Large-diameter submerged arc welding pipe end ultrasonic flaw detection device and detection method

Abstract

The invention discloses a large-diameter submerged arc welding pipe end ultrasonic flaw detection device and a detection method. A steel pipe, a rotating roller mechanism for supporting and driving the steel pipe to rotate and a water circulation system for providing coupling water for an ultrasonic probe are sequentially arranged from top to bottom; the manipulator is arranged at one end of the rotary roller mechanism and located on the axial outer side of the detected end of the steel pipe; the ultrasonic probe module comprises a group of straight probes for layered detection and two groups of inclined probes for detecting transverse injury, longitudinal injury and inclined injury; the straight probe and the angle probe are arranged at the hand part of the manipulator; during detection, the straight probe and the angle probe are located below the inner wall of the steel pipe or above the outer wall of the steel pipe. The device has the beneficial effects that the design is reasonable, the structural form that the manipulator is matched with the phased array probe group is adopted, the layering, non-layering, transverse defect and longitudinal defect identification of the submerged arc welding pipe end is completed through automatic ultrasonic flaw detection, and the identification rate of the pipe end defect is effectively improved; the operation is convenient, the labor intensity of workers is greatly reduced, and the influence of human factors is reduced.

Description

Technical Field

[0001] The invention relates to an ultrasonic flaw detection device, in particular to an ultrasonic flaw detection device and a detection method for a large-diameter submerged arc welded pipe end, belonging to the technical field of mechanical processing. Background Art

[0002] The manufacturing standards for high-grade line pipes usually require that after the hydrostatic test, ultrasonic inspection of longitudinal and transverse defects in the entire length and area of ​​the weld be carried out. Due to the blind area of ​​the pipe end caused by automatic ultrasonic inspection of steel pipes, manual ultrasonic inspection should be carried out at least 300mm from the pipe end. Within 25mm on both sides of the steel pipe weld, no defects exceeding 6.4mm along the weld and an area greater than 100mm are allowed. 2 Delamination; within 25mm of the pipe end, no delamination with a length exceeding 6.4mm along the circumferential direction and an area greater than 100mm is allowed 2 The 25mm range of the steel pipe end should be subjected to ultrasonic testing for non-delamination defects and testing of the pipe end groove surface.

[0003] Due to the constraints of existing technical conditions, the ultrasonic testing of steel pipe ends in domestic submerged arc welded pipe production lines currently adopts manual probing, which requires high operating skills of workers, has a large human influence factor, and has high labor intensity for workers. Especially when producing large-diameter (diameter ≥ 1016mm) submerged arc welded pipes, the workload of pipe end flaw detection is large, the task is heavy, and the operation is not convenient. Ultrasonic manual probing of pipe ends also has a great impact on production rhythm, and there are certain quality and safety risks. Summary of the invention

[0004] In order to overcome the above-mentioned deficiencies in ultrasonic detection of steel pipe ends in existing submerged arc welded pipe production lines, the present invention provides an ultrasonic flaw detection device and detection method for large-diameter submerged arc welded pipe ends.

[0005] The technical solution adopted by the present invention to solve its technical problems is: a large-diameter submerged arc welded pipe end ultrasonic flaw detection device, including a steel pipe, a manipulator, an ultrasonic probe module, and an operating table. The steel pipe, a rotating roller mechanism that supports and drives the steel pipe to rotate, and a water circulation system that provides coupling water to the ultrasonic probe are arranged in sequence from top to bottom; the manipulator is arranged at one end of the rotating roller mechanism and is located axially outside the inspected end of the steel pipe.

[0006] The ultrasonic probe module includes a group of straight probes for layered detection and two groups of oblique probes for detecting transverse injuries, longitudinal injuries and oblique injuries; the straight probes and oblique probes are arranged on the hand of the manipulator; during detection, the straight probes and oblique probes are located below the inner wall of the steel pipe or above the outer wall of the steel pipe.

[0007] The ultrasonic probe module is driven by a manipulator to move along the axial direction of the steel pipe.

[0008] The straight probe is extended and retracted along the radial direction of the steel pipe.

[0009] The angle between the oblique probe and the vertical radial direction of the steel pipe is θ, and the oblique probe is extended and retracted along the radial direction of the steel pipe.

[0010] The radial angles θ of the two oblique probes are in opposite directions.

[0011] The straight probe and the oblique probe adopt medium and low frequency probes with 64 array elements or 128 array elements.

[0012] The ultrasonic host's ultrasonic phased array detection board integrates 128 channels of parallel transmission, 32 receiving channels for acquisition and processing, 2.5ns sound beam delay control, and real-time data upload via PC connection.

[0013] The rotating roller mechanism includes one active roller support frame and two or more roller support frames. The active roller support frame located in the middle of the steel pipe drives the steel pipe to rotate, and the roller support frames are arranged at the front and rear ends of the active roller support frame.

[0014] The liquid outlet pipe of the water circulation system is connected to the ultrasonic probe for water supply coupling.

[0015] The manipulator is a six-axis manipulator.

[0016] The detection method of the flaw detection device is:

[0017] Layered detection: using phased array 0 degree linear scanning method;

[0018] Horizontal defect detection: Utilize the electronic deflection function of phased array technology and adopt ±45-degree bidirectional group deflection to detect horizontal defects of steel pipes;

[0019] Longitudinal defect detection: Use 45-degree shear wave wedges for linear scanning to detect longitudinal defects in pipes;

[0020] Oblique flaw detection: physical deflection + phased array electronic deflection scanning function is used to detect oblique defects in steel pipes.

[0021] The beneficial effects of the present invention are that it has a reasonable design and adopts a structural form of a manipulator equipped with a phased array probe group, and completes the identification of stratification, non-stratification, transverse defects and longitudinal defects at the ends of submerged arc welded pipes through automatic ultrasonic flaw detection, thereby effectively improving the recognition rate of pipe end defects; it is easy to operate, greatly reduces the labor intensity of workers, reduces the influence of human factors, adapts to the production rhythm of steel pipes, effectively improves production efficiency, and reduces quality and safety risks. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a structural schematic diagram of an ultrasonic flaw detection device for a large-diameter submerged arc welded pipe end of the present invention.

[0023] Figure 2 It is a schematic diagram of the ultrasonic probe module in the present invention.

[0024] Figure 3 It is a schematic diagram of the layered detection process of the present invention.

[0025] Figure 4 It is a schematic diagram of the transverse injury detection process of the present invention.

[0026] Figure 5 It is a schematic diagram of the longitudinal injury detection process of the present invention.

[0027] Figure 6 This is a schematic diagram of the oblique flaw detection process of the present invention.

[0028] In the figure: 1. steel pipe, 2. manipulator, 3. ultrasonic probe module, 4. water circulation system, 5. rotating roller mechanism, 31. straight probe, 32. oblique probe, 51. active roller support frame, 52. roller support frame. DETAILED DESCRIPTION

[0029] The present invention will be further described below in conjunction with the accompanying drawings and embodiments. However, those skilled in the art should be aware that the present invention is not limited to the specific embodiments listed, and all embodiments should be included in the protection scope of the present invention as long as they conform to the spirit of the present invention.

[0030] In the description of the present invention, it should be noted that the terms "vertical", "up", "down", "left", "right", "horizontal", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing or simplifying the description of the present invention, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0031] In the description of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", "connection", and "seal" should be understood in a broad sense. For example, the connection can be a fixed connection or a detachable connection, a direct connection, an indirect connection, or an integral connection; it can be a mechanical connection, an indirect connection through an intermediate medium, or a communication between the two components. The seal can be an oil seal, a packing seal, or other forms of seals. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0032] See attached Figure 1The present invention discloses an ultrasonic flaw detection device for the end of a large-diameter submerged arc welded pipe, comprising a steel pipe 1, a manipulator 2, an ultrasonic probe module 3, an operating table, a rotating roller mechanism 5, and a water circulation system 4. The steel pipe 1, the rotating roller mechanism 5 supporting and driving the steel pipe 1 to rotate, and the water circulation system 4 providing coupling water to the ultrasonic probe are arranged in sequence from top to bottom; the manipulator 2 is arranged at one end of the rotating roller mechanism 5, and is located axially outside the detected end of the steel pipe 1.

[0033] See attached Figure 2 . The ultrasonic probe module 3 includes a group of straight probes 31 for layered detection and two groups of oblique probes 32 for detecting transverse injuries, longitudinal injuries and oblique injuries. The straight probes 31 and the oblique probes 32 are arranged on the hand of the manipulator 2. During detection, the straight probes 31 and the oblique probes 32 are located at the weld of the inner wall of the steel pipe 1 or the outer wall of the steel pipe 1. When the ultrasonic probe module 3 is located at the inner wall of the steel pipe 1, the ultrasonic probe module 3 is located below the steel pipe 1; when the ultrasonic probe module 3 is located to detect the outer wall of the steel pipe 1, the ultrasonic probe module 3 is located above the steel pipe.

[0034] The ultrasonic probe module 3 is driven by the manipulator 2 to move axially along the steel pipe 1 .

[0035] Furthermore, the straight probe 31 is retractable along the radial direction of the steel pipe 1 .

[0036] Furthermore, the angle between the oblique probe 32 and the perpendicular radial direction of the steel pipe 1 is θ, and the oblique probe 32 is extended and retracted along the radial direction of the steel pipe 1. The radial angles θ of the two oblique probes 32 are in opposite directions.

[0037] Furthermore, the straight probe 31 and the oblique probe 32 are medium and low frequency probes with 64 array elements or 128 array elements.

[0038] The ultrasonic probe module 3 includes three probes (two groups of oblique probes and one group of straight probes). The two groups of oblique probes can rotate at a certain angle, the straight probe can be extended and retracted up and down, and the probe module can also be extended and retracted as a whole to adapt to ultrasonic detection of pipe ends of different pipe diameters.

[0039] Linear array phased array probes are used for testing. Depending on the actual situation, 64-element or 128-element probes can be used. In order to improve the electronic deflection capability of the phased array probe, small element spacing and medium and low frequency probes are used.

[0040] The ultrasonic phased array detection board of the ultrasonic host has 128 channels for parallel transmission, 32 channels for acquisition and processing, 2.5ns sound beam delay control, and is connected to a PC for real-time data upload.

[0041] The rotating roller mechanism 5 includes an active roller support frame 51 and more than two roller support frames 52. The active roller support frame 51 located in the middle of the steel pipe 1 drives the steel pipe 1 to rotate. The roller support frames 52 are arranged at the front and rear ends of the active roller support frame 51 to support the steel pipe 1. When the weld of the steel pipe 1 is a spiral weld, during ultrasonic flaw detection, the rotation speed of the steel pipe 1 ensures that the linear movement of the ultrasonic probe module 3 matches the spiral angle of the weld.

[0042] The liquid outlet pipe of the water circulation system 4 is connected to the ultrasonic probe 3 for water supply coupling. The water circulation system 4 includes a water tank, a water pump, a filter, a flow regulating valve, a control valve, etc. During ultrasonic flaw detection, the water circulation system 4 supplies water coupling to the ultrasonic probe, and the coupling water is filtered and recycled.

[0043] The manipulator 2 is a six-axis manipulator. Preferably, the six-axis manipulator has a load of about 20 kg, an arm span of about 1.8 m, and a repeatability accuracy of 0.02 mm.

[0044] The large-diameter submerged arc welded pipe end ultrasonic flaw detection device of the present invention can detect delamination, transverse damage, longitudinal damage and oblique damage of the steel pipe 1. The specific detection method is:

[0045] Layered detection: Use phased array 0 degree linear scanning method (see attached Figure 3 ). Preferably, in the case of 15mm thick steel pipe flat bottom hole (simulating delamination defect) detection, a 5MHz, 128 array elements, 0.8mm center distance linear array water immersion phased array probe is used, a 30mm water layer (the thickness of the water layer will vary depending on the wall thickness), and a 0° linear scanning mode longitudinal wave detection is used. The primary excitation aperture affects the pitch, and the aperture can be set according to the pitch (efficiency) requirements.

[0046] Horizontal defect detection: Using the electronic deflection function of phased array technology, ±45-degree bidirectional group deflection is used to detect horizontal defects of steel pipes (see attached Figure 4 , in the figure The defect direction to be detected is indicated, and the group of arrows below the oblique probe 32 is the direction of the sound beam). Preferably, in the case of transverse damage detection on the inner wall of a 15mm thick steel pipe (secondary wave detection on the outer wall is sufficient), a 5MHz, 128-element, 0.8mm center-to-center linear array water immersion phased array probe is used, and a 30mm water layer (the thickness of the water layer varies depending on the wall thickness) is used. A 45° transverse wave is generated in the steel through phased array electronic deflection technology, and a linear scanning mode is selected. The primary excitation aperture affects the pitch, and the aperture can be set according to the pitch (efficiency) requirements.

[0047] Longitudinal defect detection: Use a 45-degree shear wave wedge to perform linear scanning to detect longitudinal defects in pipes (see attached Figure 5 , in the figure The defect direction to be detected is indicated, and the group of arrows below the oblique probe 32 is the direction of the sound beam). Preferably, in the case of longitudinal damage detection on the inner wall of a 15mm thick steel pipe (secondary wave detection on the outer wall is sufficient), a 5MHz, 64-element, 1.6mm center-to-center linear array water immersion phased array probe is used, and a 30mm water layer (the thickness of the water layer varies depending on the wall thickness) is used. The probe is rotated by a certain angle through a mechanism to generate a 45° shear wave detection in the steel, and the linear scanning mode is selected. The primary excitation aperture affects the pitch, and the aperture can be set according to the pitch (efficiency) requirements.

[0048] Oblique flaw detection: Use physical deflection + phased array electronic deflection scanning function to detect oblique defects in steel pipes (see attached Figure 6 , in the figure The defect direction to be detected is indicated, and the group of arrows below the oblique probe 32 is the direction of the sound beam). Preferably, in the case of the oblique flaw detection on the inner wall of a 15mm thick steel pipe (the oblique flaw on the outer wall can be detected by secondary wave), a 5MHz, 128 array elements, 0.8mm center distance linear array water immersion phased array probe is used, and a 30mm water layer (the thickness of the water layer varies with the wall thickness) water layer is used. The probe is rotated by a certain angle through a mechanism to generate a pure shear wave in the steel and an angled linear scan is set. The primary excitation aperture affects the pitch, and the aperture can be set according to the pitch (efficiency) requirements.

[0049] The software system of the present invention has multiple group management modules, which can quickly add or delete groups and manage the arrangement of each group according to actual usage. It supports up to 32 groups of simultaneous scanning and can display up to 8 groups on the same screen, which is helpful for high-difficulty inspection under complex processes.

[0050] The software system has various gate types, including rectangular gate, linear gate, sound path gate, and projection gate, so as to remove interference signals and inherent echoes, so as to generate pure C-scan images and greatly improve data evaluation efficiency. It supports RF mode gates, positive wave, negative wave, positive and negative wave measurements; the gate measurement value supports peak value, front edge, first peak value, last peak value, and highest peak front edge.

[0051] The process of using the present invention to perform ultrasonic testing of steel pipe ends is as follows:

[0052] (1) Turn on the power switch of the device, the device starts to standby mode, and selects the preset ultrasound configuration;

[0053] (2) Click the start button on the console to start the flaw detection device;

[0054] (3) The rotating roller mechanism 5 drives the inspected steel pipe 1 to rotate;

[0055] (4) The ultrasonic probe module 3 carried by the manipulator 2 reaches the detection position;

[0056] (5) Starting the water circulation system 4 to supply water to the straight probe and the oblique probe of the ultrasonic probe module 3;

[0057] (6) The straight probe and the oblique probe begin automatic detection.

[0058] The large-diameter submerged arc welded pipe end ultrasonic flaw detection device and detection method of the present invention adopt a structural form of a manipulator equipped with a phased array probe group. On the basis of a large number of pipe end detection tests, a set of mature submerged arc welded pipe end defect (layering, non-layering, weld horizontal and vertical defects) automatic ultrasonic flaw detection technology is formed to improve the recognition rate of pipe end defects.

[0059] Detection functions: transverse and longitudinal defects of welds, delamination defects of base metals, and non-delamination defects of base metals;

[0060] Flaw detection cycle: 6 minutes / end;

[0061] Pipe end weld detection range: ≥300mm;

[0062] Detection range on both sides of the weld: ≥25mm;

[0063] The detection range of the base material layer at the pipe end: ≥50mm;

[0064] Non-delamination detection range of pipe end base material: 0~150mm.

[0065] The invention discloses an ultrasonic flaw detection device and method for large-diameter submerged arc welded pipe ends, which is an automatic device integrating multiple ultrasonic flaw detection processes such as pipe end welds, pipe end stratification, non-stratification defects, etc., and realizes accurate identification of submerged arc welded pipe end defects.

[0066] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the claims of this patent.

Claims

1. A large-diameter submerged arc welded pipe end ultrasonic flaw detection device, comprising a steel pipe, a manipulator, an ultrasonic probe module, and an operating table, characterized in that: The steel pipe, the rotating roller mechanism that supports and drives the steel pipe to rotate, and the water circulation system that provides coupling water to the ultrasonic probe are arranged in sequence from top to bottom; the manipulator is arranged at one end of the rotating roller mechanism, and is located axially outside the detected end of the steel pipe; The ultrasonic probe module includes a group of straight probes for layered detection and two groups of oblique probes for detecting transverse injuries, longitudinal injuries and oblique injuries; the straight probes and oblique probes are arranged on the hand of the manipulator; during detection, the straight probes and oblique probes are located below the inner wall of the steel pipe or above the outer wall of the steel pipe.

2. The large-diameter submerged arc welded pipe end ultrasonic flaw detection device according to claim 1 is characterized in that: The ultrasonic probe module is driven by a manipulator to move along the axial direction of the steel pipe; The straight probe is extended and retracted along the radial direction of the steel pipe; The angle between the oblique probe and the vertical radial direction of the steel pipe is θ, and the oblique probe expands and contracts along the radial direction of the steel pipe.

3. The large-diameter submerged arc welded pipe end ultrasonic flaw detection device according to claim 2 is characterized in that: The radial angles θ of the two oblique probes are in opposite directions.

4. The large-diameter submerged arc welded pipe end ultrasonic flaw detection device according to claim 3 is characterized by: The straight probe and the oblique probe adopt medium and low frequency probes with 64 array elements or 128 array elements.

5. The large-diameter submerged arc welded pipe end ultrasonic flaw detection device according to claim 4 is characterized in that: The ultrasonic host's ultrasonic phased array detection board integrates 128 channels of parallel transmission, 32 receiving channels for acquisition and processing, 2.5ns sound beam delay control, and real-time data upload via PC connection.

6. The large-diameter submerged arc welded pipe end ultrasonic flaw detection device according to claim 1 is characterized by: The rotating roller mechanism includes one active roller support frame and two or more roller support frames. The active roller support frame located in the middle of the steel pipe drives the steel pipe to rotate, and the roller support frames are arranged at the front and rear ends of the active roller support frame.

7. The large-diameter submerged arc welded pipe end ultrasonic flaw detection device according to claim 1 is characterized by: The liquid outlet pipe of the water circulation system is connected to the ultrasonic probe for water supply coupling.

8. The large-diameter submerged arc welded pipe end ultrasonic flaw detection device according to claim 1 is characterized by: The manipulator is a six-axis manipulator.

9. A detection method of the flaw detection device according to claim 1, characterized in that: Layered detection: using phased array 0 degree linear scanning method; Horizontal defect detection: Utilize the electronic deflection function of phased array technology and adopt ±45-degree bidirectional group deflection to detect horizontal defects of steel pipes; Longitudinal defect detection: Use 45-degree shear wave wedges for linear scanning to detect longitudinal defects in pipes; Oblique flaw detection: physical deflection + phased array electronic deflection scanning function is used to detect oblique defects in steel pipes.

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