Weld flaw detection device and method for horizontal high-pressure heater header pipe joints

Abstract

The present invention relates to a weld flaw detection device and method applied to a horizontal high-pressure heater header pipe joint. A controller is used to control a rotary driver, a winding motor, and a swing motor to automatically adjust the flaw detection position and angle of a probe, and the controller is further used to control the probe to perform automatic flaw detection, thereby realizing the automatic flaw detection function of the horizontal high-pressure heater header pipe joint, and solving the technical problems of the current flaw detection work of the joint weld between the horizontal high-pressure heater header and the heat exchange tube, such as high difficulty, high intensity, low efficiency, easy fatigue of the flaw detector, and high-altitude operation.

Description

Technical Field

[0001] The invention belongs to the technical field of flaw detection equipment, and in particular relates to a weld flaw detection device and method applied to a horizontal high-pressure heater header pipe joint. Background Art

[0002] High-pressure heater is a device that uses part of the steam turbine's exhaust to heat the feed water. As a heat conversion device, it is mainly used in the heat recovery system of large thermal power units. High-pressure heaters are available in two main forms: vertical and horizontal. Regardless of the form of the horizontal high-pressure heater, there is at least one header and many heat exchange tubes connected to the header. The ends of the heat exchange tubes are welded to the header. To ensure the reliability and sealing of the connection between the heat exchange tube and the header, each pipe joint weld needs to be ultrasonically inspected. During the production process, there are many heat exchange tubes connected to the header and the spacing is small. If the joint welds are inspected after all the heat exchange tubes are welded, most of the pipe joints will be blocked and cannot be inspected. Therefore, weld inspection needs to be performed at intervals during the welding process.

[0003] The heat exchange pipe joints on the header are evenly distributed circumferentially and arranged axially, and the two adjacent rows of pipe joints arranged along the axial direction have a certain angle of misalignment in the circumferential direction, which can maximize the distribution density and uniformity of the pipe joints. When connecting the heat exchange pipes, the staff starts from one end of the header and welds a circle of heat exchange pipes at the end of the header. After waiting for the flaw detector to complete the flaw detection, they weld the second circle of heat exchange pipes adjacent to the axial direction, and so on until all are welded.

[0004] Normally, the header of a vertical high-pressure heater is in a lying position when it is welded to the heat exchange tubes, and the flaw detector can easily avoid the heat exchange tubes and stand outside the header to inspect the welds of the pipe joints. However, the header of a horizontal high-pressure heater is in an upright position when it is welded to the heat exchange tubes, and the heat exchange tubes are welded from the bottom layer to the top layer. Since the heat exchange tubes, especially the serpentine heat exchange tubes (see patent number 201320727162.6, invention patent named "Header-type high-pressure heater"), have a bending area at one end welded to the header, the flaw detector's flaw detection work is hindered. The flaw detector needs to squat on the heat exchange tube to inspect the welds of the pipe joints, which can easily lead to fatigue of the flaw detector, thereby affecting work efficiency. At the same time, as the number of welded layers of the heat exchange tubes increases, the flaw detector's working height becomes higher, involving high-altitude operations, which affects work safety.

[0005] In summary, the current flaw detection work for the joint welds of the horizontal high-pressure heater header and the heat exchange tube has many problems that need to be solved urgently, such as high difficulty, high intensity, low efficiency, fatigue of inspectors, and risks of high-altitude operations. Summary of the invention

[0006] The technical problem to be solved by the present invention is to provide a weld flaw detection device applied to the high-pressure heater header pipe joint, so as to solve the technical problems that the current weld flaw detection work on the joints of the horizontal high-pressure heater header and the heat exchange tube is difficult, has high intensity, has low efficiency, is easy to fatigue the flaw detector, and involves high-altitude work.

[0007] In order to solve the above technical problems, the technical solution adopted by the present invention is: a weld flaw detection device applied to a horizontal high-pressure heater header pipe joint includes a flaw detector and a base connected to the top of a vertically arranged header, a vertically arranged rotating shaft is connected to the base, the rotating shaft is coaxial with the header, a sleeve is rotatably connected to the rotating shaft, a cantilever is vertically connected to the outer wall of the sleeve, the cantilever extends outward along the radial direction of the header, and an end of the cantilever away from the rotating shaft is movably connected to a vertically arranged lifting rod, the lifting rod can move up and down along its axis, the lifting rod is located outside the header, the probe of the flaw detector is connected to the lower end of the lifting rod, and a driving seat is also vertically connected to the outer wall of the sleeve. The driving seat and the cantilever are arranged on both sides of the sleeve. A rotating driver for driving the sleeve to rotate is arranged on the driving seat. The rotating driver is a servo motor. A large gear coaxially arranged with the rotating shaft is connected to the rotating shaft below the sleeve or the base. A first small gear is connected to the output shaft of the rotating driver, and the large gear is meshed with the first small gear. An electric control box is also arranged above the rotating shaft. The lower end of the electric control box extends to the top surface of the cantilever and the driving seat and is detachably connected to the cantilever and the driving seat. A first center slip ring coaxially arranged with the rotating shaft is connected to the electric control box. The fixed end of the first center slip ring is used to connect an external power supply, and the rotating end is electrically connected to the electric control box.

[0008] The cantilever is axially slidably connected with a slider, and a through hole is vertically opened on the slider. The lifting rod is slidably connected in the through hole. A through groove extending axially is opened on the side wall of the lifting rod facing the sleeve. The lifting rod is a hollow tube, and the through groove is connected with the inner hole of the lifting rod. A guide hole connected with the through hole is opened on the end of the slider close to the sleeve. A guide sleeve is rotatably connected in the guide hole, and the guide sleeve is in contact with the lifting rod. A reel and a winding motor for driving the reel to rotate are arranged on the cantilever, and the winding motor is connected with the electric control box.

[0009] A connecting wire is passed through the lifting rod, and the connecting wire is a tensile flexible cable. The lower part of the connecting wire is fixed to the lower end of the lifting rod, and the lower end of the connecting wire passes through the lifting rod from the lower end of the lifting rod, and the upper end of the connecting wire passes through the through groove above the guide sleeve, bypasses the guide sleeve and is wound on the reel. The reel is a hollow cylinder, and the end shaft at one end of the reel is rotatably connected to a bracket, and the bracket is fixedly connected to the cantilever. One end of the connecting wire passes through the wall of the reel and is inserted into the reel and extends to the end shaft with a center hole, and is connected to the electric control box through a second center slip ring. The second center slip ring is connected to the end of the end shaft. A measuring wheel is also rotatably connected to the cantilever, and the measuring wheel is located between the reel and the lifting rod and is adjacent to the guide sleeve. After the connecting wire bypasses the guide sleeve, it bypasses from the lower edge of the measuring wheel and is then wound onto the reel. The measuring wheel is transmission-connected to an encoder, and the measuring wheel drives the encoder to rotate synchronously. A fixing bolt is also threadedly connected to the slider. When the fixing bolt is tightened, the top of the fixing bolt is tightly pressed against the cantilever to lock the slider.

[0010] The electric control box is provided with a controller and a remote control signal transceiver. The rotary driver, the winding motor and the encoder are electrically connected to the controller respectively and are controlled by the controller. The remote control signal transceiver is electrically connected to the controller.

[0011] The probe of the flaw detector is rotatably connected to the lower end of the lifting rod through a clamping seat, and the clamping seat includes a clamping ring and a connecting plate. The upper end of the connecting plate is connected to the lower end of the lifting rod, and the clamping ring is formed by two semi-rings butted against each other. The top of the upper semi-ring is connected with a connecting seat, and the connecting seat is hinged to the connecting plate. The axial direction of the clamping ring points to the central axis of the collecting box. Any half ring includes two semi-annular end plates arranged opposite to each other and several supporting rollers connecting the two end plates. The two ends of the two end plates are respectively connected by a flange plate. The supporting rollers are evenly distributed circumferentially with the center of the clamping ring as the center, and the minimum distance from the outer circumference of any supporting roller to the center of the clamping ring is smaller than the minimum distance from the flange plate to the center of the clamping ring. All supporting rollers are used to clamp the cylindrical probe.

[0012] The outer circumference of the support roller is exposed at the edge of one side of the end plate toward the center of the clamping ring. An outer gear ring is connected to the outer circumference of the probe. The outer gear ring is located outside the side of the clamping ring away from the collecting box. A swing motor is connected to the connecting seat. A second pinion is provided on the output shaft of the swing motor. The second pinion is meshed with the outer gear ring. The swing motor is electrically connected to the controller through a connecting wire and is controlled by the controller.

[0013] The flaw detector probe is connected to the electric control box and the controller through connecting wires and is controlled by the controller.

[0014] As a preferred solution, the connecting seat is hinged to the connecting plate through a hinge shaft, and the connecting plate is provided with two adjustment holes symmetrically arranged on both sides of the hinge shaft, and the centers of the two adjustment holes are at the same height as the center of the hinge shaft, and the connecting seat is provided with two arc holes arranged on both sides of the hinge shaft, and the two arc holes are centered on the center of the hinge shaft, and the lower ends of the two arc holes are respectively opposite to the two adjustment holes, and locking bolts are detachably connected in the two adjustment holes, and the locking bolts pass through the corresponding arc holes and adjustment holes to connect the connecting plate and the connecting seat together.

[0015] As a preferred solution, the base includes a positioning ring adapted to the outer wall of the top end of the header and a base plate connected to the top end of the positioning ring. The positioning ring is circumferentially evenly distributed with at least three threaded holes, and each threaded hole is threadedly connected to a tightening bolt. The base is buckled on the top end of the header, the positioning ring is sleeved on the outer wall of the top end of the header, and the end of the tightening bolt presses against the outer wall of the header.

[0016] As a preferred solution, the fixed end of the first center slip ring is connected to the top of the rotating shaft, a wire threading hole is opened in the center of the rotating shaft, the fixed end of the first center slip ring is connected to the power cord, the power cord extends downward through the wire threading hole of the rotating shaft and is connected to the power supply, the rotating end of the first center slip ring is electrically connected to the electric control box, and rotates with the electric control box.

[0017] As a preferred solution, the rotating end of the first center slip ring is connected to the top of the electric control box, and an extension tube extending radially outward is connected to the fixed end of the first center slip ring. The power cord is passed through the extension tube, and one end of the power cord is electrically connected to the fixed end of the first center slip ring, and the other end extends from the extension tube and is connected to the power supply. The length of the extension tube is greater than the length of the cantilever.

[0018] The technical problem further to be solved by the present invention is: to provide a flaw detection method, using the above-mentioned weld flaw detection device applied to the horizontal high-pressure heater header pipe joint to automatically detect the weld of the high-pressure heater header pipe joint, so as to solve the current technical problems of high difficulty, high intensity, low efficiency, easy fatigue of the flaw detector and high-altitude operation in the joint weld flaw detection work of the horizontal high-pressure heater header and the heat exchange tube.

[0019] In order to solve the above technical problems, the technical solution adopted by the present invention is: a flaw detection method based on the above weld flaw detection device applied to the horizontal high-pressure heater header pipe joint, comprising the following specific steps:

[0020] S1. Install the base of the weld flaw detection device to the top of the vertically arranged header, adjust the coaxiality between the rotating shaft and the header so that the rotating shaft and the header are coaxial, turn on the power, and the controller actively resets the probe to the initial position.

[0021] S2. Employees start welding the heat exchange tubes from the bottom layer of the header. After welding of the heat exchange tubes in the bottom layer of the header is completed, the employees stay away from the flaw detection area.

[0022] S3. The employee uses the remote control to send a remote control signal to the controller. The controller controls the coordinated actions of the rotary drive, winding motor, and swing motor according to the control signal, and lowers the probe to the starting position above the heat exchange tube. The weld of the heat exchange tube at the starting position is subjected to multi-directional X-ray flaw detection. After the weld flaw detection device has completed the flaw detection of all the welds of the heat exchange tubes in one layer, the probe is reset upward to the initial position. The weld flaw detection device enters the standby state.

[0023] S4. The workers weld the heat exchange tubes layer by layer upwards, and repeat step S3 after welding each layer of heat exchange tubes until all heat exchange tubes are welded and flaw detection is completed.

[0024] S5. Remove the weld flaw detection device from the top of the header.

[0025] As a preferred solution, in step S3, the controller controls the coordinated actions of the rotary driver, the winding motor, and the swing motor to be automatically controlled, and the controller completes the automatic control process according to a preset program.

[0026] As a preferred solution, in step S3, the controller controls the rotary driver to rotate so that the probe moves to the top of one side of the heat exchange tube to be inspected, and then controls the swing motor to rotate to drive the probe to rotate a certain angle so that the probe is tilted downward toward the heat exchange tube to perform weld flaw detection; then the controller controls the rotary driver to drive the probe to move to just above the heat exchange tube to be inspected, and at the same time controls the swing motor to drive the probe to just below, and performs a second inspection on the weld of the heat exchange tube to be inspected; finally, the controller controls the rotary driver to drive the probe to move to the other side of the heat exchange tube to be inspected, and at the same time controls the swing motor to drive the probe to move diagonally downward toward the weld of the heat exchange tube to be inspected, and performs a third flaw detection on the weld of the heat exchange tube to be inspected; after completion, perform weld flaw detection on the next heat exchange tube according to the above steps.

[0027] The beneficial effects of the present invention are as follows: the present invention utilizes a controller to control a rotary drive, a winding motor, and a swing motor to automatically adjust the flaw detection position and angle of the probe, and further utilizes the controller to control the probe to perform automatic flaw detection, thereby realizing the automatic flaw detection function of the horizontal high-pressure heater header pipe joint, thereby solving the current technical problems of high difficulty, high intensity, low efficiency, easy fatigue of flaw detectors, and high-altitude operations in the flaw detection work of the joint welds of the horizontal high-pressure heater header and the heat exchange tube. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The specific embodiments of the present invention are further described in detail below with reference to the accompanying drawings, wherein:

[0029] Figure 1 It is a schematic diagram of the specific structure of the weld flaw detection device of the present invention;

[0030] Figure 2 yes Figure 1 A magnified view of part A in FIG.

[0031] Figure 3 It is a schematic diagram of the specific assembly structure of the reel of the present invention;

[0032] Figure 4 is a schematic diagram of the connection structure between the electric control box and the first center slip ring of the present invention;

[0033] Figure 5 It is a schematic diagram of the specific assembly structure of the probe and the clamping seat of the present invention;

[0034] Figure 6 is a front view of the clamping seat of the present invention;

[0035] Figure 7 is a schematic structural diagram of the connecting plate of the present invention;

[0036] Figure 8 yes Figure 1 A magnified view of part B in FIG.

[0037] Fig. 9 It is a schematic diagram of another connection structure between the electric control box and the first center slip ring of the present invention;

[0038] Figure 1 to Figure 9 Middle: 1. Base, 2. Rotating axis, 3. Sleeve, 4. Cantilever, 5. Slider, 6. Lifting rod, 7. Probe, 8. Drive seat, 9. Rotating driver, 10. Big gear, 11. First small gear, 12. Electric control box, 13. First center slip ring, 14. Through hole, 15. Through groove, 16. Guide hole, 17. Guide sleeve, 18. Reel, 19. Winding motor, 20. Connecting wire, 21. End shaft, 22. Bracket, 23. Second center slip ring, 24. Distance measuring wheel, 25. Encoder, 26. Fixing bolt, 27. Controller, 28. Remote control Signal transceiver, 29, clamping seat, 30, clamping ring, 30a, half ring, 31, connecting plate, 32, connecting seat, 33, end plate, 34, support roller, 35, flange plate, 36, outer gear ring, 37, swing motor, 38, second pinion, 39, hinge shaft, 40, adjustment hole, 41, arc hole, 42, locking bolt, 43, positioning ring, 44, base plate, 45, threaded hole, 46, tightening bolt, 47, threading hole, 48, power cord, 49, extension tube, 50, heat exchange tube, 51, ball sleeve linear sliding bearing, 100, header. DETAILED DESCRIPTION

[0039] The specific embodiments of the present invention are described in detail below in conjunction with the accompanying drawings.

[0040] like Figure 1 The weld flaw detection device shown in the figure is applied to the horizontal high-pressure heater header pipe joint, including a flaw detector and a base 1 connected to the top of a vertically arranged header 100, a vertically arranged rotating shaft 2 is connected to the base 1, the rotating shaft 2 is coaxial with the header 100, a sleeve 3 is rotatably connected to the rotating shaft 2, a cantilever 4 is vertically connected to the outer wall of the sleeve 3, the cantilever 4 extends radially outwardly along the header 100, and the end of the cantilever 4 away from the rotating shaft 2 is movably connected to a vertically arranged lifting rod 6, the lifting rod 6 can move up and down along its axis, the lifting rod 6 is located outside the header 100, the probe 7 of the flaw detector is connected to the lower end of the lifting rod 6, the mainframe of the flaw detector is connected to the probe 7 by wireless communication, the detection result of the probe 7 is sent to the mainframe for display, and the mainframe is carried by the operator and operated during the flaw detection process.

[0041] A driving seat 8 is also vertically connected to the outer wall of the sleeve 3. The driving seat 8 and the cantilever 4 are arranged on both sides of the sleeve 3. A rotating driver 9 for driving the sleeve 3 to rotate is arranged on the driving seat 8. The rotating driver 9 is a servo motor or a stepping motor. The servo motor has high mobility and high precision, and can accurately move the probe 7 to the target position so that the relative position of the probe 7 and the weld of the pipe joint to be inspected meets the inspection requirements. A large gear 10 coaxially arranged with the rotating shaft 2 is connected to the rotating shaft 2 or the base 1 below the sleeve 3. A first small gear 11 is connected to the output shaft of the rotating driver 9. The large gear 10 meshes with the first small gear 11. The rotating driver 9 drives the first small gear 11 to rotate, and the first small gear 11 will roll relative to the large gear 10, driving the rotating driver 9, the driving seat 8, and the sleeve 3 to rotate together. The sleeve 3 will drive the cantilever 4, the lifting rod 6, and the probe 7 to rotate around the header 100.

[0042] An electric control box 12 is also arranged above the rotating shaft 2, the lower end of which extends to the top surface of the cantilever 4 and the driving seat 8 and is detachably connected to the cantilever 4 and the driving seat 8, and the electric control box 12 is connected to a first center slip ring 13 coaxially arranged with the rotating shaft 2, the fixed end of the first center slip ring 13 is used to connect to an external power source, and the rotating end is electrically connected to the electric control box 12. The external power source supplies power to the entire weld flaw detection device through the first center slip ring 13.

[0043] A slider 5 is axially slidably connected to the cantilever 4, a through hole 14 is vertically provided on the slider 5, the lifting rod 6 is slidably connected in the through hole 14, an axially extending through slot 15 is provided on the side wall of the lifting rod 6 facing the sleeve 3, the lifting rod 6 is a hollow tube, the through slot 15 is connected to the inner hole of the lifting rod 6, a guide hole 16 connected to the through hole 14 is provided at one end of the slider 5 close to the sleeve 3, a guide sleeve 17 is rotatably connected in the guide hole 16, the guide sleeve 17 is in contact with the lifting rod 6, a reel 18 and a winding motor 19 driving the reel 18 to rotate are provided on the cantilever 4, and the winding motor 19 is connected to the electric control box 12. The electric control box 12 supplies power to the winding motor 19.

[0044] In order to ensure that the lifting rod 6 can automatically descend, a ball sleeve linear sliding bearing 51 is provided in the through hole 14 in this embodiment, and the lifting rod 6 is slidably connected in the through hole 14 via the ball sleeve linear sliding bearing 51 .

[0045] like Figure 2 As shown, a connecting wire 20 is inserted into the lifting rod 6. The connecting wire 20 is a tensile-resistant flexible cable. The lower part of the connecting wire 20 is fixed to the lower end of the lifting rod 6. The lower end of the connecting wire 20 passes through the lower end of the lifting rod 6 and passes outside the lifting rod 6. The upper end of the connecting wire 20 passes through the through slot 15 above the guide sleeve 17, bypasses the guide sleeve 17, and is wound on the reel 18. The cantilever 4 is also rotatably connected to a distance measuring wheel 24, which is located between the reel 18 and the lifting rod 6 and is adjacent to the guide sleeve 17. The connecting wire 20 bypasses the guide sleeve 17 and bypasses the lower edge of the distance measuring wheel 24, and then is wound on the reel 18. The distance measuring wheel 24 is coaxially connected to the rotating shaft of an encoder 25. The distance measuring wheel 24 drives the encoder 25 to rotate synchronously, and the encoder 25 detects the rotation angle of the distance measuring wheel 24. The slider 5 is also threadedly connected to a fixing bolt 26. When the fixing bolt 26 is tightened, the top of the fixing bolt 26 is tightly pressed against the cantilever 4 to lock the slider 5.

[0046] like Figure 3 As shown, the reel 18 is a hollow cylinder, and the end shaft 21 at one end of the reel 18 is rotatably connected to a bracket 22, and the bracket 22 is fixedly connected to the cantilever 4. One end of the connecting wire 20 passes through the wall of the reel 18 and is inserted into the reel 18 and extends to the end shaft 21 with a center hole, and is connected to the electric control box 12 through a second center slip ring 23, and the second center slip ring 23 is connected to the end of the end shaft 21.

[0047] like Figure 4As shown, the electrical control box 12 is provided with a controller 27 and a remote control signal transceiver 28. The rotary driver 9, the winding motor 19 and the encoder 25 are electrically connected to the controller 27 and controlled by the controller 27 respectively. The remote control signal transceiver 28 is electrically connected to the controller 27, and the controller 27 can receive and send wireless signals through the remote control signal transceiver 28.

[0048] In this embodiment, the fixed end of the first center slip ring 13 is connected to the top of the rotating shaft 2. A threading hole 47 is opened in the center of the rotating shaft 2. The fixed end of the first center slip ring 13 is connected to a power cord 48. The power cord 48 extends downward through the threading hole 47 of the rotating shaft 2 and is connected to a power source. The rotating end of the first center slip ring 13 is electrically connected to the electric control box 12 and rotates with the electric control box 12.

[0049] Combination Figure 5 and Figure 6 As shown, the probe 7 of the flaw detector is rotatably connected to the lower end of the lifting rod 6 through a clamping seat 29. The clamping seat 29 includes a clamping ring 30 and a connecting plate 31. The upper end of the connecting plate 31 is connected to the lower end of the lifting rod 6. The clamping ring 30 is formed by two half rings 30a connected to each other. The top of the upper half ring 30a is connected to a connecting seat 32, and the connecting seat 32 is hinged to the connecting plate 31. The axial direction of the clamping ring 30 points to the central axis of the collection box 100. Any half ring 30a includes two semi-annular end plates 33 arranged opposite to each other and several support rollers 34 connecting the two end plates 33. The two ends of the two end plates 33 are respectively connected by a flange plate 35. The support rollers 34 are evenly distributed circumferentially with the center of the clamping ring 30 as the center. The minimum distance from the outer peripheral surface of any support roller 34 to the center of the clamping ring 30 is smaller than the minimum distance from the flange plate 35 to the center of the clamping ring 30, so as to ensure that the support roller 34 is in contact with the probe 7. All support rollers 34 are used to clamp the cylindrical probe 7.

[0050] like Figure 6 As shown, the outer peripheral surface of the support roller 34 is exposed at one side edge of the end plate 33 toward the center of the clamping ring 30. Figure 5 As shown, an outer gear ring 36 is connected to the outer circumferential surface of the probe 7, and the outer gear ring 36 is located outside the side of the clamping ring 30 away from the collecting box 100. A swing motor 37 is connected to the connecting seat 32, and a second pinion 38 is provided on the output shaft of the swing motor 37. The second pinion 38 is meshed with the outer gear ring 36. The swing motor 37 is electrically connected to the controller 27 through the connecting wire 20 and is controlled by the controller 27.

[0051] The flaw detector probe 7 is connected to the electric control box 12 and the controller 27 via a connecting wire 20 , and is controlled by the controller 27 .

[0052] As a further improvement to the above technical solution, in this embodiment, the connecting seat 32 is hinged to the connecting plate 31 through a hinge shaft 39. Figure 7 As shown, the connecting plate 31 is provided with two adjustment holes 40 symmetrically arranged on both sides of the hinge shaft 39, and the centers of the two adjustment holes 40 are at the same height as the center of the hinge shaft 39. The connecting seat 32 is provided with two arc holes 41 respectively arranged on both sides of the hinge shaft 39. The two arc holes 41 are both centered on the center of the hinge shaft 39, and the lower ends of the two arc holes 41 are respectively opposite to the two adjustment holes 40. The two adjustment holes 40 are detachably connected with locking bolts 42, which pass through the corresponding arc holes 41 and the adjustment holes 40 to connect the connecting plate 31 and the connecting seat 32 together.

[0053] When locking bolts 42 are provided in the two adjustment holes 40, the axial direction of the clamping ring 30 can be kept perpendicular to the axial direction of the collecting box 100. When any one of the locking bolts 42 is removed, the clamping ring 30 can swing around the hinge shaft 39 to further adjust the detection position of the probe 7 in a vertical plane, but the adjustment range is limited by the arc hole 41. When the two locking bolts 42 are removed, the adjustment range of the detection position of the probe 7 can be further expanded. However, without the locking of the locking bolts 42, the posture of the probe 7 is not easy to fix, and the friction between the connecting plate 31 and the connecting seat 32 needs to be increased.

[0054] like Figure 8 As shown, the base 1 includes a positioning ring 43 adapted to the outer wall of the top end of the header 100 and a base plate 44 connected to the top end of the positioning ring 43. The positioning ring 43 is evenly distributed with at least three threaded holes 45 in the circumferential direction. Each threaded hole 45 is threadedly connected with a tightening bolt 46. The base 1 is buckled on the top end of the header 100, the positioning ring 43 is sleeved on the outer wall of the top end of the header 100, and the end of the tightening bolt 46 is tightened against the outer wall of the header 100.

[0055] In actual production, the connection structure between the weld flaw detection device and the external power supply can also be as follows Fig. 9 As shown, the rotating end of the first center slip ring 13 is connected to the top of the electric control box 12, and an extension tube 49 extending radially outward is connected to the fixed end of the first center slip ring 13. The power line 48 is inserted into the extension tube 49. One end of the power line 48 is electrically connected to the fixed end of the first center slip ring 13, and the other end extends from the extension tube 49 and is connected to the power supply. The extension tube 49 is located above the cantilever and its length is greater than the length of the cantilever 4, so as to avoid interference with the power line 48 when the cantilever 4 rotates.

[0056] like Fig. 9As shown, the power line is connected from the outside of the header 100. This method is relatively easy to connect. However, due to the existence of the extension tube 49 and the power line hanging at the end of the extension tube 49, the entire flaw detection device occupies a large space and is likely to affect the operation of other equipment in the workshop. Figure 4 The structure shown in which the power line is connected from the inside of the header 100 is more difficult to connect, but it greatly reduces the space occupied by the entire flaw detection device, and the power line does not affect the operation of other equipment.

[0057] Based on the above-mentioned weld flaw detection device, a flaw detection method for automatically flaw detection of the weld of the horizontal high-pressure heater header pipe joint using the weld flaw detection device is described in detail below.

[0058] A method for flaw detection of a horizontal high-pressure heater header pipe joint weld, characterized in that it comprises the following specific steps:

[0059] S1. Install the base 1 of the weld flaw detection device to the top of the vertically arranged manifold 100, adjust the coaxiality of the rotating shaft 2 and the manifold 100 so that the rotating shaft 2 is coaxial with the manifold 100, turn on the power, start the controller 27, and the controller 27 actively resets the probe 7 to the initial position; the initial position can be set manually as needed. In this embodiment, the highest position to which the probe 7 can rise and the due west direction are used as the initial position.

[0060] S2. The worker starts welding the heat exchange tubes 50 from the bottom layer of the header 100. After welding of the heat exchange tubes 50 in the bottom layer of the header 100 is completed, the worker moves away from the flaw detection area.

[0061] S3. The employee uses a remote controller (not shown in the figure) to send a remote control signal to the controller 27. The controller 27 controls the rotary driver 9, the winding motor 19, and the swing motor 37 to work together according to the control signal, and lowers the probe 7 to the starting position above the heat exchange tube 50. The welds of the pipe joints between the heat exchange tube 50 and the header 100 at the starting position are subjected to multi-directional radiographic flaw detection. After the weld flaw detection device has completed the flaw detection of the welds of all the heat exchange tubes 50 of a layer, the probe 7 is reset upward to the initial position. The weld flaw detection device enters the standby state.

[0062] The starting position described in this step is considered to be set. Since the position of the weld of the pipe joint of the header 100 is fixed, the coordinates of each heat exchange tube 50 are also fixed. The user can use the weld of a heat exchange tube 50 directly below the initial position as the first target to be inspected, and set the coordinates and swing angles of the probe 7 when inspecting the weld of this heat exchange tube 50. The controller 27 can then control the probe 7 to perform the inspection according to the preset inspection procedure.

[0063] S4. The worker welds the heat exchange tubes layer by layer upwards, and repeats step S3 after each layer of heat exchange tubes 50 is welded, until all the heat exchange tubes 50 are welded and the flaw detection is completed.

[0064] S5. Remove the weld flaw detection device from the top of the header 100.

[0065] In step S3, the controller 27 controls the rotary driver 9, the winding motor 19, and the swing motor 37 to work together for automatic control, and the controller 27 completes the automatic control process according to a preset program. In actual applications, manual remote control can also replace automatic control to cope with special working conditions.

[0066] In step S3, the controller 27 controls the rotary driver 9 to rotate so that the probe 7 moves to the upper side of the heat exchange tube 50 to be inspected, and then controls the swing motor 37 to rotate, driving the probe 7 to rotate a certain angle, so that the probe 7 is diagonally downward toward the heat exchange tube 50 to perform weld flaw detection; then the controller 27 controls the rotary driver 9 to drive the probe 7 to move to the upper side of the heat exchange tube 50 to be inspected, and at the same time controls the swing motor 37 to drive the probe 7 to face directly downward, so as to perform a second inspection on the weld of the heat exchange tube 50 to be inspected; finally, the controller 27 controls the rotary driver 9 to drive the probe to move to the other side of the heat exchange tube 50 to be inspected, and at the same time controls the swing motor 37 to drive the probe 7 diagonally downward toward the weld of the heat exchange tube 50 to be inspected, so as to perform a third flaw detection on the weld of the heat exchange tube 50 to be inspected; after completion, perform weld flaw detection on the next heat exchange tube 50 according to the above steps.

[0067] The weld quality data detected by the probe 7 is transmitted to the controller 27, which can send the data to the flaw detector host through the remote control signal transceiver 28. The probe 7 can also directly establish wireless communication with the flaw detector host to directly send the detection results to the host. The host can be carried by the employee, so it is not shown in the figure.

[0068] The present invention utilizes the controller 27 to control the rotary driver 9, the winding motor 19, and the swing motor 37 to automatically adjust the flaw detection position and angle of the probe 7, and further utilizes the controller 27 to control the probe 7 to perform automatic flaw detection, thereby realizing the automatic flaw detection function of the horizontal high-pressure heater header pipe joint, thereby solving the technical problems of the current flaw detection work of the joint welds between the horizontal high-pressure heater header and the heat exchange tube, such as high difficulty, high intensity, low efficiency, easy fatigue of the flaw detector, and the existence of high-altitude operations.

[0069] The above embodiments are only illustrative of the principles and effects of the invention, as well as some embodiments of its application, and are not intended to limit the invention. It should be pointed out that a person skilled in the art can make several modifications and improvements without departing from the inventive concept of the invention, and all of these belong to the protection scope of the invention.

Claims

1. A weld flaw detection device for horizontal high-pressure heater header pipe joints, including a flaw detector, It is characterized in that The utility model also comprises a base (1) connected to the top of a vertically arranged header (100), a vertically arranged rotating shaft (2) being connected to the base (1), the rotating shaft (2) being coaxial with the header (100), a sleeve (3) being rotatably connected to the rotating shaft (2), a cantilever (4) being vertically connected to the outer wall of the sleeve (3), the cantilever (4) extending radially outwardly along the header (100), an end of the cantilever (4) away from the rotating shaft (2) being movably connected to a vertically arranged lifting rod (6), the lifting rod (6) being movable up and down along its axis, the lifting rod (6) being located outside the header (100), a probe (7) of the flaw detector being connected to the lower end of the lifting rod (6), a driving seat (8) being vertically connected to the outer wall of the sleeve (3), the driving seat (8) and the cantilever (4) being arranged on both sides of the sleeve (3), and a driving seat (8) being arranged on the driving seat (8). A rotary driver (9) for rotating the sleeve (3), wherein the rotary driver (9) is a servo motor, a large gear (10) coaxially arranged with the rotary shaft (2) is connected to the rotary shaft (2) below the sleeve (3) or the base (1), a first small gear (11) is connected to the output shaft of the rotary driver (9), the large gear (10) meshing with the first small gear (11), an electric control box (12) is also arranged above the rotary shaft (2), the lower end of the electric control box (12) extending to the top surface of the cantilever (4) and the drive seat (8) and being detachably connected to the cantilever (4) and the drive seat (8), a first center slip ring (13) coaxially arranged with the rotary shaft (2) is connected to the electric control box (12), the fixed end of the first center slip ring (13) being used to connect to an external power source, and the rotating end being electrically connected to the electric control box (12); A slider (5) is axially slidably connected to the cantilever (4), a through hole (14) is vertically provided on the slider (5), the lifting rod (6) is slidably connected in the through hole (14), a through groove (15) extending axially is provided on the side wall of the lifting rod (6) facing the sleeve (3), the lifting rod (6) is a hollow tube, the through groove (15) is connected to the inner hole of the lifting rod (6), a guide hole (16) connected to the through hole (14) is provided at one end of the slider (5) close to the sleeve (3), a guide sleeve (17) is rotatably connected in the guide hole (16), the guide sleeve (17) is in contact with the lifting rod (6), a reel (18) and a winding motor (19) for driving the reel (18) to rotate are provided on the cantilever (4), and the winding motor (19) is connected to the electric control box (12); A connecting wire (20) is passed through the lifting rod (6), and the connecting wire (20) is a tensile-resistant flexible cable. The lower part of the connecting wire (20) is fixed to the lower end of the lifting rod (6). The lower end of the connecting wire (20) passes through the lower end of the lifting rod (6) and out of the lifting rod (6). The upper end of the connecting wire (20) passes through the through groove (15) above the guide sleeve (17), bypasses the guide sleeve (17) and is wound on the reel (18). The reel (18) is a hollow cylinder. The end shaft (21) at one end of the reel (18) is rotatably connected to a bracket (22). The bracket (22) is fixedly connected to the cantilever (4). One end of the connecting wire (20) passes through the wall of the reel (18) and is inserted into the reel (18) and extends to the end shaft (21) with a center hole, and passes through the first Two center slip rings (23) are connected to the electric control box (12), the second center slip ring (23) is connected to the end of the end shaft (21), the cantilever (4) is also rotatably connected to a distance measuring wheel (24), the distance measuring wheel (24) is located between the winding drum (18) and the lifting rod (6) and is adjacent to the guide sleeve (17), the connecting wire (20) passes around the guide sleeve (17) and then passes around the lower edge of the distance measuring wheel (24), and then is wound onto the winding drum (18), the distance measuring wheel (24) is transmission-connected to an encoder (25), the distance measuring wheel (24) drives the encoder (25) to rotate synchronously, and the slider (5) is also threadedly connected to a fixing bolt (26), when the fixing bolt (26) is tightened, the top end of the fixing bolt (26) is tightly pressed against the cantilever (4) to lock the slider (5); The electric control box (12) is provided with a controller (27) and a remote control signal transceiver (28); the rotary driver (9), the winding motor (19) and the encoder (25) are respectively electrically connected to the controller (27) and are controlled by the controller (27); the remote control signal transceiver (28) is electrically connected to the controller (27); The probe (7) of the flaw detector is rotatably connected to the lower end of the lifting rod (6) through a clamping seat (29). The clamping seat (29) includes a clamping ring (30) and a connecting plate (31). The upper end of the connecting plate (31) is connected to the lower end of the lifting rod (6). The clamping ring (30) is formed by two half rings connected to each other. The top of the upper half ring is connected to the connecting seat (32). The connecting seat (32) is hinged to the connecting plate (31). The axial direction of the clamping ring (30) points to the central axis of the header (100). It comprises two semi-annular end plates (33) arranged opposite to each other and a plurality of support rollers (34) connected to the two end plates (33), the two ends of the two end plates (33) are respectively connected via a flange plate (35), the support rollers (34) are evenly distributed in the circumferential direction with the center of the clamping ring (30) as the center, the minimum distance from the outer circumference of any support roller (34) to the center of the clamping ring (30) is smaller than the minimum distance from the flange plate (35) to the center of the clamping ring (30), and all the support rollers (34) are used to clamp the probe (7) formed in a cylindrical shape. The outer circumferential surface of the support roller (34) is exposed at an edge of a side of the end plate (33) facing the center of the clamping ring (30); an outer gear ring (36) is connected to the outer circumferential surface of the probe (7); the outer gear ring (36) is located outside the clamping ring (30) on a side away from the header (100); a swing motor (37) is connected to the connecting seat (32); a second pinion (38) is provided on the output shaft of the swing motor (37); the second pinion (38) is meshed with the outer gear ring (36); the swing motor (37) is electrically connected to the controller (27) via a connecting wire (20) and is controlled by the controller (27); The flaw detector probe (7) is connected to the electric control box (12) and the controller (27) via a connecting wire (20), and is controlled by the controller (27).

2. The weld flaw detection device according to claim 1, It is characterized in that The connecting seat (32) is hinged to the connecting plate (31) via a hinge shaft (39). The connecting plate (31) is provided with two adjustment holes (40) symmetrically arranged on both sides of the hinge shaft (39). The centers of the two adjustment holes (40) are at the same height as the center of the hinge shaft (39). The connecting seat (32) is provided with two arc holes (41) arranged on both sides of the hinge shaft (39). The two arc holes (41) are both centered on the center of the hinge shaft (39). The lower ends of the two arc holes (41) are respectively opposite to the two adjustment holes (40). Locking bolts (42) are detachably connected to the two adjustment holes (40). The locking bolts (42) penetrate the corresponding arc holes (41) and the adjustment holes (40) to connect the connecting plate (31) and the connecting seat (32) together.

3. The weld flaw detection device according to claim 1, It is characterized in that The base (1) comprises a positioning ring (43) adapted to the outer wall of the top end of the header (100) and a base plate (44) connected to the top end of the positioning ring (43). The positioning ring (43) is circumferentially evenly distributed with at least three threaded holes (45). Each threaded hole (45) is internally threadedly connected to a tightening bolt (46). The base (1) is buckled onto the top end of the header (100), the positioning ring (43) is sleeved on the outer wall of the top end of the header (100), and the end of the tightening bolt (46) is pressed against the outer wall of the header (100).

4. The weld flaw detection device according to claim 1, It is characterized in that The fixed end of the first center slip ring (13) is connected to the top of the rotating shaft (2), a threading hole (47) is provided at the center of the rotating shaft (2), the fixed end of the first center slip ring (13) is connected to a power line (48), the power line (48) passes through the threading hole (47) of the rotating shaft (2), extends downward and is connected to a power source, and the rotating end of the first center slip ring (13) is electrically connected to the electric control box (12) and rotates with the electric control box (12).

5. The weld flaw detection device according to claim 1, It is characterized in that The rotating end of the first center slip ring (13) is connected to the top of the electric control box (12); the fixed end of the first center slip ring (13) is connected to an extension tube (49) extending radially outward; a power line (48) is inserted into the extension tube (49); one end of the power line (48) is electrically connected to the fixed end of the first center slip ring (13); the other end extends from the extension tube (49) and is connected to a power source; the length of the extension tube (49) is greater than the length of the cantilever (4).

6. A flaw detection method for a weld flaw detection device applied to a horizontal high-pressure heater header pipe joint based on any one of claims 1 to 5 above, It is characterized in that The specific steps include: S1. Install the base (1) of the weld flaw detection device to the top of a vertically arranged header (100), adjust the coaxiality of the rotating shaft (2) and the header (100) so that the rotating shaft (2) and the header (100) are coaxial, turn on the power, and the controller (27) actively resets the probe (7) to the initial position; S2. The worker starts welding the heat exchange tubes (50) from the bottom layer of the header (100). After welding of a circle of heat exchange tubes (50) at the bottom layer of the header (100) is completed, the worker moves away from the flaw detection area; S3, the employee uses the remote control to send a remote control signal to the controller (27), and the controller (27) controls the rotary driver (9), the winding motor (19), and the swing motor (37) to work together according to the control signal, and lowers the probe (7) to the starting position above the heat exchange tube (50), and performs a multi-directional radiographic flaw detection on the weld of the heat exchange tube at the starting position; after the weld flaw detection device completes the flaw detection of all the welds of the heat exchange tubes (50) in one layer, the probe (7) is reset upward to the initial position; and the weld flaw detection device enters a standby state; S4, the worker welds the heat exchange tubes layer by layer upwards, and repeats step S3 once each layer of heat exchange tubes (50) is welded until all the heat exchange tubes (50) are welded and flaw detection is completed; S5. Remove the weld flaw detection device from the top of the header (100).

7. The flaw detection method according to claim 6, It is characterized in that In step S3, the controller (27) controls the rotary driver (9), the winding motor (19), and the swing motor (37) to coordinate actions for automatic control, and the controller (27) completes the automatic control process according to a preset program.

8. The flaw detection method according to claim 6, It is characterized in that In step S3, the controller (27) controls the rotary driver (9) to rotate so that the probe (7) moves to the upper side of the heat exchange tube (50) to be inspected, and then controls the swing motor (37) to rotate so as to drive the probe (7) to rotate a certain angle so that the probe (7) is tilted downward toward the heat exchange tube (50) to perform a weld flaw detection inspection. Then, the controller (27) controls the rotary driver (9) to drive the probe (7) to move to the upper side of the heat exchange tube (50) to be inspected, and at the same time controls the swing motor (37) to drive the probe (7) to the lower side, so as to perform a second inspection on the weld of the heat exchange tube (50) to be inspected. Finally, the controller (27) controls the rotary driver (9) to drive the probe (7) to move to the other side of the heat exchange tube (50) to be inspected, and at the same time controls the swing motor (37) to drive the probe (7) to the lower side toward the weld of the heat exchange tube (50) to be inspected, so as to perform a third flaw detection inspection on the weld of the heat exchange tube (50) to be inspected. After completion, the weld flaw detection inspection is performed on the next heat exchange tube (50) according to the above steps.

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