Reference block for phased array ultrasonic detection of casing circumferential weld

Abstract

The utility model discloses a reference block for phased array ultrasonic detection of a casing circumferential weld, and belongs to the technical field of nondestructive detection of oil and gas pipelines. The probe comprises a sleeve and a mother tube, a side fusion surface of the sleeve is fixedly connected with a welding joint, the other end of the welding joint is fixedly connected with a side fusion surface of the mother tube, more than two notches are arranged between the sleeve and the mother tube, the sizes and the depths of the notches are different, the probe is a phased array probe of a wafer, and the probe is a single-chip phased array probe. The probe is arranged to cover a horizontal fusion surface under the condition that the probe does not move, the probe is a phased array probe of a wafer, and the probe is arranged to cover the horizontal fusion surface under the condition that the probe does not move; the detection area comprises a sleeve side fusion surface detection area, a mother pipe side fusion surface detection area, a welding seam filling area and a heat affected area, and notches with different lengths, widths and heights are formed in the two sides of the block body of the reference block.

Description

Technical Field

[0001] The utility model relates to the technical field of ultrasonic testing, in particular to a comparison test block for phased array ultrasonic testing of casing girth welds. Background Art

[0002] In the design of a comparison test block for phased array ultrasonic testing of casing girth welds, a cross-sectional model of a Type B casing lap weld was established using computer simulation software, and full coverage detection of the acoustic beam was simulated. This method can intuitively display the coverage status of the ultrasonic beam in the weld, effectively guiding the design of the phased array ultrasonic testing process for Type B casing lap welds. At the same time, the phased array ultrasonic "triangular area analysis method" was used to evaluate the defect map, solving some problems in the detection of Type B casing lap welds and improving the stability and reliability of the test results. In general, the development of this technology is of great significance for improving the non-destructive testing capabilities of special structural welds. It can not only provide more accurate test results, but also overcome the blindness of traditional methods in parameter setting, providing strong technical support and reference for the detection of similar structures.

[0003] However, the existing comparison test blocks used in phased array ultrasonic testing of casing girth welds are not standardized enough: although some standards specify the design and dimensions of comparison test blocks, differences in process, materials and operations may lead to differences between test blocks during the actual manufacturing process, affecting the consistency of test results. At the same time, it is necessary to solve the problem that the ultrasonic beam is not perpendicular to the surface being tested during conventional phased array ultrasonic testing, which affects the height of the reflected wave amplitude and the main sound energy cannot be received by the probe. Utility Model Content

[0004] The purpose of the utility model is to solve the problem that insufficient standardization and material mismatch will affect the propagation and reflection of ultrasonic waves and thus lead to misjudgment, and to propose a comparison test block for phased array ultrasonic testing of casing girth welds, which can improve data information detection capabilities.

[0005] In order to achieve the above purpose, the present invention adopts the following technical solutions:

[0006] As a further technical solution of the present invention, it includes a sleeve and a mother pipe, a gap is provided between the sleeve and the mother pipe, a welding area is provided in the gap, the detection area includes a sleeve side fusion surface detection area, a mother pipe side fusion surface detection area, a weld filling area and a heat-affected zone; a phased array ultrasonic detection unit is provided near the detection area; the sleeve side fusion surface is fixedly connected to one end of the weld joint, the other end of the weld joint is fixedly connected to the mother pipe side fusion surface, four notches are opened between the sleeve and the mother pipe, and the sizes and depths of the four notches are different;

[0007] As a further technical solution of the present invention, the phased array ultrasonic detection unit includes a 64-element phased array probe positioned on the side of the casing, and the probe is configured to cover the horizontal fusion plane of the weld area when the probe is stationary. As a further technical solution of the present invention, four notches of varying length, width, and height are defined on the horizontal surface of the mother tube, and the horizontal positions of the four notches are all flush with the horizontal surface of the casing.

[0008] As a further technical solution of the present invention, the position of the phased array ultrasonic detection unit is set to make the output reflected wave amplitude perpendicular to the weld surface.

[0009] As a further technical solution of the present invention, the thickness of the comparison test block is 10 mm, the material is 45 steel, the outer diameter is Φ=12 cm, and the curvature of the bottom curved surface of the comparison test block is the same as the curvature of the comparison test block, and the diameter is Φ=12 cm.

[0010] As a further technical solution of the present invention, the gap is welded by means of a fillet joint, the thickness of the steel plate is 10 mm and below 12 mm, and fillet welding is performed without a groove.

[0011] As a further technical solution of the present invention, the weld joint is formed by arc welding, and the cross section of the weld joint forms an angle of 45°-60° with the reflected amplitude output by the phased array ultrasonic detection unit.

[0012] As a further technical solution of the present invention, the comparison test block has a length of 6 cm and a width of 4 cm.

[0013] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0014] 1. In the present invention, the size of the comparison test block is customized to calibrate and evaluate the defect size during ultrasonic testing. The signal generated by the comparison test block using a known reflector is compared with the actual detected signal to evaluate the equivalent size of the defect. At the same time, the comparison test block can calibrate the sound velocity and zero point of the ultrasonic flaw detection instrument to ensure the accuracy of thickness measurement.

[0015] 2. In the present invention, the probe adopts the sound beam deflection technology, so that the ultrasonic beam and the detected surface form a closer to vertical angle during the measurement process, so that the main energy of the reflected sound beam will be received by the probe, thereby improving the measurement accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a model diagram of the upper part of a comparison test block for phased array ultrasonic testing of casing girth welds proposed in the present invention;

[0017] Figure 2 This is a cross-sectional view of a weld test block for detecting the fusion surface of a mother pipe of a comparison test block for phased array ultrasonic testing of casing girth welds proposed in the present invention;

[0018] Figure 3 This is a lower model diagram of a comparison test block for phased array ultrasonic testing of casing girth welds proposed in the present invention;

[0019] Figure 4 A partial enlarged diagram of the upper model of a comparison test block for phased array ultrasonic testing of casing girth welds proposed in the present invention;

[0020] Figure 5 FIG3 is a partial enlarged view B of the lower model diagram of a comparison test block for phased array ultrasonic testing of casing girth welds proposed in the present invention;

[0021] Figure 6 This is a diagram of a B-type girth weld fillet joint of a comparison test block for phased array ultrasonic testing of casing girth welds proposed in the utility model;

[0022] Figure 7 This is a reflection amplitude diagram of different sizes of comparison test blocks for phased array ultrasonic testing of casing girth welds proposed in the utility model;

[0023] Figure 8 This is a reflection amplitude difference diagram of different sizes of comparison test blocks for phased array ultrasonic testing of casing girth welds proposed in the utility model;

[0024] Figure 9 This is a schematic diagram of the principle of a phased array ultrasonic testing unit in a comparison test block for phased array ultrasonic testing of casing girth welds proposed in the present invention;

[0025] Legend: 1. Fusion surface on the mother pipe side; 2. Fusion surface on the casing side; 3. Mother pipe; 4. Weld filling area; 5. Notch; 6. Casing; 7. Weld joint; 8. Notch depth. DETAILED DESCRIPTION

[0026] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0027] See also Figure 1-8, The utility model provides a technical solution: a comparison test block for phased array ultrasonic testing of casing girth welds, comprising a casing 6 and a mother pipe 3, wherein the casing side fusion surface 2 is fixedly connected with a welding joint 7, and the other end of the welding joint 7 is fixedly connected to the mother pipe side fusion surface 1, and more than three notches 5 are provided between the casing 6 and the mother pipe 3, and the sizes and depths of the notches 5 are different. The probe is a 64-chip phased array probe, and the probe is configured to cover the horizontal fusion surface when the probe is stationary, and the detection area includes the casing side fusion surface 2 detection area, the mother pipe side fusion surface 1 detection area, the weld filling area 4 and the heat-affected zone, and notches 5 of different length, width and height are provided on both sides of the block of the comparison test block, and the horizontal position of the notch 5 is flush with the horizontal surface of the casing 6. The position of the detection unit is set to make the output reflected amplitude perpendicular to the weld surface. The thickness of the block of the comparison test block is 10 mm, the material is 45 steel, the outer diameter is Φ=12 cm, and the curvature of the bottom curved surface of the block of the comparison test block is the same as the curvature of the block of the comparison test block, with a diameter of Φ=12 cm. The two sections of the sleeve ring to be welded are welded using a corner joint 7. The thickness of the steel plate is 10 mm and below 12 mm, and corner welding is performed without beveling. The welding method is arc welding. Arc welding uses the heat generated by arc discharge to melt the welding rod and the workpiece, so that the workpiece forms a solid weld after cooling. The comparison test block for ultrasonic testing uses a semi-tubular test block, which increases the range of adjustment of ultrasonic detection. The length of the comparison test block for ultrasonic testing is 6 cm and the width is 4 cm.

[0028] In a further embodiment, a comparative test block for phased array ultrasonic testing of casing girth welds includes a casing 6 and a mother pipe 3, wherein a gap is provided between the casing 6 and the mother pipe 3, the gap is provided with a welding area, and the testing area includes a casing side fusion surface 2 testing area, a mother pipe side fusion surface 1 testing area, a weld filling area 4 and a heat-affected zone; again referring to Figure 1-Figure 3 The distance between the mother pipe 3 and the welding area is 200mm, the distance between the welding area and the horizontal plane of the mother pipe 3 is 24mm, and one end of the mother pipe 3 is 360mm away from one end of the sleeve 6, wherein a phased array ultrasonic detection unit is arranged near the detection area; due to the particularity of the weld structure, defects inside the weld cannot be detected by X-rays, and only ultrasonic detection can be used, and ultrasonic detection can only be performed on one side and two sides outside the pipe. At present, the conventional detection method for B-type sleeves is a phased array ultrasonic detection technology based on the pulse reflection principle. In a specific embodiment, the ultrasonic phased array is the latest ultrasonic technology. This technology can change the sound beam angle from the search unit, making it more flexible to use. This technology is an ultrasonic imaging detection technology that realizes the functions of ultrasonic beam movement, deflection and focusing by applying different time delay rules (focusing rules) to different units of the transducer array when transmitting or receiving sound waves.

[0029] It should be added that when using this phased array linear scanning technology, a 64-element phased array probe needs to be placed on one side of the sleeve 6. The horizontal fusion surface can be covered without moving the probe. An appropriate linear scanning angle needs to be set. When there is an unfused defect on the horizontal surface, the reflected wave amplitude of the fusion surface is just perpendicular to the weld surface. At this time, the secondary reflected wave of the weld surface to the defect is received by the probe, and the defect can be identified and determined.

[0030] In a further technical embodiment, a phased array ultrasonic testing unit primarily consists of a transducer array and a control unit. The transducer elements are arranged according to a specific pattern and have independent transmit / receive control modules. When the transducer is in the transmitting state, the control unit controls the transmit delay of each transducer element according to a specific delay rule, thereby controlling the focus and direction of the transmitted ultrasonic beam, achieving movement, deflection, and focus of the beam within a certain range. The transducer receiving process also follows the aforementioned geometric focusing delay rule and is the inverse of the transducer's transmitting state. During detection, the acoustic beam propagates through the medium according to a specific pattern. When the acoustic impedance at a defect in the medium changes, a reflected signal of a certain intensity is generated. This point takes different paths to each element in the transducer array, resulting in different arrival times for the reflected signal generated at that point. Each element delays and sums the echo signal according to a set delay Δt, bringing the echo signal from the defect into phase, achieving enhancement and achieving receive focus.

[0031] In a further technical solution, one end of a weld joint 7 is fixedly connected to the sleeve-side fusion surface 2 of the sleeve 6, and the other end of the weld joint 7 is fixedly connected to the fusion surface 1 of the mother tube. Three or more notches 5 are defined between the sleeve 6 and the mother tube 3, and the notches 5 vary in size and depth 8. In conventional technology, the ultrasonic beam cannot form a near-perpendicular angle with the surface being inspected. The majority of the reflected sound beam's energy is reflected in other directions and cannot be received by the probe, resulting in low ultrasonic energy returned along the transmission path and received by the probe.

[0032] This patent focuses on the inspection of circumferential fillet welds, where the thickness of the welds is inconsistent on both sides, and there is a certain gap between the sleeve and the main pipe. The main inspection areas for this weld can be divided into three parts: first, the sleeve side fusion surface: the main defect is the lack of fusion between the filler material and the vertical groove surface of the sleeve; second, the main pipe side fusion surface: the main defect is the lack of fusion between the filler material and the horizontal groove surface of the main pipe; third, the weld filler area and heat-affected zone, which mainly contain defects such as porosity, slag inclusions, lack of fusion in the weld area, and cracks in the weld and heat-affected zone. The test block designed in this patent is primarily used for inspecting the main pipe side fusion surface.

[0033] This utility model designs a comparison test block for phased array testing of the fusion zone on the mother tube side. Phased array line scanning technology is used for testing on this comparison test block. The unique structure of the B-type sleeve weld surface creates secondary reflections of horizontal lack of fusion, enabling detection of lack of fusion defects on the mother tube side fusion surface. This solves the problem of conventional phased array ultrasonic testing, where the ultrasonic beam is not perpendicular to the surface being tested, affecting the height of the reflected wave amplitude and preventing the probe from receiving the main sound energy. Defects can also be evaluated based on the reflected wave amplitude and length.

[0034] The specific implementation method is as follows: First, based on the material, size, and welding process of the casing 6 to be inspected, a comparison test block with similar characteristics is selected. The probe has the same size and curvature as the mother pipe 3 to simulate actual inspection conditions. Then, slots 5 of different lengths, widths, and heights are opened in the weld filling area 4 to serve as debugging reflectors. The detection sensitivity and the influence of the reflector size on the reflection amplitude are determined by the amplitude of the reflection waves of slots 5 of different sizes. Then, appropriate detection parameters are set for the probe. The phased array probe is then placed on the comparison test block and inspection is performed according to a predetermined scanning path. The detected ultrasonic data is collected and the inspection process is monitored in real time to ensure data integrity and accuracy. Then, the above-mentioned spectrum data is measured to obtain the difference in amplitude of different reflector sizes. The reflection amplitude of slots of different sizes varies, and the wider the slot, the higher the reflection amplitude. The reflection amplitude of one slot 5 can be used as a benchmark for comparison with the amplitudes of other signals. Based on the amplitude, the equivalent of the defect is estimated, thereby evaluating the defect signal.

[0035] Working Principle: During use, personnel first carefully select or fabricate a comparison test block with similar characteristics to the casing 6 to be inspected, taking into account the material properties, dimensions, and welding process. The probe and the parent pipe 3 have the same curvature, allowing for testing under identical physical conditions. Slots 5 of varying length, width, and height are then precisely machined into the comparison test block. These slots 5 serve as known reflectors, simulating potential defects in the weld and facilitating subsequent sensitivity setting and calibration. Appropriate test parameters are then set for the probe based on the performance of the phased array ultrasonic testing equipment and the characteristics of the comparison test block. These parameters include probe frequency, number of elements, focal law, scanning speed, and gain. These parameters ensure proper coupling between the phased array probe and the reference test piece. The test piece is then inspected according to the predetermined scanning path. Furthermore, the operator monitors the inspection process in real time to ensure data integrity and accuracy. By comparing the reflected wave amplitudes generated by slots of different sizes, differences are analyzed. Wider slots produce higher reflected wave amplitudes. The reflected wave amplitude of one slot is then selected as a benchmark against which the other signal amplitudes are compared to assess the size of the defect. Based on the reflected wave amplitude, the equivalent size of the defect is estimated, and the defect signal is quantitatively evaluated. Finally, the inspection process, data analysis results, and evaluation conclusions are documented in detail in the inspection report. It is important to set an appropriate line scan angle when applying this technique. For example, if a lack of fusion defect exists on a horizontal surface, the reflected wave amplitude from the fusion surface is perpendicular to the weld surface. Secondary reflections from the weld surface are received by the probe, allowing for defect identification and determination. Conventional line scans are used to set the active aperture and beam range to ensure focus and lateral resolution while ensuring coverage of the inspection area. Perform TCG calibration on SGB-PA or other equivalent test blocks. After calibration, adjust the secondary reflection amplitude of the specified size slot on the special comparison test block to 80% of the full screen height as the benchmark sensitivity. Adjust the amplitude of the bottom plane reflected to the weld surface on the special comparison test block and the workpiece to the same height, and compensate the corresponding gain difference to the instrument as compensation for the coupling difference caused by different surface conditions. The test results are displayed in a conventional phased array view, and views A, B, C, and D can be displayed simultaneously or separately. Through the above spectral data measurement, it is found that there are certain differences in the amplitudes of different reflector sizes. The specific values ​​and trends are shown in Table 1.

[0036] Table 1 Schematic diagram of spectrum data measurement

[0037]

[0038] From the above analysis, we can see that: slots of different sizes have different reflection amplitudes. The wider the slot, the higher the reflection amplitude. The reflection amplitude of one slot can be used as a benchmark to compare the amplitudes of other signals. Based on the amplitude, the equivalent of the defect can be estimated, thereby evaluating the defect signal.

[0039] Phased array line scanning technology is used for debugging on a comparison test block. The special structure of the B-type sleeve weld surface is used to produce secondary reflections of the lack of fusion on the horizontal surface. This allows the detection of the lack of fusion defects on the fusion surface of the mother pipe side. This solves the problem of the ultrasonic beam not being perpendicular to the surface being tested, which affects the height of the reflected wave amplitude during conventional phased array ultrasonic testing. The main sound is received by the probe, and the defect is then evaluated based on the reflected wave amplitude and length.

[0040] The above is only a preferred specific implementation method of the present invention, but the protection scope of the present invention is not limited to this. Any technician familiar with the technical field within the technical scope disclosed by the present invention can make equivalent replacements or changes based on the technical solution and utility model concept of the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A comparative test block for phased array ultrasonic testing of casing girth welds, comprising a casing (6) and a mother pipe (3), characterized in that: A gap is provided between the sleeve (6) and the mother tube (3), and a welding area is provided in the gap. The detection area includes a sleeve side fusion surface (2) detection area, a mother tube side fusion surface (1) detection area, a weld filling area (4) and a heat-affected zone; wherein a phased array ultrasonic detection unit is provided near the detection area; the sleeve side fusion surface (2) of the sleeve (6) is fixedly connected to one end of a welding joint (7), and the other end of the welding joint (7) is fixedly connected to the mother tube side fusion surface (1); four notches (5) are provided between the sleeve (6) and the mother tube (3), and the sizes and notch depths (8) of the four notches (5) are different.

2. The comparison test block for phased array ultrasonic testing of casing girth welds according to claim 1, characterized in that: The phased array ultrasonic detection unit comprises a 64-chip phased array probe arranged on the side of the sleeve (6), and the probe is arranged to cover the horizontal fusion surface of the welding area when the probe is not moved.

3. The comparison test block for phased array ultrasonic testing of casing girth welds according to claim 1, characterized in that: Four notches (5) with different lengths, widths and heights are provided on the horizontal plane of the mother pipe (3), and the horizontal positions of the four notches (5) are all flush with the horizontal plane of the sleeve (6).

4. The comparison test block for phased array ultrasonic testing of casing girth welds according to claim 1, characterized in that: The position of the phased array ultrasonic detection unit is set to make the output reflected wave amplitude perpendicular to the weld surface.

5. A comparison test block for phased array ultrasonic testing of casing girth welds according to any one of claims 1 to 4, characterized in that: The thickness of the comparison test block is 10 mm, the material is 45 steel, the outer diameter is Φ=12 cm, and the curvature of the bottom curved surface of the comparison test block is the same as the curvature of the comparison test block, and the diameter is Φ=12 cm.

6. The comparison test block for phased array ultrasonic testing of casing girth welds according to claim 1, characterized in that: The gap is welded in the form of a fillet joint (7), the thickness of the steel plate is 10 mm and below 12 mm, and the fillet welding is performed in the form of no groove.

7. The comparison test block for phased array ultrasonic testing of casing girth welds according to claim 1, characterized in that: The welded joint (7) is formed by arc welding, and a cross section of the welded joint (7) forms an angle of 45°-60° with the reflected amplitude output by the phased array ultrasonic detection unit.

8. The comparison test block for phased array ultrasonic testing of casing girth welds according to claim 1, characterized in that: The comparison test block has a length of 6 cm and a width of 4 cm.

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