漏磁检测技术的研究与发展现状
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摘要
漏磁检测技术是一种用来检测铁磁性材料表面腐蚀、凹坑、凹槽、裂纹等缺陷的电磁无损检测方法,已被广泛应用于大型常压储罐、压力管道及元件和钢丝绳的检测。本文给出了漏磁检测技术的原理及特点;综述了国内外漏磁检测技术的理论研究和应用研究现状及漏磁检测信号的放大、滤波、处理方式和缺陷识别等处理方法;分析了影响漏磁检测结果的磁化强度、提离、扫查速度、缺陷位置及形状、表面状态等各种影响因素;介绍了国内外钢管(棒)生产线自动化漏磁检测设备、钢丝绳漏磁检测仪、储罐底板漏磁检测仪、管道外部漏磁检测仪、管道内漏磁检测器等仪器设备和相应的检测标准;最后指出漏磁检测技术目前仍然存在的问题和发展趋势。
Magnetic flux leakage(MFL) testing technique is a kind of electromagnetic nondestructive testing(NDT) methods, which is used to detect defects on ferromagnetic materials, such as corrosion, pit, notch, crack and etc. It has been widely applied for testing of large atmospheric tanks, pressure vessel, pressure piping and wire rope. In this paper, the principle and features of MFL testing technique are introduced. The research and application progress and signal processing methods such as amplification, filtering and defect identification of MFL technique are overviewed. The influence factors such as magnetization, lift off, scanning speed, defect location and shape, surface condition and so on are analyzed. The domestic and foreign steel pipe(rod) production line automatic MFL testing equipment, wire rope MFL instrument, tank floor MFL instrument, pipeline external MFL instrument, pipeline inner MFL detector and the corresponding testing standards are introduced. Finally, the existing problems and development trend of MFL testing technology are pointed out.
Magnetic flux leakage(MFL) testing technique is a kind of electromagnetic nondestructive testing(NDT) methods, which is used to detect defects on ferromagnetic materials, such as corrosion, pit, notch, crack and etc. It has been widely applied for testing of large atmospheric tanks, pressure vessel, pressure piping and wire rope. In this paper, the principle and features of MFL testing technique are introduced. The research and application progress and signal processing methods such as amplification, filtering and defect identification of MFL technique are overviewed. The influence factors such as magnetization, lift off, scanning speed, defect location and shape, surface condition and so on are analyzed. The domestic and foreign steel pipe(rod) production line automatic MFL testing equipment, wire rope MFL instrument, tank floor MFL instrument, pipeline external MFL instrument, pipeline inner MFL detector and the corresponding testing standards are introduced. Finally, the existing problems and development trend of MFL testing technology are pointed out.
引文
[1]任吉林,林俊明.电磁无损检测[M].北京:科学出版社,2008.
[2]廖晓玲,王飞,赵丹,等.工业管道漏磁检测技术及发展现状综述[J].价值工程,2016,35(10):236-237.
[3]GB/T 31212-2014无损检测漏磁检测总则[S].
[4]丁忠平,康宜华.无损检测中的漏磁法原理与实践[J].电测与仪表,1995,32(06):15-18.
[5]左宪章.永磁体漏磁检测原理及其在无损检测中的应用[J].电测与仪表,1994,31(11):16-19.
[6]Shcherbinin V E,Zatsepin N N.Calculation of the magnetostatic field of surface defects.I.Field topography of defect models[J].Defectoscopy,1966,(05):385-393.
[7]Shcherbinin V E,Zatsepin N N.Calculation of the magnetostatic field of surface defects.II.Experimental verification of the principal theoretical relationships[J].Defectoscopy,1966,(05):394-399.
[8]Shcherbinin V E,Pashagin A.Influence of the extension of a defect on the magnitude of its magnetic field[J].Defektoskopiya,1972,8(04):84-78.
[9]Edwards C,Palmer S B.The magnetic leakage field of surface-breaking cracks[J].Journal of Physics D:Applied Physics,1986,19(04):657-673.
[10]Hwang J,Lord W.Finite element analysis of the magnetic field distribution inside a rotating ferromagnetic bar[J].IEEE Transactions on Magnetics,1974,10(04):1113-1118.
[11]Atherton D L.Finite element calculations and computer measurements of magnetic flux leakage patterns for pits[J].British Journal of Non-Destructive Testing,1988,30(03):159-162.
[12]Kim H M,Park G S.A study on the estimation of the shapes of axially oriented cracks in CMFL type NDT system[J].IEEE Transactions on Magnetics,2014,50(02):109-112.
[13]杨理践,张国光,刘刚.管道漏磁内检测技术[M].北京:化学工业出版社,2014.
[14]Edwards C,Palmer S B.The prod magnetization method of magnetic particle inspection[J].British Journal of Non-Destructive Testing,1983,25(06):305-308.
[15]李光海,刘时风,沈功田.压力容器无损检测--漏磁检测技术[J].无损检测,2004,26(12):638-642.
[16]张国光.管道周向励磁漏磁内检测技术的研究[D].沈阳:沈阳工业大学,2010.
[17]林俊明.漏磁检测技术及发展现状研究[J].无损探伤,2006,30(01):1-5.
[18]Kim H M,Rho Y W,Yoo HR,et al.A study on the measurement of axial cracks in the Magnetic Flux Leakage NDT system[C]//Automation Science and Engineering(CASE),2012 IEEE International Conference on.IEEE,2012:624-629.
[19]康宜华,武新军,杨叔子.磁性无损检测技术中的磁化技术[J].无损检测,1999,21(05):206-209.
[20]康宜华,陈艳婷,孙燕华.超强磁化下漏磁检测的穿透深度[J].无损检测,2011,33(6):27-29.
[21]Sun Y,Feng B,Liu S,et al.A methodology for identifying defects in the magnetic flux leakage method and suggestions for standard specimens[J].Journal of Nondestructive Evaluation,2015,34(03):1-9.
[22]Sun Y,Kang Y.Magnetic compression effect in present MFL testing sensor[J].Sensors and Actuators A:Physical,2010,160(01):54-59.
[23]Wang X,Wu X,Xu J,et al.Study on the liftoff effect on MFL signals with magnetic circuit model and 3D FEM[J].Insight-Non-Destructive Testing and Condition Monitoring,2012,54(09):505-510.
[24]李路明,张家骏.用有限元方法优化漏磁检测[J].无损检测,1997,19(06):154-158.
[25]李路明,黄松岭,杨海青,等.缺陷长度对漏磁场的影响[J].科学技术与工程,2002,(04):52-53.
[26]黄作英,阙沛文.计算机仿真在管道漏磁检测中的应用[J].计算机仿真,2004,21(10):174-177.
[27]杨理践,邢燕好,高松巍.高精度管道漏磁在线检测系统的研究[J].无损探伤,2005,29(01):20-22.
[28]张国光.管道漏磁检测中漏磁信号与缺陷特征关系的研究[J].检测与仪表,2008,35(02):39-41.
[29]戴光,崔巍,杨志军,等.换热管漏磁检测磁化结构有限元分析[J].化工机械,2010,37(06):726-729.
[30]何辅云,董文雯,王爱民.在役管线无损检测设备的研究[J].合肥工业大学学报:自然科学版,2004,(07):738-741.
[31]吴德会,游德海,柳振凉,等.交流漏磁检测法趋肤深度的机理与实验研究[J].仪器仪表学报,2014,35(02):327-336.
[32]王晓红,吴德会,李雪松,等.小型磁化器条件下的变励磁MFL检测新方法[J].仪器仪表学报,2015,36(01):70-77.
[33]Wang P,Gao Y,Tian G Y,et al.Velocity effect analysis of dynamic magnetization in high speed magnetic flux leakage inspection[J].NDT&E International,2014,(64):7-12.
[34]沈功田.承压设备的无损检测与评价技术发展现状[J].机械工程学报,2017,53(12):1-12.
[35]周燕,董怀荣,周志刚,等.油气管道内检测技术的发展[J].石油机械,2011,39(03):74-77.
[36]何辅云.钢管三维漏磁检测系统的再研究[J].无损检测,2000,22(02):68-70.
[37]黄辉,何仁洋,熊昌胜,等.漏磁检测技术在管道检测中的应用及影响因素分析[J].管道技术与设备,2010,(03):17-19.
[38]于清澄,张迪.管道漏磁检测提离值影响的研究[J].中国仪器仪表,2009,(S1):75-77.
[39]吴德会,柳振凉,张忠远,等.漏磁检测中提离值影响的三维有限元仿真分析[J].应用基础与工程科学学报,2013,21(06):1188-1198.
[40]杨理践,袁希平,高松巍.输气管道漏磁内检测的速度效应分析[J].管道技术与设备,2013,(05):19-21.
[41]邓志扬,杨芸,冯搏,等.表面粗糙度对裂纹漏磁检测的影响[J].无损检测,2016,(02):40-44.
[42]黄松岭,李路明.管道漏磁检测中的信号处理[J].无损检测,2000,22(02):55-57.
[43]陈正阁,王长龙,梁四洋,等.小波变换在漏磁检测信号处理中的应用[J].火力与指挥控制,2009,34(02):154-157.
[44]宋志强,张莹,吴江.基于小波包-Haar小波变换的漏磁检测信号降噪数据压缩方法[J].机床与液压,2017,45(02):126-129.
[45]田凯,孙永泰,高慧,等.贝叶斯算法BP神经网络缺陷量化研究[J].中国测试,2014,40(03):93-97.
[46]Daniel J,Mohanagayathriand R,Abudhahir A.Characterization of defects in Magnetic Flux Leakage(MFL)images using wavelet transform and neural network[C]//Electronics and Communication Systems(ICECS),2014International Conference on.IEEE,2014:1-5.
[47]Nara T,Fujieda M,Gotoh Y.Non-destructive inspection of ferromagnetic pipes based on the discrete Fourier coefficients of magnetic flux leakage[J].Journal of Applied Physics,2014,115(17):17E509-17E509-3.
[48]焦敬品,常予,李光海,等.铁磁构件内外表面裂纹低频漏磁检测技术研究[J].仪器仪表学报,2016,37(08):1808-1817.
[49]杨理践,郭天昊,高松巍,等.油气管道特殊部件的漏磁检测信号特征分析[J].沈阳工业大学学报,2017,39(01):43-47.
[50]Ong J K,Kerr D,Bouazza-Marouf K.Design of a semi-autonomous modular robotic vehicle for gas pipeline inspection[J].Proceedings of the Institution of Mechanical Engineers Part I-Journal of Systems and Control Engineering,2003,217(12):109-122.
[51]Caleyo F,Hallen J M,Gonzalez J L.Pipeline inspection-1-reliability-based method assesses corroding pipelines[J].Oil&Gas Journal,2003,101(01):54-58.
[52]Anon,Pipeline inspection failure blamed for oil spill[J].Pipeline&Gas Journal,2002,229(09):2-5.
[2]廖晓玲,王飞,赵丹,等.工业管道漏磁检测技术及发展现状综述[J].价值工程,2016,35(10):236-237.
[3]GB/T 31212-2014无损检测漏磁检测总则[S].
[4]丁忠平,康宜华.无损检测中的漏磁法原理与实践[J].电测与仪表,1995,32(06):15-18.
[5]左宪章.永磁体漏磁检测原理及其在无损检测中的应用[J].电测与仪表,1994,31(11):16-19.
[6]Shcherbinin V E,Zatsepin N N.Calculation of the magnetostatic field of surface defects.I.Field topography of defect models[J].Defectoscopy,1966,(05):385-393.
[7]Shcherbinin V E,Zatsepin N N.Calculation of the magnetostatic field of surface defects.II.Experimental verification of the principal theoretical relationships[J].Defectoscopy,1966,(05):394-399.
[8]Shcherbinin V E,Pashagin A.Influence of the extension of a defect on the magnitude of its magnetic field[J].Defektoskopiya,1972,8(04):84-78.
[9]Edwards C,Palmer S B.The magnetic leakage field of surface-breaking cracks[J].Journal of Physics D:Applied Physics,1986,19(04):657-673.
[10]Hwang J,Lord W.Finite element analysis of the magnetic field distribution inside a rotating ferromagnetic bar[J].IEEE Transactions on Magnetics,1974,10(04):1113-1118.
[11]Atherton D L.Finite element calculations and computer measurements of magnetic flux leakage patterns for pits[J].British Journal of Non-Destructive Testing,1988,30(03):159-162.
[12]Kim H M,Park G S.A study on the estimation of the shapes of axially oriented cracks in CMFL type NDT system[J].IEEE Transactions on Magnetics,2014,50(02):109-112.
[13]杨理践,张国光,刘刚.管道漏磁内检测技术[M].北京:化学工业出版社,2014.
[14]Edwards C,Palmer S B.The prod magnetization method of magnetic particle inspection[J].British Journal of Non-Destructive Testing,1983,25(06):305-308.
[15]李光海,刘时风,沈功田.压力容器无损检测--漏磁检测技术[J].无损检测,2004,26(12):638-642.
[16]张国光.管道周向励磁漏磁内检测技术的研究[D].沈阳:沈阳工业大学,2010.
[17]林俊明.漏磁检测技术及发展现状研究[J].无损探伤,2006,30(01):1-5.
[18]Kim H M,Rho Y W,Yoo HR,et al.A study on the measurement of axial cracks in the Magnetic Flux Leakage NDT system[C]//Automation Science and Engineering(CASE),2012 IEEE International Conference on.IEEE,2012:624-629.
[19]康宜华,武新军,杨叔子.磁性无损检测技术中的磁化技术[J].无损检测,1999,21(05):206-209.
[20]康宜华,陈艳婷,孙燕华.超强磁化下漏磁检测的穿透深度[J].无损检测,2011,33(6):27-29.
[21]Sun Y,Feng B,Liu S,et al.A methodology for identifying defects in the magnetic flux leakage method and suggestions for standard specimens[J].Journal of Nondestructive Evaluation,2015,34(03):1-9.
[22]Sun Y,Kang Y.Magnetic compression effect in present MFL testing sensor[J].Sensors and Actuators A:Physical,2010,160(01):54-59.
[23]Wang X,Wu X,Xu J,et al.Study on the liftoff effect on MFL signals with magnetic circuit model and 3D FEM[J].Insight-Non-Destructive Testing and Condition Monitoring,2012,54(09):505-510.
[24]李路明,张家骏.用有限元方法优化漏磁检测[J].无损检测,1997,19(06):154-158.
[25]李路明,黄松岭,杨海青,等.缺陷长度对漏磁场的影响[J].科学技术与工程,2002,(04):52-53.
[26]黄作英,阙沛文.计算机仿真在管道漏磁检测中的应用[J].计算机仿真,2004,21(10):174-177.
[27]杨理践,邢燕好,高松巍.高精度管道漏磁在线检测系统的研究[J].无损探伤,2005,29(01):20-22.
[28]张国光.管道漏磁检测中漏磁信号与缺陷特征关系的研究[J].检测与仪表,2008,35(02):39-41.
[29]戴光,崔巍,杨志军,等.换热管漏磁检测磁化结构有限元分析[J].化工机械,2010,37(06):726-729.
[30]何辅云,董文雯,王爱民.在役管线无损检测设备的研究[J].合肥工业大学学报:自然科学版,2004,(07):738-741.
[31]吴德会,游德海,柳振凉,等.交流漏磁检测法趋肤深度的机理与实验研究[J].仪器仪表学报,2014,35(02):327-336.
[32]王晓红,吴德会,李雪松,等.小型磁化器条件下的变励磁MFL检测新方法[J].仪器仪表学报,2015,36(01):70-77.
[33]Wang P,Gao Y,Tian G Y,et al.Velocity effect analysis of dynamic magnetization in high speed magnetic flux leakage inspection[J].NDT&E International,2014,(64):7-12.
[34]沈功田.承压设备的无损检测与评价技术发展现状[J].机械工程学报,2017,53(12):1-12.
[35]周燕,董怀荣,周志刚,等.油气管道内检测技术的发展[J].石油机械,2011,39(03):74-77.
[36]何辅云.钢管三维漏磁检测系统的再研究[J].无损检测,2000,22(02):68-70.
[37]黄辉,何仁洋,熊昌胜,等.漏磁检测技术在管道检测中的应用及影响因素分析[J].管道技术与设备,2010,(03):17-19.
[38]于清澄,张迪.管道漏磁检测提离值影响的研究[J].中国仪器仪表,2009,(S1):75-77.
[39]吴德会,柳振凉,张忠远,等.漏磁检测中提离值影响的三维有限元仿真分析[J].应用基础与工程科学学报,2013,21(06):1188-1198.
[40]杨理践,袁希平,高松巍.输气管道漏磁内检测的速度效应分析[J].管道技术与设备,2013,(05):19-21.
[41]邓志扬,杨芸,冯搏,等.表面粗糙度对裂纹漏磁检测的影响[J].无损检测,2016,(02):40-44.
[42]黄松岭,李路明.管道漏磁检测中的信号处理[J].无损检测,2000,22(02):55-57.
[43]陈正阁,王长龙,梁四洋,等.小波变换在漏磁检测信号处理中的应用[J].火力与指挥控制,2009,34(02):154-157.
[44]宋志强,张莹,吴江.基于小波包-Haar小波变换的漏磁检测信号降噪数据压缩方法[J].机床与液压,2017,45(02):126-129.
[45]田凯,孙永泰,高慧,等.贝叶斯算法BP神经网络缺陷量化研究[J].中国测试,2014,40(03):93-97.
[46]Daniel J,Mohanagayathriand R,Abudhahir A.Characterization of defects in Magnetic Flux Leakage(MFL)images using wavelet transform and neural network[C]//Electronics and Communication Systems(ICECS),2014International Conference on.IEEE,2014:1-5.
[47]Nara T,Fujieda M,Gotoh Y.Non-destructive inspection of ferromagnetic pipes based on the discrete Fourier coefficients of magnetic flux leakage[J].Journal of Applied Physics,2014,115(17):17E509-17E509-3.
[48]焦敬品,常予,李光海,等.铁磁构件内外表面裂纹低频漏磁检测技术研究[J].仪器仪表学报,2016,37(08):1808-1817.
[49]杨理践,郭天昊,高松巍,等.油气管道特殊部件的漏磁检测信号特征分析[J].沈阳工业大学学报,2017,39(01):43-47.
[50]Ong J K,Kerr D,Bouazza-Marouf K.Design of a semi-autonomous modular robotic vehicle for gas pipeline inspection[J].Proceedings of the Institution of Mechanical Engineers Part I-Journal of Systems and Control Engineering,2003,217(12):109-122.
[51]Caleyo F,Hallen J M,Gonzalez J L.Pipeline inspection-1-reliability-based method assesses corroding pipelines[J].Oil&Gas Journal,2003,101(01):54-58.
[52]Anon,Pipeline inspection failure blamed for oil spill[J].Pipeline&Gas Journal,2002,229(09):2-5.