Combined phased array imaging in-situ detection method and device

Abstract

The invention belongs to the technical field of nondestructive testing, particularly relates to a combined phased array imaging in-situ detection method and device, and aims to solve the problems of small detection coverage, low defect judgment accuracy and low efficiency. The method comprises the following steps: constructing a combined phased array imaging in-situ detection device, and connecting the detection device with a data detection system; initializing defect detection parameters based on the type and defect characteristics of the workpiece surface of the to-be-detected workpiece; scanning the to-be-detected workpiece by using the detection device to obtain defect detection data and inputting the defect detection data to the data detection system; and outputting defect result data according to a defect identification method, when the defect result data exceeds a set threshold value, outputting an alarm signal to an alarm, observing the position and the size of the defect, if the defect result data is incorrect, re-detecting, and if the defect result data is correct, ending, and judging the next to-be-detected workpiece. According to the device and the method, the detection efficiency is improved, the detection accuracy and reliability are improved, and the device and the method are safe, efficient and low in cost and have wide application prospects.

Description

Technical Field

[0001] The present invention belongs to the technical field of non-destructive testing, and particularly relates to a combined phased array imaging in-situ detection method and device. Background Art

[0002] With the increasing depth of oil exploration, the drilling difficulty is getting greater and greater, and the service environment of drill pipes and internal blowout preventers is becoming more and more severe, so the probability of thread failure or even breakage of drill pipes and internal blowout preventers is increasing; at the same time, the pressure in the wellbore is getting higher and higher, and the well control risk is increasing. During the process of handling overflow, the liquid-gas separator tank is eroded by gas-containing drilling fluid, and erosion pits are likely to appear, affecting its pressure-bearing capacity; during the operation of the accumulator cylinder, it repeatedly bears the internal pressure and impact of hydraulic oil, and internal cracks are likely to occur and then leak and fail due to stabbing. Therefore, it is necessary to perform non-destructive testing on drill pipes, internal blowout preventers, liquid-gas separators and accumulator cylinders through non-destructive testing methods to detect defects and eliminate potential hazards.

[0003] Through on-site technical research on drill pipe and internal blowout preventer thread, liquid-gas separator, and accumulator cylinder manufacturing enterprises, these enterprises generally adopt the "A-scan ultrasonic + magnetic particle" non-destructive testing technology during the manufacturing process of drill pipe threads, liquid-gas separator tanks, and accumulator cylinders according to the requirements of industry standards; while for users, due to the influence of the space structure and anti-corrosion paint layer of the liquid-gas separator tank and accumulator cylinder, visual inspection is generally used for rough inspection, which cannot meet the requirements of non-destructive testing. The existing non-destructive testing technology methods cannot meet the requirements of refined non-destructive testing for drill pipe and internal blowout preventer threads, liquid-gas separators, and accumulator cylinders.

[0004] At present, domestic manufacturing enterprises generally use magnetic particle inspection and A-scan ultrasonic inspection to detect the surface and welds of the drill pipe and internal blowout preventer tool threads, tank bodies, and cylinder bodies during the production and manufacturing of drill pipes, internal blowout preventer tools, liquid-gas separators, and accumulator cylinders. When inspecting the threads of drill pipes and internal blowout preventer tools, A-scan ultrasonic inspection cannot detect thread end faces with a size less than 8 mm; accurate judgment of the defect position and size can only be based on experience wells; magnetic particle inspection can only detect shallow surface defects within 1-2 mm from the surface; magnetic particle inspection and conventional ultrasonic inspection of the surface and welds of tank bodies and cylinder bodies have problems such as small inspection coverage, low accuracy in defect judgment, and low efficiency; after the liquid-gas separator and accumulator cylinder are put into use, due to the anti-corrosion paint layer covering the surface, large surface area, and complex space around the body, it is difficult to remove the paint layer. Coupled with the large volume of the liquid-gas separator tank body and large displacement of the inspection space, the inspection is difficult; compared with the drill pipe and internal blowout preventer tool threads, and the accumulator cylinder and the liquid-gas separator tank body, the volumes are about 1 / 500 and 1 / 80 of it respectively, with a large difference, and it is necessary to solve the large difference in the sizes of inspection instruments; moreover, after the liquid-gas separator tank body and accumulator cylinder are installed, restricted by the surrounding racks and fixtures, the inspection space is small and complex, affecting the inspection effect and efficiency. The user unit has basically not carried out any work on non-destructive testing. Therefore, it is necessary to carry out research and application of non-destructive testing technologies suitable for the characteristics of drill pipe and internal blowout preventer tool threads, liquid-gas separator tank bodies, and accumulator cylinders.

[0005] Ultrasonic phased array technology is composed of many elements arranged in an array. The ultrasonic phased array transducer consists of multiple independent piezoelectric wafers arranged in an array. According to certain rules and time sequences, an electronic system is used to control and excite each wafer unit to adjust and control the position of the focus and the focusing direction.

[0006] Based on this, the present invention proposes a combined phased array imaging in-situ detection method and device. Summary of the Invention

[0007] In order to solve the above problems in the prior art, that is, restricted by the surrounding racks and fixtures, the inspection space is small and complex, affecting the inspection effect and efficiency, and magnetic particle inspection and conventional ultrasonic inspection of the surface and welds of tank bodies and cylinder bodies have problems such as small inspection coverage, low accuracy in defect judgment, and low efficiency, the present invention provides a combined phased array imaging in-situ detection method and device.

[0008] The present invention proposes a combined phased array imaging in-situ detection method, which includes the following steps:

[0009] Step S10, construct a combined phased array imaging in-situ detection device and connect the detection device to a data detection system; the detection device is constructed based on the thread end face, the cylindrical surface of the accumulator cylinder, and the spherical surface of the liquid-gas separator.

[0010] Step S20: Initialize the defect detection parameters based on the type of the workpiece surface and the defect characteristics of the workpiece to be detected;

[0011] Step S30: Use the detection device to scan the workpiece to be detected, obtain defect detection data, and input it into the data detection system;

[0012] Step S40: Output defect result data according to the defect recognition method. When the number of the defect results exceeds the set threshold, output an alarm signal to the alarm, observe the defect position and size. If it is incorrect, jump to Step S20. If it is correct, end and proceed to judge the next workpiece to be detected;

[0013] Among them, the defect recognition method is based on the defect shapes and defect detection parameters built in the data detection system and is constructed by using a three-dimensional defect algorithm.

[0014] In some preferred embodiments, the three-dimensional defect algorithm includes methods for crack, hole, and groove recognition and judgment.

[0015] On the other hand, the present invention proposes a combined phased array imaging in-situ detection device, based on a combined phased array imaging in-situ detection method. The combined phased array imaging in-situ detection device is constructed based on the threaded end face, and includes an adjustment mechanism, a rotating base, a cross beam, a detection probe, a probe fixture, and an encoding wheel;

[0016] The adjustment mechanism is fixed to the bracket. The adjustment mechanism is connected to the rotating base by a bearing. A cross beam is fixed on the rotating base. The probe fixture and the encoding wheel are respectively movably and fixedly arranged at both ends of the cross beam. The detection probe is fixed on the probe fixture. The detection probe is used to detect the defect result data of the workpiece to be detected. The encoding wheel is used to obtain the running position of the detection probe, so as to determine the defect position of the defect result data.

[0017] In some preferred embodiments, the adjustment mechanism includes a tightening bracket, a first support frame, and an adjustment nut;

[0018] The tightening bracket is fixed to the first support frame. The first support frame is fixed to the bracket. The tightening bracket is threadedly connected to the adjustment nut. The adjustment nut is connected to the rotating base by a bearing.

[0019] In some preferred embodiments, the detection probe is a flat phased array probe.

[0020] In the third aspect of the present invention, a combined phased array imaging in-situ detection device is proposed, based on a combined phased array imaging in-situ detection method. The combined phased array imaging in-situ detection device is constructed based on the cylindrical surface of an accumulator cylinder and the spherical surface of a liquid-gas separator, and includes a handle assembly, a second support frame, an encoder assembly, a first chain assembly, a second chain assembly, and a probe holder.

[0021] The handle assembly is fixed to the middle of the second support frame. The length direction of the second support frame is parallel to the axis direction of the cylindrical surface of the accumulator cylinder or perpendicular to the radial direction of the spherical surface of the liquid-gas separator. The first chain assembly and the second chain assembly are respectively installed at both ends of the second support frame, and the first chain assembly and the second chain assembly are used to fix the two ends of the accumulator cylinder or the spherical surface of the liquid-gas separator to be detected in a surrounding manner.

[0022] The second support frame is also provided with an encoder assembly and a probe holder. The encoder assembly is used to obtain the position of the detection probe, and the probe holder is used to hold the detection probe.

[0023] In some preferred embodiments, both the first chain assembly and the second chain assembly include a plurality of connecting plates detachably fixed by pin posts. The number of connecting plates is increased or decreased according to the diameter of the cylindrical surface of the accumulator cylinder or the spherical surface of the liquid-gas separator, so as to achieve different lengths.

[0024] In some preferred embodiments, the detection probe is a curved phased array probe.

[0025] In some preferred embodiments, both the coding wheel and the encoder assembly include a roller-type optoelectronic device that moves with the probe.

[0026] In some preferred embodiments, a plurality of the detection probes are connected to the data detection system inlet through a common dedicated interface and a data acquisition line.

[0027] Advantages of the present invention:

[0028] (1) Through the multi-channel ultrasonic probes and data acquisition system in the form of an array, parallel detection of three-dimensional imaging can be realized, improving the detection efficiency.

[0029] (2) The present invention can obtain three-dimensional images inside the object to be measured, improving the accuracy and reliability of detection.

[0030] (3) The device and method of the present invention are safe, efficient, and low-cost, and have broad application prospects. Description of the Drawings

[0031] Other features, objects, and advantages of the present application will become more apparent from the following detailed description of non-limiting embodiments read in conjunction with the accompanying drawings:

[0032] Figure 1 is a schematic flow chart of a combined phased array imaging in-situ detection method according to the first embodiment of the present invention;

[0033] Figure 2 is a schematic structural diagram of a combined phased array imaging in-situ detection device according to the second embodiment of the present invention;

[0034] Figure 3 is a schematic structural diagram of a combined phased array imaging in-situ detection device according to the third embodiment of the present invention;

[0035] Figure 4 is a schematic structural diagram of a combined phased array imaging in-situ detection device during use according to the third embodiment of the present invention. Detailed Embodiments

[0036] The present application will be further described in detail below in conjunction with the accompanying drawings and embodiments. It can be understood that the specific embodiments described herein are only for explaining the relevant invention and are not intended to limit the invention. Additionally, it should be noted that for the sake of description, only parts related to the relevant invention are shown in the drawings.

[0037] It should be noted that, without conflict, the embodiments in the present application and the features in the embodiments can be combined with each other. The present application will be described in detail below with reference to the drawings and in conjunction with the embodiments.

[0038] Refer to Figure 1 , the first embodiment of the present invention provides a combined phased array imaging in-situ detection method, and the method includes the following steps:

[0039] Step S10, construct a combined phased array imaging in-situ detection device and connect the detection device to a data detection system; the detection device is constructed based on the threaded end face, the cylindrical surface of the accumulator cylinder, and the spherical surface of the liquid-gas separator;

[0040] Step S20, initialize defect detection parameters based on the type and defect characteristics of the workpiece surface of the workpiece to be detected;

[0041] Step S30, use the detection device to scan the workpiece to be detected, obtain defect detection data, and input the data into the data detection system;

[0042] Step S40: Output defect result data according to the defect recognition method. When the number of defect results exceeds the set threshold, output an alarm signal to the alarm, observe the defect position and size. If it is incorrect, jump to step S20. If it is correct, end and proceed to judge the next workpiece to be detected;

[0043] Among them, the defect recognition method is constructed based on the defect shapes and defect detection parameters built into the data detection system and by using a three-dimensional defect algorithm.

[0044] Among them, the three-dimensional defect algorithm includes methods for crack, hole, and groove recognition and judgment. It combines the standard parameter values of the three types of defects with the imaging data analysis method, specifically including: the standard parameter values of the three types of defects, namely cracks, holes, and grooves, are determined by the TFM algorithm and then fixed in the detection system. Different defect recognition module algorithms are constructed to achieve online real-time monitoring, intelligent analysis, and automatic judgment of defects.

[0045] Among them, the data monitoring system is applied to the three-dimensional imaging detection device, and the three-dimensional imaging detection device includes: a data acquisition and transmission line, a computer, and an integrated display; the method part includes: different defect recognition modules and a defect threshold alarm module.

[0046] Among them, judge the defect shape according to the output result of the defect recognition method. If the alarm does not work within the allowable range of defect determination; if the determination exceeds the allowable range of the defect, the alarm will sound.

[0047] According to the actual shapes of the drill tool, the liquid-gas separator, and the accumulator cylinder, the spatial detection position conditions, and the set threshold of the set defect parameters, the computer replaces manual work to judge whether the characteristic values exceed the set threshold according to the defect result data obtained in real time.

[0048] See Figure 2 , the second embodiment of the present invention provides a combined phased array imaging in-situ detection device. Based on the combined phased array imaging in-situ detection method of the first embodiment, the combined phased array imaging in-situ detection device is constructed based on the thread end face, including an adjustment mechanism, a rotating base 1-4, a cross beam 1-5, a detection probe 1-6, a probe fixture 1-7, and a coding wheel 1-8;

[0049] The adjusting mechanism is fixed to the bracket. The adjusting mechanism is connected to the rotating base 1-4 by bearings. A cross beam 1-5 is fixed on the rotating base 1-4. The probe fixture 1-7 and the coding wheel 1-8 are respectively movably and fixedly arranged at both ends of the cross beam 1-5. A detection probe 1-6 is fixed on the probe fixture 1-7. The detection probe 1-6 is used to detect the defect result data of the workpiece to be detected. The coding wheel 1-8 is used to obtain the running position of the detection probe 1-6, so as to determine the defect position of the defect result data.

[0050] As a further explanation of the present invention, the adjusting mechanism includes a tightening bracket 1-1, a first support frame 1-2 and an adjusting nut 1-3;

[0051] The tightening bracket 1-1 is fixed to the first support frame 1-2. The first support frame 1-2 is fixed to the bracket. The tightening bracket 1-1 is threadedly connected to the adjusting nut 1-3. The adjusting nut 1-3 is connected to the rotating base 1-4 by bearings.

[0052] Among them, the detection probe 1-6 is a flat phased array probe.

[0053] When operating to detect the thread end face of the drill tool, according to Figure 2 the method shown, according to the distance of the thread end face, adjust the position of the adaptive probe fixture 1-7 to make it consistent with the distance of the thread end face, ensure that the detection probe 1-6 covers the detection thread end face, then rotate the rotating base 1-4 one week along the thread end face. When detecting, the ultrasonic probe generates ultrasonic waves. During the process of moving the probe, scan the surface of the workpiece to be detected. The echo signal is received by the data detection system and converted into an electrical signal. After the electrical signal is processed by digital signal processing (DSP), the defect information is extracted to form a three-dimensional image and displayed through a display, and then the detection of the thread end face can be completed.

[0054] See Figure 3 Referring to , a combined phased array imaging in-situ detection device according to the third embodiment of the present invention is based on a combined phased array imaging in-situ detection method according to the first embodiment. The combined phased array imaging in-situ detection device is constructed based on the cylindrical surface of the accumulator cylinder and the spherical surface of the liquid-gas separator, and includes a handle assembly 2-1, a second support frame 2-2, an encoder assembly 2-3, a first chain assembly 2-4, a second chain assembly 2-5 and a probe clamping member 2-6;

[0055] The handle assembly 2-1 is fixed to the middle of the second support frame 2-2. The length direction of the second support frame 2-2 is parallel to the axis direction of the cylindrical surface of the accumulator cylinder or perpendicular to the radial direction of the spherical surface of the liquid-gas separator. The first chain assembly 2-4 and the second chain assembly 2-5 are respectively installed at both ends of the second support frame 2-2. The first chain assembly 2-4 and the second chain assembly 2-5 are used to fix the two ends of the cylindrical surface of the accumulator cylinder or the spherical surface of the liquid-gas separator to be detected in a surrounding manner.

[0056] An encoder assembly 2-3 and a probe holder 2-6 are also installed on the second support frame 2-2. The encoder assembly 2-3 is used to obtain the position of the detection probe, and the probe holder 2-6 is used to hold the detection probe.

[0057] Among them, as Figure 4 shown, it is a diagram of the device in use. In the diagram, 2-7 is the accumulator cylinder.

[0058] As a further explanation of the present invention, both the first chain assembly 2-4 and the second chain assembly 2-5 include a plurality of connecting plates detachably fixed by pin columns. The number of connecting plates is increased or decreased according to the diameter of the cylindrical surface of the accumulator cylinder or the spherical surface of the liquid-gas separator, so as to achieve different lengths.

[0059] As a further explanation of the present invention, the detection probe is a curved surface phased array probe.

[0060] Among them, the detection probe includes a curved surface phased array probe applicable to the spherical surface of the liquid-gas separator and a narrow curved surface phased array probe applicable to the cylindrical surface of the accumulator cylinder.

[0061] As a further explanation of the present invention, both the coding wheel 1-8 and the encoder assembly 2-3 include a roller type optoelectronic device that follows the movement of the probe.

[0062] As a further explanation of the present invention, a plurality of the detection probes 1-6 are connected to the data detection system entrance through a shared dedicated interface and a data acquisition line.

[0063] When operating to detect the cylindrical surface of the accumulator cylinder, in accordance with Figure 3The device shown adjusts the lengths of the first chain assembly 2-4 and the second chain assembly 2-5 simultaneously according to the size of the outer diameter of the cylindrical surface, so that it can completely clamp and fix the cylindrical surface. Then, cover the probe holder on the cylindrical surface, push the handle assembly 2-1, and move it up and down along the cylindrical surface to complete the detection of one scanning surface. Then, rotate the whole by a certain angle to scan the next detection surface, and so on, to complete the detection of other scanning surfaces. When detecting, the ultrasonic probe generates ultrasonic waves. During the process of moving the probe, the surface of the workpiece to be detected is scanned. The echo signal is received by the data detection system and converted into an electrical signal. After the electrical signal is processed by digital signal processing (DSP), the defect information is extracted to form a three-dimensional image, which is then displayed on the display, and the detection of the steel cylinder can be completed.

[0064] When operating the spherical surface of the detection liquid-gas separator, in accordance with Figure 3 The device shown adjusts the lengths of the first chain assembly 2-4 and the second chain assembly 2-5 simultaneously according to the size of the outer diameter of the spherical surface, so that it can completely clamp and fix the spherical surface. Then, cover the probe holder on the spherical surface, push the handle assembly 2-1, and move it up and down along the spherical surface to complete the detection of one scanning surface. Then, rotate the whole by a certain angle to scan the next detection surface, and so on, to complete the detection of other scanning surfaces. When detecting, the ultrasonic probe generates ultrasonic waves. During the process of moving the probe, the surface of the workpiece to be detected is scanned. The echo signal is received by the data detection system and converted into an electrical signal. After the electrical signal is processed by digital signal processing (DSP), the defect information is extracted to form a three-dimensional image, which is then displayed on the display, and the detection of the spherical surface of the tank can be completed.

[0065] This combined scanning device can not only achieve safe, efficient and low-cost detection, but also obtain a three-dimensional image of the interior of the object to be measured, improving the accuracy and reliability of the detection.

[0066] Terms such as "first", "second", etc. are used to distinguish similar objects, rather than to describe or represent a specific order or sequence.

[0067] The term "comprising" or any other similar term is intended to cover non-exclusive inclusion, so that a process, method, article or device / equipment comprising a series of elements not only includes those elements, but also includes other elements not expressly listed, or also includes elements inherent in these processes, methods, articles or devices / equipment.

[0068] So far, the technical solution of the present invention has been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easily understood by those skilled in the art that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present invention.

Claims

1. A combined phased array imaging in-situ detection method, characterized in that, the method comprises the following steps: Step S10, construct a combined phased array imaging in-situ detection device and connect the detection device to a data detection system; the detection device is constructed based on the threaded end face, the cylindrical surface of the accumulator cylinder and the spherical surface of the liquid-gas separator; Step S20, initialize the defect detection parameters based on the type and defect characteristics of the workpiece surface of the workpiece to be detected; Step S30, use the detection device to scan the workpiece to be detected, obtain defect detection data and input it into the data detection system; Step S40, output defect result data according to the defect recognition method. When the number of defect results exceeds the set threshold, output an alarm signal to the alarm, observe the defect position and size. If it is incorrect, jump to Step S20. If it is correct, end and judge the next workpiece to be detected; wherein, the defect recognition method is constructed based on the defect shape and defect detection parameters built in the data detection system and using a three-dimensional defect algorithm.

2. A combined phased array imaging in-situ detection method according to claim 1, characterized in that, the three-dimensional defect algorithm includes crack, hole, and groove recognition and judgment methods.

3. A combined phased array imaging in-situ detection device, based on the combined phased array imaging in-situ detection method according to claim 1 or 2, characterized in that, Construct the combined phased array imaging in-situ detection device based on the threaded end face, including an adjustment mechanism, a rotating base (1-4), a cross beam (1-5), a detection probe (1-6), a probe fixture (1-7) and an encoding wheel (1-8); The adjustment mechanism is fixed to the bracket, the adjustment mechanism is connected to the rotating base (1-4) by bearings, the cross beam (1-5) is fixed on the rotating base (1-4), the probe fixture (1-7) and the encoding wheel (1-8) are movably and fixedly arranged at both ends of the cross beam (1-5) respectively, the detection probe (1-6) is fixed on the probe fixture (1-7), the detection probe (1-6) is used to detect the defect result data of the workpiece to be detected, and the encoding wheel (1-8) is used to obtain the running position of the detection probe (1-6) so as to determine the defect position of the defect result data.

4. A combined phased array imaging in-situ detection method according to claim 3, characterized in that, the adjustment mechanism includes a tightening bracket (1-1), a first support frame (1-2) and an adjustment nut (1-3); The tightening bracket (1-1) is fixed to the first support frame (1-2), the first support frame (1-2) is fixed to the bracket, the tightening bracket (1-1) is threadedly connected to the adjustment nut (1-3), and the adjustment nut (1-3) is connected to the rotating base (1-4) by bearings.

5. A combined phased array imaging in-situ detection device, based on the combined phased array imaging in-situ detection method according to claim 1 or 2, characterized in that, The combined phased array imaging in-situ detection device is constructed based on the cylindrical surface of the accumulator cylinder and the spherical surface of the liquid-gas separator, and includes a handle assembly (2-1), a second support frame (2-2), an encoder assembly (2-3), a first chain assembly (2-4), a second chain assembly (2-5), and a probe holder (2-6). The middle of the handle assembly (2-1) is fixed to the second support frame (2-2). The length direction of the second support frame (2-2) is parallel to the axis direction of the cylindrical surface of the accumulator cylinder or perpendicular to the radial direction of the spherical surface of the liquid-gas separator. The first chain assembly (2-4) and the second chain assembly (2-5) are respectively installed at both ends of the second support frame (2-2), and the first chain assembly (2-4) and the second chain assembly (2-5) are fixed at both ends of the cylindrical surface of the accumulator cylinder or the spherical surface of the liquid-gas separator to be detected in a surrounding manner. The second support frame (2-2) is also provided with an encoder assembly (2-3) and a probe holder (2-6). The encoder assembly (2-3) is used to obtain the position of the detection probe, and the probe holder (2-6) is used to hold the detection probe.

6. A combined phased array imaging in-situ detection device according to claim 5, wherein, Both the first chain assembly (2-4) and the second chain assembly (2-5) include a plurality of connecting plates connected by pin posts in a detachable and fixed manner. The number of connecting plates is increased or decreased according to the diameter of the cylindrical surface of the accumulator cylinder or the spherical surface of the liquid-gas separator, so as to achieve different lengths.

7. A combined phased array imaging in-situ detection device according to claim 3, wherein, The detection probe (1-6) is a flat phased array probe.

8. A combined phased array imaging in-situ detection device according to claim 5, wherein, The detection probe is a curved phased array probe.

9. A combined phased array imaging in-situ detection device according to any one of claims 3 or 5, wherein, Both the coding wheel (1-8) and the encoder assembly (2-3) include a roller-type optoelectronic device that follows the movement of the probe.

10. A combined phased array imaging in-situ detection device according to claim 9, wherein, A plurality of the detection probes (1-6) are connected to the data detection system entrance through a shared dedicated interface and a data acquisition line.

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