CN109425656B - Ultrasonic flaw detection method for identifying bead clamping defects of submerged-arc welded pipe - Google Patents
Ultrasonic flaw detection method for identifying bead clamping defects of submerged-arc welded pipe Download PDFInfo
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Abstract
The invention discloses an ultrasonic flaw detection method for identifying a bead clamping defect of a submerged-arc welding pipe, which is characterized in that metallographic dissection is carried out on a bead clamping defect and a pore defect in a welding seam found in the actual inspection process of a production field, the appearance and the characteristics of the bead clamping defect and the pore defect are known, then preliminary confirmation is carried out by aiming at the waveform and the position of a reflected wave at the welding toe of the submerged-arc welding and the relative position of a probe and the defect on the basis of understanding of an ultrasonic flaw detection theory, and finally final confirmation is carried out by using a high-precision transverse wave probe. By adopting the invention, the judgment error can be avoided to the maximum extent, so that the partial degradation and the end cutting of the pipe are saved, the risk of the leakage of the defect of the clamped bead is avoided, and a large amount of pipe materials which need to be degraded originally are saved.
Description
Technical Field
The invention relates to a transverse wave water film method ultrasonic flaw detection technology, in particular to an ultrasonic flaw detection method for identifying a bead clamping defect of a submerged arc welding pipe.
Background
The longitudinal welded pipe factory is a production department specially responsible for producing large-diameter longitudinal submerged arc welded pipes. The energy source has been supplied for large energy engineering projects at home and abroad, such as West-east gas transmission three-line, QGC (Kunstland, Australia), TANAP (Turkey) and the like. The conveying medium is mainly natural gas, and the conveying pressure is high, so that the product has the characteristic of high risk. The most common spherical volume defects in different specifications of UOE welded pipes are air holes and clamping beads. The bead clamping is caused by the fact that air holes and beads are generated at the bottom of a molten pool during inner welding to form air hole covered welding slag, the quality of the air holes containing the welding slag is larger than that of pure air holes, and the welding speed is high, so that the bead clamping type air holes formed near the bottom of the inner welding molten pool are difficult to float upwards and escape, and the air holes are formed in the inner welding process at the position close to an inner welding heat bias influence area through carbon arc gouging processing analysis. The shape of the natural gas pipeline is spherical and semicircular, small cracks are easy to generate under the stress of diameter expansion and water pressure in many cases due to the inclusion of the clamping beads, and the common air hole defects generally cannot generate crack-like linear defects under the stress condition, so that the clamping bead defects are not allowed to exist on the pipeline for conveying the natural gas, and whether the air holes can be released is evaluated according to the diameter and the number of points, if the air holes in the standard range are evaluated as clamping beads, unnecessary waste is caused, and if the clamping bead defects are originally evaluated as the air holes in the standard range, serious quality risks are caused. Therefore, it is necessary to distinguish the two. Because the positions of the two are close to each other, the shape of the X-ray flat plate DR is spherical, so that field flaw detection personnel can hardly distinguish whether the shape defect in the welding seam is welding seam clamping beads or air holes.
At present, the discrimination of the clamping bead and the air hole in the welding seam at home and abroad is generally distinguished by images on an X-ray industrial digital imaging system. Because welding seam clamping beads, air holes and the like belong to volume type defects, and certain thickness difference exists between the welding seam clamping beads, the welding seam clamping beads and the air holes without defects, the air holes and the clamping bead type volume defects can be found through ray transillumination, at the moment, the clamping beads are usually found on a ray imaging plate (DR) through the clamping beads, the phenomenon that a black shadow exists in a circular defect is considered to be the clamping beads, the air holes are generally circular on the image, and no black shadow exists in the circular shape. The limitations of the above methods are that the beads in many weld beads are very small and appear very little or essentially invisible on the radiographic image, especially when the nominal thickness of the parent material is above 22mm and the beads in the beads are small, which is difficult to detect on the ray DR. Meanwhile, the defect that an image of two small air holes at the same position and different depths, which is displayed on a DR ray flat plate when the ray irradiates, is similar to a bead is also existed, so that the weld seam air hole is easily mistaken for the bead, the judgment standards of the two are different, the bead defect is not allowed to exist on a pipeline for conveying natural gas, and the air hole is evaluated to be passable according to the diameter and the number of points, if the air hole in the standard range is evaluated to be the bead, unnecessary waste is caused, and the quality risk is caused if the original bead defect is evaluated to be the air hole in the standard range.
In conclusion, the existing radiographic inspection method cannot comprehensively and effectively determine the quality of welding seam clamping beads and welding seam air holes, is low in detection efficiency, and easily causes misjudgment of qualified pipe materials in batches, so that the quality of finished submerged arc welding pipes cannot be effectively guaranteed.
Disclosure of Invention
The invention aims to solve the defects, provides an ultrasonic flaw detection method for identifying the bead clamping defects of the submerged-arc welding pipe, and can quickly and accurately judge whether the spherical and semicircular defects are bead clamping defects or air hole defects, so that a large number of degraded pipes and cut pipes are saved, and the quality risk is strictly controlled.
In order to achieve the above object, the present invention adopts the following technical solutions.
An ultrasonic flaw detection method for identifying bead clamping defects of a submerged arc welded pipe comprises the following steps:
A. respectively detecting the weld joint by adopting transverse wave probes which are sequentially arranged on one side of the weld joint and at positions which are equidistant from the weld joint and spaced by 45 degrees, so as to preliminarily identify defects;
B. respectively detecting at two sides of the welding seam in sequence by adopting a transverse wave probe so as to identify the defects again;
C. and (4) placing a microchip high-precision transverse wave probe on the welding seam position of the bead clamping defect identified in the step B for 360-degree rotary detection to make final confirmation.
In step a, the preliminary defect identification includes:
when an echo exists in a welding seam when the position of one side of the welding seam is detected, namely the transverse wave is an obvious defect wave and 2-3 defect waves with lower wave amplitudes are attached to the front and the back of the welding seam, the detection results of the rest positions are the same, and only a certain difference exists in equivalent weight, the defect of the clamped bead can be preliminarily judged;
when the echo is found in the weld joint by detecting the position of one side of the weld joint, namely the echo is an obvious defect wave and no defect wave exists in the front and the back of the weld joint, the detection results of the other positions are the same, and the air hole defect can be preliminarily judged only by a certain difference in equivalent weight.
In step B, said re-identifying the defect comprises:
when one side of the welding seam detects that the inner welding seam has a near-side echo, namely a primary echo is a defect wave, and the other side detects that the far side also has a defect wave, but the amplitude is very low, and the defect waves are all 'mountain' -shaped echoes, the defect can be judged as a bead clamping defect again;
when one side of the welding seam detects that the inner welding seam has a near-side echo, namely a primary echo is a defect wave and is reflected obviously, and the other side detects that a far-side echo also has an obvious primary defect wave and the defect waves are single echoes, the defect of the air hole can be judged again.
In step B, said re-identifying the defect comprises:
when one side of the welding seam detects that the inner welding seam has a far-side echo, namely a secondary echo is a defect wave and is reflected obviously, and the other side detects that the near-side defect wave does not exist, and the defect waves are single echoes, the defect of the air hole can be judged again;
when one side of the welding seam detects that the inner welding seam has a near-side echo, namely a secondary echo is a defect wave, the reflection is obvious, and the other side detects that the far-side defect wave does not exist, and the defect waves are all 'mountain' -shaped echoes, the defect of the clamped bead can be judged again.
In the step B, the re-identified bead clamping defects are further identified by scanning with a transverse wave probe:
when the waveform is 2-3 reflected waves in a static state and is in a shape of a Chinese character 'shan', and the envelope curve of the echo is in a shape of a saddle in a dynamic state, the defect of the clamped bead can be further judged;
when the wave form is a single reflection wave under the static state, and the envelope curve of the echo is a smooth hill shape under the dynamic state, the defect of the air hole can be further judged.
In step C: the microchip of the microchip high-precision transverse wave probe is made of piezoelectric composite materials, the size of the microchip high-precision transverse wave probe is 3 x 8mm, the damping is 50 omega, the gain is 40dB, the effective detection width range is 6mm, and the detection center frequency is 17.45 MHZ.
In step C, the final confirmation is: when the rotating detection shows that the echoes are all in the shape of a Chinese character 'shan', the equivalent weight is basically the same, and the defect of the clamped bead is confirmed.
In the technical scheme of the invention, the ultrasonic flaw detection method for identifying the bead clamping defects of the submerged arc welding pipe is characterized in that metallographic dissection is carried out on the bead clamping and air hole defects in a welding seam found in the actual inspection process of a production field, the shapes and the characteristics of the bead clamping and the air hole defects are known, then preliminary confirmation is carried out on the waveform and the position of a reflected wave at the welding toe of the submerged arc welding and the relative positions of a probe and the defects on the basis of understanding of the ultrasonic flaw detection theory, and finally final confirmation is carried out by using a high-precision transverse wave probe. By adopting the invention, the judgment error can be avoided to the maximum extent, so that the partial degradation and the end cutting of the pipe are saved, the risk of the leakage of the defect of the clamped bead is avoided, and a large amount of pipe materials which need to be degraded originally are saved.
Drawings
FIG. 1 is a schematic view of the preliminary identified probe locations of the present invention;
FIG. 2 is a waveform diagram of the primary reflection echo obtained from the left and right detection air holes in step B of the present invention;
FIG. 3 is a waveform diagram of a primary reflection echo obtained by detecting a bead on the left and right sides in step B of the present invention;
FIG. 4 is a waveform diagram of the secondary reflection echo obtained from the left and right detection air holes in step B of the present invention;
FIG. 5 is a waveform diagram of the second reflection echo obtained by detecting the bead on the left and right sides in step B of the present invention;
FIGS. 6a and 6B are static and dynamic waveforms obtained by scanning a clamped bead in step B of the present invention, respectively;
fig. 7a, 7B are static and dynamic waveforms respectively obtained by scanning the air holes in step B of the present invention.
Detailed Description
The technical scheme of the invention is further explained by combining the attached drawings.
The ultrasonic flaw detection method for identifying the bead clamping defects of the submerged arc welded pipe specifically comprises the following steps of:
and step A, detecting the two sides of the welding seam at equal intervals by 45 degrees through the clamping beads, the air holes and other volume defects of the welding seam, and identifying according to different transverse wave reflection characteristics to distinguish the clamping beads, the air holes and other defects.
Specifically, as shown in fig. 1, a transverse wave probe 1 (the transverse wave probes 1 are all conventional transverse wave probes) is placed on one side of a welding seam 2 for detection, and if an echo is found in the welding seam 2, namely, 2-3 defect waves with lower wave amplitude are attached after 1 obvious defect wave front is found, and the reflection is obvious; the transverse wave probe 1 is clockwise separated by 45 degrees for oblique detection, 2-3 defect waves with lower wave amplitude are attached after 1 obvious defect wave front is found to be the same, the probe is clockwise moved by 45 degrees again, the probe rides on the welding seam 2 to detect the result, the result is uniformly moved for 8 times, the finally found defect waves are all the defect waves with the lower wave amplitude and attached after 1 obvious defect wave front, only certain difference exists in equivalent weight, and the defect of the clamped bead can be preliminarily judged;
if the transverse wave probe 1 is placed on one side of the welding seam 2, the echo is found in the welding seam 2, namely the echo is 1 obvious defect wave front without defect wave, and the reflection is obvious; and then the transverse wave probe 1 is obliquely detected at an interval of 45 degrees clockwise, the transverse wave is found to be 1 obvious defect wave front without a defect wave, the probe is moved clockwise by 45 degrees again, the probe rides on the welding seam 2 to detect the result, the probe is uniformly moved for 8 times, the finally found defect waves are all 1 obvious defect wave front without a defect wave, and only a certain difference exists in equivalent weight, so that the pore defect can be preliminarily judged.
Although the defects of the air holes and the clamped beads can be preliminarily distinguished through the step A, the quantity of slag inclusions in the defects of the clamped beads is small sometimes, so that although reflected waves of the clamped beads exist, the wave amplitude of the reflected waves is low and even the reflected waves are submerged in grass-shaped waves caused by noise, in another case, the defects of the clamped beads exist near the air holes, the characteristics of the reflected waves are also confused with the defects of the clamped beads, but the defects of the air holes, the clamped beads and other volume types can be clearly distinguished at the moment, but the following two steps are combined for comprehensive judgment in order to further confirm whether the clamped beads or the defects of the air holes.
And step B, respectively detecting the two sides of the welding seam 2 by adopting the transverse wave probe 1 in sequence so as to identify the defects of the air holes or the clamped beads again.
Specifically, there are four identification cases as follows: referring to fig. 2, a transverse wave probe 1 is placed on the left side, and if a near-side echo is found in a weld joint 2, namely a primary echo is a defect wave, the reflection is obvious; then the transverse wave probe 1 is placed on the right side, and if a far side is found, an obvious echo is also generated; the horizontal position is basically in the middle of the welding seam 2, the equivalent weight of the near side is generally higher than phi 1.6 vertical through holes by more than 6dB, all defect waves are single echoes, and the air holes in the welding seam 2 can be judged again at the moment;
referring to fig. 3, similarly, during left-side detection, if a near-side echo is found in the weld 2, that is, the primary wave is a notch; during right-side detection, a far side echo is also found, but the amplitude is very low; the horizontal position is generally 0-4 mm in the weld toe, the equivalent weight of the near side is generally higher than that of the phi 1.6 vertical through hole by 6dB, the far side is lower than that of the phi 1.6 vertical through hole by about 6dB, all defect waves are generally inverted-mountain-shaped echoes, the detected defect position is basically deviated to one side of the width direction of the weld joint 2, and the bead clamping defect in the weld joint 2 can be judged again at the moment.
Referring to fig. 4, during left-side detection, if a welding seam 2 is found to have a far-side echo, that is, a secondary wave is a defect wave, the reflection is obvious; when detecting on the right side, no obvious echo on the near side is found, namely no defect-free echo; the horizontal position is generally in the middle of the welding seam 2, the far-side equivalent is generally lower than phi 1.6 vertical through holes by about 0-2 dB, and the defect wave is a single echo, so that the defect of the air hole at the side of the welding seam 2 can be judged again.
Referring to fig. 5, similarly, during left-side detection, if a near-side echo is found in the weld 2, that is, a secondary wave is a notch; when detecting on the right side, no obvious secondary echo is found on the far side; the horizontal position is generally 0-4 mm in the weld toe, the equivalent weight of the near side is generally higher than phi 1.6 vertical through holes by 6dB, all defect waves are generally echo waves in a shape like a Chinese character 'shan', the detected defect position is basically deviated to one side of the width direction of the welding seam 2, and the bead clamping defect of the welding seam 2 can be judged again at the moment.
In addition, the re-determined defect of the clamped bead can be further identified through different static and dynamic waveforms of parent metal inclusion, welded bead clamping and air hole reflection echoes at the welding site:
referring to fig. 6a and 6b, the weld joint is first scanned by a transverse wave probe, and when a longitudinal defect is found, the waveform of the weld joint is 2-3 reflected waves in a static state and is in a shape of a Chinese character 'shan'. Meanwhile, the transverse wave probe is moved back and forth, and the envelope curve of the echo wave in dynamic movement is found to be saddle-shaped. This is because the beads contain other impurities and have different sound velocities, and therefore, 2 to 3 reflected waves having different amplitudes are statically reflected, and at this time, the beads can be further determined as the point-like beads at the edge of the weld seam. Referring to fig. 7a and 7b, during scanning, when a longitudinal defect is found, the waveform of the longitudinal defect is a single reflected wave in a static state, and meanwhile, the transverse wave probe is moved back and forth, the envelope curve of the echo wave in a dynamic movement is found to be a smooth 'hill' shape, and at this time, the longitudinal defect can be further determined as an air hole in the weld joint. The pores and beads can be basically distinguished after the step, but more refined detection is needed for final confirmation for the hundred percent of bead defects.
And C, placing a microchip high-precision transverse wave probe on the welding seam position of the bead clamping defect identified in the step B for 360-degree rotary detection for final confirmation.
Since the conventional transverse wave probe cannot find some small reflection echoes through field experiments, a microchip high-precision transverse wave probe is also needed, the transverse wave probe is designed for point-like bead clamping, and the parameters are as follows: damping 50 Ω, gain 40dB, wafer size 3 × 8mm, effective detection range 6mm wide. The center frequency of detection was 17.45 MHZ. The wafer is made of a piezoelectric composite material. Such small, punctiform beads can be detected because of the small wafer size, small near field length, high signal-to-noise ratio and resolution, high center frequency, and concentrated energy. However, if the efficiency of directly identifying the bead clamping defect of the welding seam is low, in the invention, the point bead clamping defect identified in the step B is finally confirmed, and when the 360-degree rotation detection shows that the point bead clamping defect has the Chinese character 'shan', the equivalent is basically the same, and the point bead clamping defect can be finally confirmed as the bead clamping defect.
In summary, the ultrasonic flaw detection method of the present invention has the following advantages:
1. the method is provided by integrating a large amount of practical experience and theoretical analysis, has high theoretical performance and accuracy, and is actually verified.
2. The situations that the defects of the edge of the welding seam cannot be determined qualitatively, the working efficiency is low and misjudgment is easy to occur are changed.
3. Through identification, a large amount of pipe materials which need to be degraded originally can be effectively saved, and if the method is used in the west-gas-east transportation project, 500 calculations are saved, and more than 550 ten thousand yuan can be saved for enterprises.
4. Is suitable for popularization, and solves the qualitative ability of the defects, thereby greatly reducing the related metallographic experiment.
It should be understood by those skilled in the art that the above embodiments are only for illustrating the present invention and are not to be used as a limitation of the present invention, and that changes and modifications to the above described embodiments are within the scope of the claims of the present invention as long as they are within the spirit and scope of the present invention.
Claims (6)
1. An ultrasonic flaw detection method for identifying a bead clamping defect of a submerged arc welded pipe is characterized by comprising the following steps of:
A. respectively detecting the weld joint by adopting transverse wave probes which are sequentially arranged on one side of the weld joint and at positions which are equidistant from the weld joint and spaced by 45 degrees, so as to preliminarily identify defects;
B. respectively detecting at two sides of the welding seam in sequence by adopting a transverse wave probe so as to identify the defects again;
C. placing a microchip high-precision transverse wave probe on the welding seam position of the bead clamping defect identified in the step B for 360-degree rotary detection for final confirmation,
in step a, the preliminary defect identification includes:
when an echo is found in a weld joint by detecting at one side of the weld joint, the echo is an obvious defect wave and is additionally provided with 2-3 defect waves with lower wave amplitudes in the front and the back, the detection results of the rest positions are the same, and only certain difference exists in equivalent weight, so that the defect of bead clamping can be preliminarily judged;
when the echo is found in the weld joint by detecting the position of one side of the weld joint, the echo is an obvious defect wave and no defect wave exists in the front and the back, the detection results of the rest positions are the same, and the air hole defect can be preliminarily judged only by a certain difference in equivalent weight.
2. The ultrasonic testing method for identifying bead defects in submerged arc welded pipes according to claim 1, wherein in step B, the re-identifying defects comprises:
when one side of the welding seam detects that the inner welding seam has a near-side echo, the first echo is a defect wave, and the other side detects that the far side also has a defect wave, but the amplitude is very low, and the defect waves are all 'mountain' -shaped echoes, the defect can be judged as a bead clamping defect again;
when one side of the welding seam detects that the inner welding seam has a near-side echo, the first echo is a defect wave which is obvious in reflection, and the other side detects that the far side also has an obvious first defect wave which is a single echo, the defect wave can be judged as the air hole defect again.
3. The ultrasonic testing method for identifying bead defects in submerged arc welded pipes according to claim 1, wherein in step B, the re-identifying defects comprises:
when one side of the welding seam detects that the inner welding seam has a far-side echo, the secondary echo is a defect wave which is obviously reflected, and the other side detects that the near-side has no defect wave, and the defect wave is a single echo, the defect can be judged as the air hole defect again;
when one side of the welding seam detects that the inner welding seam has a near-side echo, the secondary echo is a defect wave which is obvious in reflection, and the other side detects that the far-side has no defect wave, and the defect waves are all 'mountain' -shaped echoes, the defect can be judged as a bead clamping defect again.
4. An ultrasonic testing method for identifying bead defects in submerged arc welded pipes according to claim 2 or 3 wherein in step B, the re-identified bead defects are further identified by scanning with a transverse wave probe:
when the waveform is 2-3 reflected waves in a static state and is in a shape of a Chinese character 'shan', and the envelope curve of the echo is in a shape of a saddle in a dynamic state, the defect of the clamped bead can be further judged;
when the wave form is a single reflection wave under the static state, and the envelope curve of the echo is a smooth hill shape under the dynamic state, the defect of the air hole can be further judged.
5. The ultrasonic testing method for identifying bead defects in submerged arc welded pipes according to claim 1, wherein in step C: the microchip of the microchip high-precision transverse wave probe is made of piezoelectric composite materials, the size of the microchip high-precision transverse wave probe is 3 x 8mm, the damping is 50 omega, the gain is 40dB, the effective detection width range is 6mm, and the detection center frequency is 17.45 MHZ.
6. An ultrasonic testing method for identifying bead defects in submerged arc welded pipes according to claim 4 wherein in step C, the final confirmation is: when the rotating detection shows that the echoes are all in the shape of a Chinese character 'shan', the equivalent weight is basically the same, and the defect of the clamped bead is confirmed.
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