A phased array ultrasonic testing method for reaction blades of flue gas turbines

Abstract

The present invention relates to a phased array ultrasonic detection method for reaction blade type moving blades of a flue gas turbine, comprising: performing a force analysis on a three-dimensional model of a moving blade: based on the force analysis of the moving blade, intercepting a two-dimensional cross-sectional image of the moving blade according to the blade stress level; importing the two-dimensional cross-sectional image of the moving blade into a phased array detection instrument to generate a special simulation software; utilizing the fusion of the phased array detection instrument and the special simulation software to track and resolve the ultrasonic sound velocity line / surface, and confirm the reflected wave echo of its structure / detection defect; setting a phased array detection instrument probe and determining the scanning position according to the outer dimensions of the moving blade and the part to be scanned; combining the simulation software and the phased array detection instrument to formulate a focusing law; and performing phased array ultrasonic detection on the moving blade as a whole. The present invention introduces phased array detection technology into the detection of moving blades of a flue gas turbine, realizes the matching of probe scanning and instrument simulation software, and realizes phased array ultrasonic detection of the entire moving blade of a flue gas turbine.

Description

Technical Field

[0001] The invention relates to the technical field of moving blade detection, and in particular to a phased array ultrasonic detection method for reactionary blade-shaped moving blades of a flue gas turbine. Background Art

[0002] The scale of domestic catalytic devices varies from 4000kW to 40000kW due to different construction periods and different manufacturing capabilities of processes and equipment. The specifications of flue gas turbines used in the devices are relatively large, ranging from 4000kW to 40000kW. The aerodynamic structure of the moving blades of flue gas turbines of different specifications is currently mostly a high-efficiency reactionary three-dimensional curved surface structure, and the blade root is a tree-branch structure. The overall structure and shape of the moving blades are complex, and conventional non-destructive testing methods cannot be effectively tested, nor can they detect the tiny original manufacturing defects inside and under the shallow surface and the fatigue expansion defects after one or more cycles of operation, causing the moving blades of the flue gas turbine to suddenly break during normal operation, thereby causing fluctuations in the production of the device, and failing to achieve "long, full, and excellent" operation, which brings huge losses and safety production and environmental protection risks to oil refining and petrochemical companies.

[0003] At present, the non-destructive testing technology of shallow surface and internal tiny original manufacturing defects and fatigue expansion defects after one or more cycles of operation in the manufacturing process of flue gas turbine rotor blades in the refining and petrochemical industries has become a difficult problem that needs to be solved urgently. Summary of the invention

[0004] In order to overcome the above technical problems, the present invention provides a phased array ultrasonic detection method for flue gas turbine reaction blade type moving blades, which realizes phased array ultrasonic detection of flue gas turbine moving blades of different model levels. According to different scanning positions, different simulation model software and probe performance configuration are selected to accurately detect internal and shallow surface quality defects.

[0005] To achieve the above object, the technical solution of the present invention is as follows:

[0006] A phased array ultrasonic detection method for reactionary blade-shaped moving blades of a flue gas turbine, the method comprising:

[0007] S1: Force analysis of the three-dimensional model of the moving blade:

[0008] S2: Based on the force analysis of the moving blades, a two-dimensional cross-sectional diagram of the moving blades is obtained according to the blade stress level;

[0009] S3: The two-dimensional image of the moving blade cross section is pre-processed and then imported into the phased array detection instrument, and after secondary processing, a special simulation software for the phased array of the moving blades of the flue gas turbine is generated;

[0010] S4: Utilizing the integration of the phased array detection instrument and the phased array simulation software for the smoke turbine rotor blades, the ultrasonic sound velocity line and / or surface is tracked and resolved to confirm the structure and / or the reflected wave echo of the detection defect.

[0011] S5: According to the dimensions of the model-level moving blade and the parts to be scanned, the phased array detection instrument probe is set and the scanning position is determined;

[0012] S6: Combine phased array simulation software and phased array detection instruments to develop focusing laws;

[0013] S7: Perform phased array ultrasonic testing on the entire moving blade.

[0014] Preferably, before the step S1 is implemented, the following steps are also included:

[0015] Legally obtain the three-dimensional model drawing from the owner of the blade model; or

[0016] Draw a three-dimensional model drawing of the model-level moving blade using a two-dimensional drawing authorized by the model-level blade owner; or

[0017] Reverse engineering is used to map the model-level blades to generate a three-dimensional image and obtain a three-dimensional model image of the model-level moving blades.

[0018] Preferably, step S1 comprises the following steps:

[0019] Obtain the actual operating status of the flue gas turbine;

[0020] Using finite element method to conduct stress analysis, it is found that the stress value is relatively large under the combined effect of three main stresses: thermal stress, centrifugal force, and differential pressure stress between the front and rear of the blade.

[0021] Combined with the possible mechanical precision error value after the moving blade is processed, the dangerous area where the stress of the moving blade is relatively large is obtained.

[0022] Preferably, the blade stress levels in step S2 are differentiated according to different parts of the moving blade, including but not limited to stress on the blade root, stress on the joint surface between the blade root and the blade body, and stress on the middle part of the blade body.

[0023] Preferably, the step S5 of setting the phased array detection instrument probe includes: setting the probe outer dimensions, configuring the specifications and quantity of the probe wafers, and configuring the array arrangement of the probe wafers.

[0024] Preferably, the setting and determining of the scanning position in step S5 comprises the following steps:

[0025] The scanning position is determined according to the size of the dangerous area with greater stress on the model-level moving blades. The probe dimensions, probe chip specifications and quantity, and array layout of the probe chips are set while ensuring the sensitivity and effective movement of the probe.

[0026] Preferably, the formulating of the focusing law in step S6 comprises the following steps:

[0027] Probe parameter settings: including but not limited to selecting probe type, selecting the number of phased array test instrument probes, setting voltage, setting scanning mode, setting pulse repetition frequency, setting test material, setting frequency band, setting sound wave mode, and selecting wedges;

[0028] By utilizing the established special phased array simulation software for the smoke turbine moving blades, different two-dimensional images of the blade cross-section are selected according to the scanning position of the probe of the phased array detection instrument.

[0029] Scanning parameter settings: including but not limited to selecting the scanning method, focus type, resolution, longitudinal wave starting angle, and shear wave starting angle.

[0030] The beneficial effects of the present invention are:

[0031] The present invention establishes a three-dimensional model by classifying the moving blades of the flue gas turbine according to the model level, and establishes a simulation model for scanning with a phased array ultrasonic probe according to the stress distribution of the force, and imports the phased array detection instrument into a dedicated simulation software to realize the phased array ultrasonic detection of the moving blades of the flue gas turbine. The present invention can realize the phased array ultrasonic detection of the moving blades of the flue gas turbine according to different model levels, and according to different scanning positions, different simulation model software and probe performance configurations are selected, so that the internal and superficial quality defects can be accurately detected. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0033] Figure 1 The present invention is a flow chart of a phased array ultrasonic detection method for reactionary blade-shaped moving blades of a flue gas turbine. DETAILED DESCRIPTION

[0034] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0035] In order to make the purpose, technical solution and advantages of the present invention clearer, a phased array ultrasonic detection method for reactionary blade-shaped moving blades of a flue gas turbine for which protection is sought by the present invention will be further elaborated in detail below in conjunction with specific embodiments.

[0036] Combination Figure 1 As shown, the present invention provides a phased array ultrasonic detection method for reactionary blade-shaped moving blades of a flue gas turbine, comprising:

[0037] S1: Force analysis of the three-dimensional model of the moving blade:

[0038] S2: Based on the force analysis of the moving blades, a two-dimensional cross-sectional diagram of the moving blades is obtained according to the blade stress level;

[0039] S3: The two-dimensional image of the moving blade cross section is pre-processed and then imported into the phased array detection instrument, and after secondary processing, a special simulation software for the phased array of the moving blades of the flue gas turbine is generated;

[0040] S4: Utilizing the integration of the phased array detection instrument and the phased array simulation software for the smoke turbine rotor blades, the ultrasonic sound velocity line and / or surface is tracked and resolved to confirm the structure and / or the reflected wave echo of the detection defect.

[0041] S5: According to the dimensions of the model-level moving blade and the parts to be scanned, the phased array detection instrument probe is set and the scanning position is determined;

[0042] S6: Combine phased array simulation software and phased array detection instruments to develop focusing laws;

[0043] S7: Perform phased array ultrasonic testing on the entire moving blade.

[0044] Preferably, before the step S1 is implemented, the following steps are also included:

[0045] Legally obtain the three-dimensional model drawing from the owner of the blade model; or

[0046] Draw a three-dimensional model drawing of the model-level moving blade using a two-dimensional drawing authorized by the model-level blade owner; or

[0047] Reverse engineering is used to map the model-level blades to generate a three-dimensional image and obtain a three-dimensional model image of the model-level moving blades.

[0048] Preferably, step S1 comprises the following steps:

[0049] Obtain the actual operating status of the flue gas turbine;

[0050] Using finite element method to conduct stress analysis, it is found that the stress value is relatively large under the combined effect of three main stresses: thermal stress, centrifugal force, and differential pressure stress between the front and rear of the blade.

[0051] Combined with the possible mechanical precision error value after the moving blade is processed, the dangerous area where the stress of the moving blade is relatively large is obtained.

[0052] Preferably, the blade stress levels in step S2 are differentiated according to different parts of the moving blade, including but not limited to stress at the blade root, stress at the junction of the blade root and the blade body, and stress at the middle part of the blade body.

[0053] Preferably, the step S5 of setting the phased array detection instrument probe includes: setting the probe outer dimensions, configuring the specifications and quantity of the probe wafers, and configuring the array arrangement of the probe wafers.

[0054] Preferably, the setting and determining of the scanning position in step S5 comprises the following steps:

[0055] The scanning position is determined according to the size of the dangerous area with greater stress on the model-level moving blades. The probe dimensions, probe chip specifications and quantity, and array layout of the probe chips are set under the premise of ensuring the sensitivity and effective movement of the probe.

[0056] Preferably, the formulating of the focusing law in step S6 comprises the following steps:

[0057] Probe parameter settings: including but not limited to selecting the probe type, selecting the number of phased array test instrument probes, setting the voltage, setting the scanning mode, setting the pulse repetition frequency, setting the test material, setting the frequency band, setting the sound wave mode, and selecting the wedge;

[0058] By utilizing the established special phased array simulation software for the smoke turbine moving blades, different two-dimensional images of the blade cross-section are selected according to the scanning position of the probe of the phased array detection instrument.

[0059] Scanning parameter settings: including but not limited to selecting the scanning method, focus type, resolution, longitudinal wave starting angle, and shear wave starting angle.

[0060] Taking one of the possible embodiments as an example, the focus law setting is explained. Specifically, the probe parameter setting: the probe uses a one-dimensional linear array probe. It should be noted that different parameters can be selected according to different probes. Set 1 probe, select 50V for voltage, select single-side scanning for scanning mode, set the pulse repetition frequency to 1K, set the detection material to steel, set the frequency band to 5M or 7.5M, and the sound wave mode can select transverse wave or longitudinal wave. Different wedges can be selected according to different probes. For example, when using a straight probe, no wedge is selected, and when using a self-focusing probe, a flat wedge, an inner arc surface, or an outer arc surface wedge is selected. Using the established special simulation software for the phased array of the moving blades of the flue gas turbine, different cross-sectional diagrams are selected for matching according to the probe detection position. Scanning parameter setting: The scanning can select fan scanning, the focusing type selects the sound path, the resolution is set to 0.5°, the longitudinal wave starting angle is set to -35° to 35°, and the transverse wave starting angle is set to 30° to 70°.

[0061] In summary, compared with the prior art, the present invention provides a phased array ultrasonic detection method for reaction-blade moving blades of a flue gas turbine, which divides the moving blades of the flue gas turbine into different model-level blades according to their design criteria, and establishes three-dimensional simulation models for each of them, cuts sections according to their stress distribution rules to establish simulation models and software for phased array ultrasonic probe scanning, and imports them into a phased array detection instrument to become a dedicated software for phased array ultrasonic detection of the moving blades of the flue gas turbine, laying a foundation for distinguishing the structural waves and defect waves of the moving blades and accurately locating the defect positions; based on the structure and size of the model-level moving blades, as well as the relevant detection rules of the phased array ultrasonic instrument, the position of the detection probe is confirmed, and the scanning position and range need to be simulated and confirmed according to the three-dimensional model of the moving blades of the flue gas turbine or confirmed on-site by the actual moving blades, and finally the characteristic parameters of the probe chip combination within a certain size are determined, so as to achieve matching between the probe scanning and the instrument simulation software, and realize the phased array ultrasonic detection of the entire body of the moving blades of the flue gas turbine.

[0062] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. The present invention may be subject to various changes and improvements without departing from the spirit and scope of the present invention. These changes and improvements fall within the scope of the present invention. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A phased array ultrasonic detection method for reactionary blades of flue gas turbines, characterized in that: The method comprises: S1: Force analysis of the three-dimensional model of the moving blade: S2: Based on the force analysis of the moving blades, a two-dimensional cross-sectional diagram of the moving blades is obtained according to the blade stress level; S3: After the two-dimensional image of the moving blade cross section is preprocessed to obtain a simulation model, the simulation model is imported into the phased array detection instrument, and after secondary processing, a special simulation software for the phased array of the moving blade of the flue gas turbine is generated; S4: using the fusion of the phased array detection instrument and the phased array simulation software for the flue gas turbine rotor blades, the ultrasonic sound velocity line and / or surface is tracked and resolved to confirm the structure and / or the reflected wave echo of the detection defect; S5: According to the dimensions of the model-level moving blade and the parts to be scanned, the phased array detection instrument probe is set and the scanning position is determined; S6: Combine phased array simulation software and phased array detection instruments to develop focusing laws; Formulate focusing rules, including the following steps: Probe parameter settings: including but not limited to selecting probe type, selecting the number of phased array test instrument probes, setting voltage, setting scanning mode, setting pulse repetition frequency, setting test material, setting frequency band, setting sound wave mode, and selecting wedges; Using the established phased array simulation software for the flue gas turbine blades, different two-dimensional cross-sectional images of the blades are selected according to the scanning position of the probe of the phased array detection instrument; Scanning parameter settings: including but not limited to selecting the scanning method, focus type, resolution, longitudinal wave starting angle, and shear wave starting angle; S7: Perform phased array ultrasonic testing on the entire moving blade.

2. A phased array ultrasonic detection method for reactionary blades of flue gas turbine according to claim 1, characterized in that: Before the step S1 is implemented, the following steps are also included: Legally obtain the three-dimensional model drawing from the owner of the blade model; or Draw the three-dimensional model drawing of the model-level moving blade through the two-dimensional drawing authorized by the model-level blade owner; or Reverse engineering is used to map the model-level blades to generate a three-dimensional image and obtain a three-dimensional model image of the model-level moving blades.

3. The phased array ultrasonic detection method for reactionary blades of flue gas turbine according to claim 1, characterized in that: The step S1 comprises the following steps: Obtain the actual operating status of the flue gas turbine; Using finite element method to conduct stress analysis, it is found that the stress value is relatively large under the combined effect of three main stresses: thermal stress, centrifugal force, and differential pressure stress between the front and rear of the blade. Combined with the possible mechanical precision error value after the moving blade is processed, the dangerous area where the stress of the moving blade is relatively large is obtained.

4. The phased array ultrasonic detection method for reactionary blades of flue gas turbine according to claim 1, characterized in that: In step S2, the blade stress levels are differentiated according to different parts of the moving blade, including but not limited to the stress on the blade root, the stress on the joint surface between the blade root and the blade body, and the stress on the middle part of the blade body.

5. The phased array ultrasonic detection method for reactionary blades of flue gas turbine according to claim 1, characterized in that: The step S5 of setting the phased array detection instrument probe includes: setting the probe outer dimensions, configuring the specifications and quantity of the probe wafers, and configuring the array arrangement of the probe wafers.

6. The phased array ultrasonic detection method for reactionary blades of flue gas turbine according to claim 1, characterized in that: Determining the scanning position in step S5 includes the following steps: The scanning position is determined according to the size of the dangerous area with greater stress on the model-level moving blades. The probe dimensions, probe chip specifications and quantity, and array layout of the probe chips are set while ensuring the sensitivity and effective movement of the probe.

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