gray level curve residual wall thickness number percent is 84%, the promptly lack of penetration degree of depth is about 6mm * (1-84%)=0.96mm.
3) Figure 24 is seen in 219mm * lack of penetration depth survey of 6mm pipeline.
Show that on the gray level curve residual wall thickness number percent is 84%, the promptly lack of penetration degree of depth is about 6mm * (1-86%)=0.84mm.
4) Figure 25 is seen in 273mm * lack of penetration depth survey of 8mm pipeline.
Show that on the gray level curve residual wall thickness number percent is 83%, the promptly lack of penetration degree of depth is about 8mm * (1-83%)=1.36mm.
2 ammonia refrigeration pressure pipelines are not shut down the checking of complete examination method feasibility
In order to verify that the ammonia refrigeration pressure pipeline do not shut down the feasibility of complete examination method, we have implemented the detection of not tearing insulation open, not arranging medium to the liquefied ammonia pipeline of Beijing Xin Pulao Food Co., Ltd.
(1) detects choosing of position
This detected object is the pipeline of liquefied ammonia for band insulation, medium.Detecting choosing of position is that process and applying unit are consulted, and in conjunction with the pipeline improvement project, confirms sensing range in advance.After the detection, when the pipeline modification engineering construction, carry out the pipe cutting contrast verification to detecting the position.
(2) do not tear open insulation, do not arrange the detection of medium to the ammonia refrigeration pressure pipeline
We have carried out the infrared thermal imaging detection to pipeline by the sensing range pipeline, confirmed one run cold specification be 38mm * 3mm bend part as detected object, see Figure 26.Can find out that from picture this elbow external protection local temperature and environment temperature differ about 20 ℃, exist and run cold phenomenon.
After the detection position is confirmed, elbow corrosion situation and weld seam situation are detected, see Figure 27 with Israel's Portable X-ray digital imaging detection system.
As can be seen from Figure 27, having under the situation of heat-insulation layer, can clearly see corrosion type defective and lack of penetration, the misalignment defective in the weld seam on the pipeline.On the basis of this figure, carry out relief sculpture treatment, can find out the picture element index of defect situation and image intuitively, see Figure 28.
Can be clearly seen that hoop incomplete penetration defect and misalignment the weld seam from the embossment display image, image can recognize the picture element silk the ten No. three, has satisfied the detection demand fully.On the basis of this figure, can carry out the measurement of the pitch corrosion and the lack of penetration degree of depth of hoop, see Figure 29, Figure 30.
Measurement to specified point corrosion shown in Figure 29 can be clearly seen that on the gray level curve corrosion residual wall thickness number percent is 74%.
Utilize the gray level curve that the lack of penetration degree of depth is measured, measuring demonstration commissure, seized position residual wall thickness is 90%, and the promptly lack of penetration degree of depth is 10% of a throat depth.
(3) inspection of the elbow behind pipe cutting situation
In the pipeline modification engineering, elbow to be detected is taken a sample, the pipeline outward appearance is seen Figure 31.
Can find out that from Figure 31 there is tubercular corrosion in the pipeline outside, there is the misalignment phenomenon in weld seam.The seized position of erosion profile and Figure 23 relief sculpture treatment image basically identical.
Seized pipeline is cutd open pipe, carried out the lack of penetration situation inspection of pipe welding seam, see Figure 32 a and 32b, Figure 32 a is the lack of penetration situation outside drawing of seized elbow weld seam; Figure 32 b is the lack of penetration situation detection of seized elbow weld seam figure.Seized elbow weld seam exists lack of penetration and the misalignment situation.The about 1mm of section position unfitness of butt joint, lack of penetration about 1mm.
(4) the ammonia refrigeration pressure pipeline is not shut down the conclusion that completely examines method validation
Through adopting the ammonia refrigeration pressure pipeline not shut down the complete examination method Beijing Xin Pulao Food Co., Ltd ammonia refrigeration pressure pipeline is detected, and the pipe cutting sampling compares checking, can draw to draw a conclusion:
X ray digital imagery testing result with remove the pipe insulation macro check, cut open pipe check result basically identical.Prove through contrast verification, adopt this kind method that the ammonia refrigeration pressure pipeline is implemented not shut down complete examination, can find the major defect of pipeline fast and accurately, can also use software to carry out defectoscopy and evaluation work based on PC.With respect to the conventional sense method, this method has economy, characteristics of high efficiency.The complete examination of not shutting down that this technology is applied to the liquefied ammonia pressure pipeline is very feasible.
3 pairs of ammonia refrigeration pressure pipelines are implemented the X ray digital imagery and are detected some problem that notes
3.1 the influence that pipeline cold insulation layer and different cold insulation material detect the ammonia refrigeration pressure pipeline
(1) when pipeline contains the outerwrap layer, influence below integument can produce final DR ray image:
1) integument can produce certain scattering process to ray, influences the sharpness of final image, but integument will be lower than the scattering process of the interior liquid medium of pipeline to ray widely to the scattering process of ray.
Image quality indicator can only be attached on the pipeline outerwrap layer when 2) detecting, and image quality indicator meeting enlarged and displayed influences the measurement effect of image quality indicator to picture quality on detected image.
Figure 33 a and Figure 33 b have shown the contrast that does not contain and contain two kinds of situation of integument at pipeline.
Figure 33 a has shown that pipeline does not contain the detected image of integument, amplifies the back embossment and shows that can clearly see the picture element silk No. 12, No. 13 silk is comparatively fuzzy.Figure 33 b has shown that pipeline contains the detected image of integument, amplifies the back embossment and shows that can clearly see the picture element silk No. 11, No. 12 silk is comparatively fuzzy.
Can find out that the final ray detection picture noise of band cold insulation layer pipeline is than with the figure image height of heat-insulation layer, the ray image of picture element index than time, the picture element silk that can discern number low grade not with the cold insulation layer.But the cold insulation layer is for the liquid medium of pipe interior; Picture element decay to ray image is less; And heat-insulation layer is undamped basically to ray energy, in the time of promptly in actual detected, can using and not be with the cold insulation layer to detect, and detected parameters such as identical tube voltage and tube current.
(2) influence that detects for DR of the cold insulation layer of unlike material:
The cold insulation layer of liquefied ammonia pressure pipeline mainly contains two kinds at present: be respectively rubber and plastic foam and polyurethane material.This problem test material is three layers of thick rubber and plastic foam of 3cm and the thick polyurethane of 5cm watt shell.Figure 34 a and 34b are the testing result under two kinds of heat-insulation layers.
Figure 34 a and Figure 34 b are respectively the detection figure of rubber and plastic foam and two kinds of cold insulation materials of polyurethane foam; The rubber and plastic foamed material that Figure 34 a shows detects figure amplification back embossment and shows; Can clearly see the picture element silk No. 13; Blur and see silk No. 14, embossment showed after the polyurethane foam material that Figure 34 b shows detected the figure amplification, can clearly see the picture element silk No. 13.
This shows two kinds of used in test heat-insulation layers, for final detection result, certain influence is arranged, but impact effect is little, in liquefied ammonia pipeline actual detected in the future, the factor of heat-insulation layer material is can it goes without doing too many to be considered.
3.2 the digital detector noise adopts the digital detector images acquired to this problem experimental facilities that influences of testing result, radiographic source is selected two kinds of portable impulse source and continuous sources for use.When using the radiographic source of different size; It is different that radiogenic energy field distributes; This will cause each pixel array element of DR digital detector that there is certain difference in the sensitization degree of X-ray in the energy field; Just may cause the detected image noise to increase, occur the obviously not equal phenomenon of gray scale on the digital radial image that is reflected to, be very important so carry out the work of detector noise reduction to specific radiographic source.Can adjust to unanimity or approaching level to each pixel array element to the light sensitivity of X-ray photon in the radiographic source energy field through noise reduction, can reduce the detector noise, improve image quality.The detection comparison diagram that is the noise reduction front and back to same workpiece shown in Figure 35.Shown in Figure 35, the left side is that detector has passed through average noise reduction 20 times, and the noise reduction average time is many more, can reduce the noise immediately of detector array element more, and the imaging plate on right side does not pass through any noise reduction.
The picture noise that detector obtained through behind the noise reduction is starkly lower than the detector without noise reduction; So in real work; Should at first choose the radiographic source of specifying specification, and carry out detector coupling noise reduction, to obtain more excellent DR radial imaging quality to the radiographic source of this model.
3.3 about choosing of filter band
When using the continous way radiographic source to carry out the DR detection; Because the ray energy that radiographic source sends is inhomogeneous, will produce a large amount of soft raies, these soft raies detect for DR will cause very large influence; So in detection, need to use the filter band of appointment to filter the soft ray that sends in the radiographic source; Improve and detect quality, for the selection of filter band, European E2597-07E1 has made specified in more detail; Using the continous way radiographic source to carry out can choosing filter band with reference to the content of this standard when DR detects, the part of E2597-07E1 is stipulated as follows:
5.3Filters for Measuring Efficiency of the DDA-The following filter thicknesses (5.3.1-5.3.7) and alloys (5.3.8) shall be used to obtain different radiation beam qualities and are to be placed at the output of the beam.The tolerance for these thicknesses shall be ± 1mm (± 0.004in.) (filter band is to the influence of DDA flat panel detector image quality---choosing of filter band please with reference to the regulation among the following 5.3.1-5.3.7; As use the alloy filter band; Please strictly observe the 5.3.8 concrete regulation carries out filter band and chooses; Obtain the preferable image quality in the time of can guaranteeing to detect like this, filter band generally is close to is placed on radiographic source launch window front.)
5.3.1No external filter (50kV). (not needing filter band below the 50KV);
5.3.230mm (1.2in.) Al (90kV). (can select the thick aluminium sheet of 30mm during 90KV) as filter band;
5.3.340mm (1.6in.) Al (120kV). (selecting the thick aluminium sheet of 40mm during 120KV) as filter band;
5.3.43mm (0.12in.) Cu (120kV). (also can select the thick copper coin of 3mm during 120KV) as filter band;
5.3.510mm (0.4in.) Fe (160kV). (can select the thick iron plate of 10mm during 160KV as filter band 0;
5.3.68mm (0.3in.) Cu (220kV). (can select the thick copper coin of 8mm during 220KV) as filter band;
5.3.716mm (0.6in.) Cu (420kV). (can select the thick copper coin of 16mm during 420KV) as filter band;
5.3.8The (filter band generally is close to is placed on radiographic source launch window place to filters shall be placed directly at the tube window.The aluminum filter shall be composed of Aluminum 6061.The Copper shall be composed of99.9%purity or better.The Iron filter shall be composed of Stainless steel 304.; When using aluminium sheet as filter band, should adopt label is 6061 aluminium sheet; When using copper coin, should adopt purity at the copper coin more than 99.9% as filter band; When using steel plate as filter band, should adopt label is 304 steel plate.)
According to the regulation of above standard content, combining concrete detection case, the filter band that should select copper coin and steel plate to detect as DR, the concrete thickness of filter band will be selected according to ray tube voltage.
Claims (10)
1. band heat preservation pressure pipeline is not shut down the complete examination method, it is characterized in that, may further comprise the steps:
(1) utilize that infrared thermal imaging technique confirms that band heat preservation pressure corrosive pipeline detects the emphasis location;
(2) utilize x radiographic real-time imaging technology that the position that need detect is detected.
2. band heat preservation pressure pipeline according to claim 1 is not shut down the complete examination method; It is characterized in that; The concrete operation method of step (1) is: utilize thermal infrared imager that the infrared energy distribution pattern of measured target is reflected in the photosensitive unit of infrared eye, convert infrared energy to electric signal by detector, show Infrared Thermogram through processing and amplifying, conversion or video standard signal through TV screen or monitor; This thermography is corresponding with the heat distribution field of body surface; The heat distribution field is relevant with the insulation quality of band heat preservation pressure pipeline, utilizes this association, through analyzing the emphasis location that thermography confirms that corrosion detects.
3. band heat preservation pressure pipeline according to claim 1 is not shut down the complete examination method; It is characterized in that; The detection that detects in the step (2) be selected from pipeline welded joint detection, weld metal crack depth survey, pipe thickness measuring, calibrate, corrosive pipeline depth detection and misalignment in detecting one or multinomial; Wherein, weld metal crack depth survey and corrosive pipeline depth detection are utilized the gray scale measuring method; The pipe thickness measuring, calibrate to detect with Survey Software and detect with misalignment, wherein the pipe thickness measuring, calibrate and adopt the dual energy exposure mode.
4. band heat preservation pressure pipeline according to claim 1 is not shut down the complete examination method, it is characterized in that, the detection focal length in the step (2) is greater than 500mm, and tube voltage is greater than 100kv.
5. band heat preservation pressure pipeline according to claim 1 is not shut down the complete examination method; It is characterized in that; Step (2) utilizes the continuous x ray source to detect, and utilizes filter band to filter the soft ray that sends in the radiographic source, and the selection of filter band is with reference to the regulation of European E2597-07E1.
6. band heat preservation pressure pipeline according to claim 1 is not shut down the complete examination method, it is characterized in that, step (2) utilizes the pulsed radiographic source to detect, and aligns detection to radiographic source and workpiece, guarantees detector simultaneously, radiographic source, workpiece sight alignment.
7. band heat preservation pressure pipeline according to claim 1 is not shut down the complete examination method, it is characterized in that, carries out in the step (2) with the next item down or multinomial detection: utilize the measurement of the surveyors' staff of DR ray detection image to the tubercular corrosion size; Change based on gray level, uniform corrosion test specimen wall thickness is measured; Use the line profile instrument to carry out the mensuration of corrosion depth; The built-in line profile function of using system is carried out wall thickness measuring; , the undercut degree of depth lack of penetration based on the gray level measure of the change.
8. band heat preservation pressure pipeline according to claim 1 is not shut down the complete examination method, it is characterized in that, the x radiographic real-time imaging technology of step (2) comprises carries out detector coupling noise reduction and/or initial pictures carried out the step of relief sculpture treatment radiographic source.
9. do not shut down the complete examination method according to each described band heat preservation pressure pipeline of claim 1-8, it is characterized in that said band heat preservation pressure pipeline is the refrigerant pressure pipeline.
10. band heat preservation pressure pipeline according to claim 9 is not shut down the complete examination method, it is characterized in that, said refrigerant pressure pipeline is the ammonia refrigeration pressure pipeline.
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