Phased array ultrasonic simulation test block for detecting fillet weld of small connecting pipe of pressure vessel

Abstract

The utility model relates to the technical field of nondestructive testing, in particular to a phased array ultrasonic simulation test block for detecting a fillet weld of a small connecting pipe of a pressure vessel, which comprises a flat plate and the small connecting pipe, the small connecting pipe is inserted into the flat plate, the flat plate and the small connecting pipe form the fillet weld through double-sided full penetration welding, the groove form of the fillet weld is a K-shaped groove, and the small connecting pipe is inserted into the flat plate. A pipe wall side crack artificial defect is arranged on the inner surface of the fillet weld, a flat plate side crack artificial defect is arranged on the outer surface of the fillet weld, and a pipe wall incomplete fusion artificial defect, a strip slag artificial defect, a groove incomplete fusion artificial defect and a transverse crack artificial defect are arranged in the fillet weld. Six different artificial defects are arranged on one simulation test block, so that the calibration of an instrument and a probe, the control of detection sensitivity and the determination of the geometric dimension of the defects during phased array ultrasonic detection of the fillet weld of the plug-in small connecting pipe are facilitated, and the detection efficiency of the phased array ultrasonic detection instrument is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of nondestructive testing, in particular to a phased array ultrasonic simulation test block for detecting small pipe fillet welds of pressure vessels. Background Art

[0002] Due to the influence of adverse factors such as welding and defects in the manufacturing stage, strong assembly in the installation stage, corrosion and erosion of the working medium in the service stage, the fillet welds connecting the pressure vessels and the small pipes in the petrochemical industry are prone to corrosion, surface cracking, buried crack cracking and other damage. In severe cases, the defects expand and corrosion perforation and weld fracture occur. The leaked working medium is toxic, harmful, flammable and explosive. The resulting combustion and explosion failure consequences pose a great threat to the life safety of the equipment personnel and normal production needs.

[0003] For non-destructive testing of corner welds of pipes, phased array ultrasonic testing technology has the advantages of multiple probes, multiple angles, and time-delay control. Compared with traditional non-destructive testing technologies (ultrasonic testing, X-ray testing), it has the characteristics of high testing efficiency and high testing accuracy.

[0004] The current NB / T 47013.15-2021 phased array ultrasonic testing technical standard has an application range of cylinder (or head) ≥500mm, inner / outer diameter ratio ≥60%, pipe inner diameter ≥200mm, and pipe wall thickness ≥6mm for inserted pipe fillet welds. However, there is no corresponding applicable standard for the detection of pipe fillet welds with an inner diameter of less than 200mm or a wall thickness of less than 6mm.

[0005] The existing phased array ultrasonic simulation test blocks for pipe corner weld detection have the limitation of a single defect type in a single test block. For example, the "A simulation test piece for ultrasonic phased array detection of pipe seat corner welds" with the publication number CN211453473U sets three unfused defects of different sizes at the corner welds connecting the mother pipe and the pipe, simulating the defects of the pipe seat corner welds of the header, so as to optimize and verify the phased array ultrasonic detection process of the pipe seat corner welds. However, its application object is the welds connecting the pipeline and the small pipe, and the other defects are all unfused, without considering other planar defects (incomplete penetration, cracks) and volume defects (pores, slag inclusions, strip defects). When faced with the situation where multiple defect types appear in the pipe corner welds, multiple simulation test blocks are required for calibration, which reduces the efficiency of detection. At present, most of the single-sided V-shaped grooves are used for pipe corner welds, while the K-shaped grooves are mostly used in equipment manufacturing and installation. The authenticity and accuracy of the phased array defect detection will be affected due to the different groove forms during detection. Utility Model Content

[0006] The purpose of this section is to summarize some aspects of the embodiments of the utility model and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section and the specification abstract and utility model name of this application to avoid blurring the purpose of this section, specification abstract and utility model name, and such simplifications or omissions cannot be used to limit the scope of the utility model.

[0007] The technical problem to be solved by the utility model is how to improve the detection efficiency of a phased array ultrasonic detection instrument.

[0008] In order to solve the above technical problems, the utility model provides the following technical solutions: a phased array ultrasonic simulation test block for detecting fillet welds of small pipes of pressure vessels, comprising a flat plate and a small pipe, the small pipe being inserted into the flat plate, the flat plate and the small pipe being welded together by double-sided full penetration welding to form a fillet weld, the groove form of the fillet weld being a K-type groove, the inner surface of the fillet weld being provided with an artificial defect of a pipe wall side crack, the outer surface of the fillet weld being provided with an artificial defect of a plate side crack, the interior of the fillet weld being provided with an artificial defect of unfused pipe wall, an artificial defect of a slag strip, an artificial defect of unfused groove and an artificial defect of a transverse crack, which is used for calibration of a phased array ultrasonic detection instrument and a probe.

[0009] As an optimal solution of the phased array ultrasonic simulation test block for detecting small pipe corner welds of pressure vessels described in the utility model, the artificial defects of side cracks on the pipe wall, the artificial defects of side cracks on the plate, the artificial defects of unfused pipe wall, the artificial defects of slag strips, the artificial defects of unfused grooves and the artificial defects of transverse cracks are evenly arranged along the circumferential direction, and the positions of adjacent artificial defects are 50° to 60° apart in the circumferential direction of the weld, and the intervals are 10 to 50 mm.

[0010] As a preferred solution of the phased array ultrasonic simulation test block for detecting small pipe corner welds of pressure vessels described in the utility model, the defect length of the artificial defect of the pipe wall side crack is 9 mm, and the defect height is 3 mm.

[0011] As a preferred solution of the phased array ultrasonic simulation test block for detecting small pipe fillet welds of pressure vessels described in the utility model, the defect length of the artificial defect of the flat plate side crack is 9 mm, and the defect height is 3 mm.

[0012] As an optimal solution of the phased array ultrasonic simulation test block for detecting small pipe corner welds of pressure vessels described in the utility model, the defect length of the artificial defect of unfused pipe wall is 6mm, the defect height is 3mm, and the defect depth is 1 / 2 of the thickness of the flat plate; the defect length of the artificial defect of slag strip is 6mm, the defect height is 2mm, and the defect depth is 1 / 3 of the thickness of the flat plate; the defect length of the artificial defect of unfused groove is 10mm, the defect height is 4mm, and the defect depth is 1 / 3 of the thickness of the flat plate; the defect length of the artificial defect of transverse crack is 9mm, and the defect depth is 2 / 3 of the thickness of the flat plate.

[0013] As a preferred solution of the phased array ultrasonic simulation test block for detecting corner welds of small pipes of pressure vessels described in the utility model, the material of the flat plate is Q345R alloy steel, the material of the small pipe is 10# or 20# steel, the inner diameter of the small pipe is less than 200mm, and the wall thickness is less than 6mm.

[0014] Beneficial effect: By setting six different artificial defects on a simulated test block, it is convenient to calibrate the instrument and the probe, control the detection sensitivity, and determine the defect geometric size when using phased array ultrasonic testing for inserted small pipe fillet welds, thereby improving the detection efficiency of the phased array ultrasonic testing instrument. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the technical solutions of the embodiments of the present utility model, the following briefly introduces the drawings required for the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative labor. Among them:

[0016] Figure 1 Schematic diagram of the overall structure of the phased array ultrasonic simulation test block for detecting small nozzle fillet welds of pressure vessels.

[0017] Figure 2 This is a top view of the phased array ultrasonic simulation test block used for testing small nozzle fillet welds in pressure vessels.

[0018] In the figure: 1. Flat plate; 2. Connecting pipe; 3. Fillet weld; 4. Artificial defect of side crack of pipe wall; 5. Artificial defect of side crack of flat plate; 6. Artificial defect of unfused pipe wall; 7. Artificial defect of slag strip; 8. Artificial defect of unfused groove; 9. Artificial defect of transverse crack. DETAILED DESCRIPTION

[0019] In order to make the above-mentioned purposes, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0020] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0021] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure or characteristic that may be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive with other embodiments.

[0022] Example

[0023] Reference Figure 1 and Figure 2 The present embodiment provides a phased array ultrasonic simulation test block for detecting fillet welds of small pipes of pressure vessels, comprising a flat plate 1 and a small pipe 2, wherein the small pipe 2 is inserted into the flat plate 1, and the flat plate 1 and the small pipe 2 are welded by double-sided full penetration welding to form a fillet weld 3, wherein the groove form of the fillet weld 3 is a K-type groove, and the inner surface of the fillet weld 3 is provided with a pipe wall side crack artificial defect 4, and the outer surface of the fillet weld 3 is provided with a plate side crack artificial defect 5, and the interior of the fillet weld 3 is provided with a pipe wall unfusion artificial defect 6, a strip slag artificial defect 7, a groove unfusion artificial defect 8 and a transverse crack artificial defect 9, which are used for calibration of a phased array ultrasonic detection instrument.

[0024] The simulation test block is mainly composed of a flat plate 1 and a small pipe 2, one end of the small pipe 2 is completely inserted into the flat plate 1, that is, the inserted end face of the small pipe 2 is flush with the bottom surface of the flat plate 1, and the flat plate 1 and the small pipe 2 are welded by a double-sided full penetration structure to form a fillet weld 3, and the groove form of the fillet weld 3 is a K-type groove, and an artificial defect 4 of a pipe wall side crack is arranged on the inner surface of the fillet weld 3, and an artificial defect 5 of a plate side crack is arranged on the outer surface of the fillet weld 3. The inside of the fillet weld 3 is also provided with an artificial defect 6 of a pipe wall unfusion, an artificial defect 7 of a strip slag, an artificial defect 8 of an unfusion groove, and an artificial defect 9 of a transverse crack. By arranging six different artificial defects on a simulation test block, it is convenient to calibrate the instrument and the probe, control the detection sensitivity, and determine the defect geometric size when the phased array ultrasonic detection is performed on the fillet weld 3 with an inserted small pipe 2 with a K-type groove, thereby improving the detection efficiency of the phased array ultrasonic detection instrument.

[0025] Furthermore, in this embodiment, the artificial defect 4 of the side crack of the pipe wall, the artificial defect 5 of the side crack of the plate, the artificial defect 6 of the unfused pipe wall, the artificial defect 7 of the slag strip, the artificial defect 8 of the unfused groove and the artificial defect 9 of the transverse crack are evenly arranged in the circumferential direction, and the positions of two adjacent artificial defects are 50° to 60° apart in the circumferential direction of the weld, and the interval is 10 to 50 mm, so as to ensure that there is no interference effect when detecting each artificial defect, thereby improving the authenticity and accuracy of the simulation test block for the calibration of the phased array ultrasonic detection instrument.

[0026] Furthermore, in this embodiment, the defect length of the artificial defect 4 of the tube wall side crack is set to 9 mm, the defect height is set to 3 mm, the defect length of the artificial defect 5 of the flat plate side crack is set to 9 mm, the defect height is set to 3 mm, the defect length of the artificial defect 6 of the tube wall unfusion is set to 6 mm, the defect height is set to 3 mm, the defect depth is set to 1 / 2 of the plate thickness of the flat plate 1, the defect length of the artificial defect 7 of the slag strip is set to 6 mm, the defect height is set to 2 mm, the defect depth is set to 1 / 3 of the plate thickness of the flat plate 1, the defect length of the artificial defect 8 of the groove unfusion is set to 10 mm, the defect height is set to 4 mm, the defect depth is set to 1 / 3 of the plate thickness of the flat plate 1, the defect length of the artificial defect 9 of the transverse crack is set to 9 mm, and the defect depth is set to 2 / 3 of the plate thickness of the flat plate 1. When setting the defect height size, the requirement of the minimum detected defect height size is taken into account, and when setting the defect depth size, the plate thickness depth that is most likely to cause defects in actual work experience is referred to, thereby further improving the authenticity and accuracy of the simulation test block for the calibration of the phased array ultrasonic testing instrument.

[0027] Furthermore, in this embodiment, the material of the flat plate 1 is Q345R alloy steel, and the material of the small pipe 2 is 10# or 20# steel, which are the same as the materials of the actual pressure vessel and the small pipe 2, thereby once again improving the authenticity and accuracy of the simulation block for the calibration of the phased array ultrasonic detection instrument. The inner diameter of the small pipe 2 is less than 200 mm and the wall thickness is less than 6 mm, so that the simulation block can be suitable for the detection of pipe corner welds with an inner diameter of less than 200 mm or a wall thickness of less than 6 mm.

[0028] The specific verification process is:

[0029] (1) Check the design and manufacturing of the pressure vessel and the relevant regulations and standards and other technical documents to determine the inspection timing and inspection technology level of the corner weld 3 connecting the pressure vessel and the pipe 2.

[0030] (2) According to the non-destructive testing standard NB / T 47013.15-2021 "Phased Array Ultrasonic Testing", determine the simulation test block, test surface, scanning method, scanning settings and probe position, probe, wedge block, activation aperture, and scanning angle according to the testing technology level and workpiece thickness.

[0031] (3) Grind the surface of plate 1 and the surface of the grinding wedge to ensure that the probe is in close contact with the detection surface. When grinding, the geometric dimensions of the wedge should be remeasured and the impact on the sound beam should be considered.

[0032] (4) Use TCG (including ACG) for sensitivity setting.

[0033] (5) Determine the width and height of the test area to ensure that the test surface is flat to facilitate the movement of the probe. The surface roughness Ra ≤ 12.5um. If there are undercuts, large ridges and depressions on the weld surface, appropriate grinding should be carried out and a smooth transition should be made to avoid affecting the evaluation of the test results. Make good test marks and reference lines.

[0034] (6) Place the phased array ultrasonic detection probe on the surface of the flat plate 1, adjust the distance between the probe and the fillet weld 3, ensure that the detection sound beam range completely covers the fillet weld 3, and select a combination of longitudinal vertical scanning and electronic scanning for scanning. The electronic scanning adopts sector scanning, and the display mode can select sound path display imaging or geometric structure display imaging to complete the detection of defects.

[0035] (7) Compare the phased array ultrasonic testing results with the specific positions and sizes of the six different artificial defects designed in the simulation test block, calibrate the phased array ultrasonic testing equipment, and adjust the detection sensitivity until the defects of the fillet weld 3 are effectively detected and the detection process is verified.

[0036] It should be noted that the above embodiments are only used to illustrate the technical solution of the utility model rather than to limit it. Although the utility model has been described in detail with reference to the preferred embodiments, ordinary technicians in the field should understand that the technical solution of the utility model can be modified or replaced by equivalents without departing from the spirit and scope of the technical solution of the utility model, which should be included in the scope of the claims of the utility model.

Claims

1. A phased array ultrasonic simulation test block for detecting small pipe fillet welds of pressure vessels, characterized in that: The invention comprises a flat plate (1) and a small pipe (2), wherein the small pipe (2) is inserted into the flat plate (1), and the flat plate (1) and the small pipe (2) are welded by double-sided full penetration welding to form a fillet weld (3), wherein the groove of the fillet weld (3) is a K-type groove, the inner surface of the fillet weld (3) is provided with an artificial defect of a pipe wall side crack (4), the outer surface of the fillet weld (3) is provided with an artificial defect of a plate side crack (5), and the interior of the fillet weld (3) is provided with an artificial defect of a pipe wall non-fusion (6), an artificial defect of a slag strip (7), an artificial defect of a groove non-fusion (8) and an artificial defect of a transverse crack (9), and is used for calibration of a phased array ultrasonic detection instrument and a probe.

2. The phased array ultrasonic simulation test block for detecting small pipe fillet welds of pressure vessels according to claim 1, characterized in that: The pipe wall side crack artificial defect (4), the plate side crack artificial defect (5), the pipe wall unfused artificial defect (6), the slag strip artificial defect (7), the groove unfused artificial defect (8) and the transverse crack artificial defect (9) are evenly arranged along the circumferential direction, and adjacent artificial defect positions are spaced 50° to 60° and 10 to 50 mm apart in the circumferential direction of the weld.

3. The phased array ultrasonic simulation test block for detecting small pipe fillet welds of pressure vessels according to claim 2, characterized in that: The defect length of the pipe wall side crack artificial defect (4) is 9 mm, and the defect height is 3 mm.

4. The phased array ultrasonic simulation test block for detecting small pipe fillet welds of pressure vessels according to claim 3, characterized in that: The defect length of the flat plate side crack artificial defect (5) is 9 mm, and the defect height is 3 mm.

5. The phased array ultrasonic simulation test block for detecting small pipe fillet welds of pressure vessels according to claim 4, characterized in that: The defect length of the tube wall unfused artificial defect (6) is 6 mm, the defect height is 3 mm, and the defect depth is 1 / 2 of the plate thickness of the flat plate (1); the defect length of the slag artificial defect (7) is 6 mm, the defect height is 2 mm, and the defect depth is 1 / 3 of the plate thickness of the flat plate (1); the defect length of the groove unfused artificial defect (8) is 10 mm, the defect height is 4 mm, and the defect depth is 1 / 3 of the plate thickness of the flat plate (1); the defect length of the transverse crack artificial defect (9) is 9 mm, and the defect depth is 2 / 3 of the plate thickness of the flat plate (1).

6. The phased array ultrasonic simulation test block for detecting small pipe fillet welds of pressure vessels according to claim 5, characterized in that: The material of the flat plate (1) is Q345R alloy steel, the material of the small connecting pipe (2) is 10# or 20# steel, the inner diameter of the small connecting pipe (2) is less than 200 mm, and the wall thickness is less than 6 mm.

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