A method for improving the accuracy of consumable carrying

Abstract

The application discloses a method for improving the carrying accuracy of consumables, which comprises the following steps: S1: for different projects, different specifications of parts are extracted respectively for consumable spraying; S2: according to the specifications of the parts and the consumable consumption, the unit area consumption of each part is calculated; S3: according to the unit area consumption of different parts and the number of parts, the carrying amount of consumables of the current project is calculated; S4: according to the carrying amount of consumables of the project and the actual usage, the carrying accuracy of consumables of the project is calculated. The application finds the corresponding relationship between the carrying amount of consumables and the workload, and the resource allocation is carried out according to the method, so that the carrying accuracy of consumables can be improved to more than 90%.

Description

Technical Field

[0001] This invention relates to the field of equipment maintenance technology, and in particular to a method for improving the accuracy of consumable carrying. Background Technology

[0002] Magnetic particle testing, as an important method of surface inspection, plays a vital role in modern manufacturing, especially during the overhaul of power generation units. Extensive testing is required to detect surface and near-surface defects, making a significant contribution to eliminating potential equipment hazards in power plants. Every year, power generation companies require non-destructive testing of metal components, particularly surface inspection. Inspection personnel need to carry a large quantity of contrast enhancer used in magnetic particle testing each time. However, it has been found that there is a significant discrepancy between the amount of testing agent carried and the amount used on-site. Carrying too much leads to resource waste, while carrying too little affects on-site work.

[0003] Currently, finding the relationship between the workload of inspecting workpieces and the consumables carried, and achieving refined management of consumables to meet on-site needs while saving costs, is a technical problem that urgently needs to be solved. Summary of the Invention

[0004] The purpose of this invention is to provide a method for improving the accuracy of consumable carrying, so as to solve the technical problem of how to improve the accuracy of consumable carrying.

[0005] This invention is achieved using the following technical solution: a method for improving the accuracy of consumable carrying, comprising the following steps:

[0006] S1: For different projects, different specifications of components are selected for consumable spraying;

[0007] S2: Calculate the consumption per unit area of ​​each component based on the component specifications and consumable consumption;

[0008] S3: Calculate the material carrying capacity for the current project based on the consumption per unit area of ​​different components and the number of components;

[0009] S4: Calculate the consumable carrying accuracy rate of this project based on the amount of consumables carried and the actual usage.

[0010] Furthermore, the components include welds, fillet welds, and elbows.

[0011] Furthermore, the component specifications include weld diameter D1, fillet weld mean diameter D2, and elbow straight pipe diameter D3; the consumable consumption includes weld consumption △m1, fillet weld consumption △m2, and elbow consumption △m3.

[0012] Furthermore, the calculation of the unit area consumption of each component includes the unit area consumption of welds, the unit area consumption of fillet welds, and the unit area consumption of elbows; wherein,

[0013] Weld consumption per unit area: σ1=△m1 / k1D1;

[0014] Consumption per unit area of ​​fillet weld: σ2=△m2 / k2D2;

[0015] Consumption per unit area of ​​elbow: σ3=△m3 / k3D3;

[0016] In the formula, k1 is the unit area consumption coefficient of the weld, k2 is the unit area consumption coefficient of the fillet weld, and k3 is the unit area consumption coefficient of the elbow.

[0017] Furthermore, the size of k1 is: 45π≤k1≤75π; the size of k2 is: 350π≤k2≤450π; and the size of k3 is: 100π≤k3≤180π.

[0018] Furthermore, the size of k1 is 60π; the size of k2 is 450π; and the size of k3 is 120π.

[0019] Furthermore, the formula for calculating the carrying capacity of the consumables is as follows:

[0020] ;

[0021] In the formula, S is the total amount of consumables carried in the entire project; M is the average original weight of each can of consumables; X1 is the amount of consumables carried for welds; X2 is the amount of consumables carried for fillet welds; and X3 is the amount of consumables carried for elbows.

[0022] Furthermore, the calculation method for X1 is as follows: The calculation method for X2 is as follows: The calculation method for X3 is as follows: ;in, Indicates different weld specifications; Indicates different fillet weld specifications; This indicates different elbow specifications.

[0023] Furthermore, the method for calculating the accuracy of consumable carrying is as follows: In the formula, S represents the total amount of consumables carried in the entire project. This represents the actual amount of materials consumed in the project. To ensure the accuracy of consumables carried by this project.

[0024] The beneficial effects of this invention are as follows: This invention finds the correspondence between the amount of consumables carried and the workload. By allocating resources according to the method of this invention, the accuracy of consumables carrying can be increased to over 90%. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0026] Figure 1 This is a flowchart of the present invention. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0028] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0029] The following detailed description of some embodiments of the present invention is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0030] Example 1

[0031] See Figure 1 A method for improving the accuracy of consumable carrying includes the following steps:

[0032] S1: For different projects, different specifications of components are selected for consumable spraying;

[0033] S2: Calculate the consumption per unit area of ​​each component based on the component specifications and consumable consumption;

[0034] S3: Calculate the material carrying capacity for the current project based on the consumption per unit area of ​​different components and the number of components;

[0035] S4: Calculate the consumable carrying accuracy rate of this project based on the amount of consumables carried and the actual usage.

[0036] In this embodiment, the consumable uses FA-5 type contrast enhancer, and the components used are common power plant components such as circumferential welds, elbows, and fillet welds. The method used is the loss-in-weight method. The specific method is as follows:

[0037] First, welds, fillet welds (outer diameter of the pipe less than 108mm), and elbows of different specifications were randomly selected on-site for testing. Before testing, the surface oxide scale needed to be removed. Following the magnetic particle testing requirements of standard NB / T47013.4, a uniform coating was applied to the relevant areas. Weighing was performed before and after each test, with the weight before the test recorded as m1 and the weight after the test as m2. Material consumption was denoted as Δm. Several test results were averaged to obtain the weld consumption as Δm1, the fillet weld consumption as Δm2, and the elbow consumption as Δm3. The weld diameter was D1, the fillet weld mean diameter as D2 (2D2 = larger pipe diameter + smaller pipe diameter), and the elbow straight pipe diameter as D3, with an angle of 90 degrees.

[0038] Then, the unit area consumption of each component is calculated: Weld unit area consumption (including heat-affected zone) σ1 = Δm1 / k1D1, where k1 is the weld unit area consumption coefficient, ranging from 45π to 75π, preferably 60π. Fillet weld unit area consumption (including heat-affected zone) σ2 = Δm2 / k2D2, where k2 is the fillet weld unit area consumption coefficient, ranging from 350π to 450π, preferably 420π. Elbow unit area consumption (including heat-affected zone) σ3 = Δm3 / k3D3, where k3 is the elbow unit area consumption coefficient, ranging from 100π to 180π, preferably 120π.

[0039] Then, calculate the total amount of consumables carried: Let M be the average original weight of each can of consumables, S be the amount of consumables carried, and the actual usage of the project be... The weld specifications are d1, d2…dn, and the consumable carrying capacity is as follows: The fillet weld mid-diameters are z1, z2…zn, respectively. (Consumable carrying capacity) The outer diameters of the straight pipe sections of the elbows are w1, w2…wn; then the consumable carrying capacity is as follows: Therefore, the total amount of consumables carried for the entire project is: .

[0040] Finally, the accuracy of consumable carrying rate is calculated: In the formula, S represents the total amount of consumables carried in the entire project. This represents the actual amount of materials consumed in the project. To ensure the accuracy of consumables carried by this project.

[0041] Based on the above embodiments, the present invention can reduce the waste caused by bringing too many consumables to the site, and can also budget the consumables on site, reducing the need for emergency procurement and other methods to replenish consumables when there are too few on site.

[0042] It should be noted that, for the sake of simplicity, the foregoing embodiments are all described as a series of actions. However, those skilled in the art should understand that this application is not limited to the described order of actions, because according to this application, some steps can be performed in other orders or simultaneously. Furthermore, those skilled in the art should also understand that the embodiments described in the specification are preferred embodiments, and the actions involved are not necessarily essential to this application.

[0043] The above embodiments describe 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 embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Modifications and variations made by those skilled in the art without departing from the spirit and scope of the invention should be within the protection scope of the appended claims.

Claims

1. A method for improving the accuracy of consumable carrying, characterized in that, Includes the following steps: S1: For different projects, different specifications of components are selected for consumable spraying; S2: Calculate the consumption per unit area of ​​each component based on the component specifications and consumable consumption; S3: Calculate the material carrying capacity for the current project based on the consumption per unit area of ​​different components and the number of components; S4: Calculate the consumable carrying accuracy rate of this project based on the amount of consumables carried and the actual usage. The components include welds, fillet welds, and elbows; The component specifications include weld diameter D1, fillet weld mean diameter D2, and elbow straight pipe diameter D3; the consumable consumption includes weld consumption △m1, fillet weld consumption △m2, and elbow consumption △m3. The calculation of the unit area consumption of each component includes the unit area consumption of welds, fillet welds, and elbows; among which, Weld consumption per unit area: σ1=△m1 / k1D1; Consumption per unit area of ​​fillet weld: σ2=△m2 / k2D2; Consumption per unit area of ​​elbow: σ3=△m3 / k3D3; In the formula, k1 is the unit area consumption coefficient of the weld, k2 is the unit area consumption coefficient of the fillet weld, and k3 is the unit area consumption coefficient of the elbow. The formula for calculating the carrying capacity of the consumables is as follows: ； In the formula, S is the total amount of consumables carried in the entire project; M is the average original weight of each can of consumables; X1 is the amount of consumables carried for welds; X2 is the amount of consumables carried for fillet welds; and X3 is the amount of consumables carried for elbows.

2. The method for improving the accuracy of consumable carrying as described in claim 1, characterized in that, The value of k1 is: 45π≤k1≤75π; the value of k2 is: 350π≤k2≤450π; the value of k3 is: 100π≤k3≤180π.

3. The method for improving the accuracy of consumable carrying as described in claim 2, characterized in that, The size of k1 is 60π; the size of k2 is 450π; and the size of k3 is 120π.

4. The method for improving the accuracy of consumable carrying as described in claim 1, characterized in that, The method for calculating X1 is as follows: The calculation method for X2 is as follows: The calculation method for X3 is as follows: ;in, Indicates different weld specifications; Indicates different fillet weld specifications; This indicates different elbow specifications.

5. The method for improving the accuracy of consumable carrying as described in claim 1, characterized in that, The method for calculating the accuracy of the consumable carrying rate is as follows: In the formula, S represents the amount of consumables carried by the project. This represents the actual amount of materials consumed in the project. To ensure the accuracy of consumables carried by this project.

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