管道漏磁内检测关键技术问题研究
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摘要
管道内检测是确定管道变形、腐蚀、裂纹、缺陷程度的重要手段,检测结果为管道运行、维护、安全评价提供科学依据。本文以管道缺陷检测和预判方法为研究重点,通过对漏磁检测理论与应用的研究,分析了两种结构漏磁检测装置的缺陷检测能力,提出了空间弱磁场条件下内外缺陷识别(ID/OD)方法,为管道缺陷检测的完整性评价确定了技术基础;在铁磁材料磁畴结构的微观机理研究基础上,提出了弱磁条件下检测应力集中区域的方法,通过实验证明了方法的可行性,为解决管道的安全评价提供了一种有效的手段。
本文研究了管道缺陷内检测机理和检测模型,应用磁偶极子方法对不同励磁方向下,缺陷处磁场分布进行了数学解析计算;应用有限元方法对同一规格缺陷在高饱和状态下、近饱和状态下表面漏磁场分布,空间弱磁场条件下的内外缺陷表面磁场分布情况进行了数值仿真计算。通过对漏磁检测装置两种结构的研究,提出了一种解决传统管道漏磁内检测设备结构复杂,管道通过能力低的方法;通过对空间弱磁场检测的研究,提出了识别管道缺陷内外壁分布的一种有效方法。
实验分析了两种结构装置的缺陷漏磁检测(磁极中间区域检测和磁极后部区域检测)信号特征和识别能力:磁极中间区域检测精度为内缺陷最小识别面积表面直径φ3mm,深度10%壁厚的凹坑缺陷,外缺陷最小面积识别表面直径φ3mm,深度20%壁厚的凹坑缺陷,可以检测到直径φ2mm的透孔;磁极后部区域检测精度为内缺陷最小面积识别表面直径φ4mm,深度20%壁厚的凹坑缺陷;外缺陷最小面积识别表面直径φ4mm,深度40%壁厚的凹坑缺陷;可以检测到直径φ3.5mm的透孔,通过比较实验结果可知磁极后部区域检测可以在适当降低检测要求的条件下,作为简化管道内检测装置的一种手段。
实验研究了空间弱磁场条件下内外缺陷识别的信号特征和识别能力:可以有效检测出内表面直径φ2mm,深度10%壁厚的凹坑缺陷;而对外表面宽度10mm,深度50%壁厚的凹槽缺陷无有效检测信号,该方法可以作为内外缺陷识别的有效途径。
根据铁磁学的相关理论,研究了磁畴模型下铁磁体的内部磁特性;分析了铁磁材料磁畴结构产生的微观机理,并通过对磁畴结构运动变化规律,即磁畴壁移动和磁矩转动规律的研究,分析了外加磁场和外加应力对磁畴的影响,以及由此引起的材料磁特性的变化;通过理论分析和仿真实验,针对管道完整性评价中缺陷区域的预判问题,提出了一种弱磁场条件下应力集中区域的检测方法。
实验设计了Q235(钢材号)应力模型试件,建立了在无外部励磁、弱磁场激励、强磁场激励条件下的实验方案。地磁条件下对没有形成应力集中区的标准试件和两条具有不同应力值的试件进行直接磁检测,得到了在无外部励磁的条件下应力集中区域的信号特征,应力集中区域表面磁感应强度水平分量和垂直分量信号峰峰值均达到1.4Gs;在外部励磁条件下,通过改变试件与励磁装置的相对位置,得到了在不同励磁条件下应力集中区域的信号特征,应力集中区域表面磁感应强度垂直分量信号峰峰值均可以达到14Gs-24Gs。实验结果表明:强磁场激励条件下应力集中区不敏感;弱磁场条件下应力集中区域可以检测,而且检测结果具有很好的重复性;无励磁条件下,应力集中区可以测量,但信号受外界条件影响很大,而且外加强磁场后,自身有效信号消失,不可恢复。实验证明了弱磁场条件下应力集中区域检测方法的可行性,该方法可以作为应力集中区域检测的有效途径。
通过理论分析和实验研究,验证了所采用基本理论的正确性和方法的可行性。
The internal pipeline detection is an important means to determine pipeline deformation, corrosion, cracks, and defective degrees, the result of which provides a scientific basis for the pipeline operation, maintenance, and its safety evaluation. In this thesis, with a focus study on pipeline defect inspection and pre-judgment method and with a main research into magnetic flux leakage (MFL) detection theory and application, the defect detection capability of inspection device used in two kinds of structure is analysed and inner-outer defect identification (ID/OD) method is proposed under the condition of weak magnetic field, which has laid a technical basis for the evaluation of the pipeline defect integrity. Based on the research into the micro-mechanism structure of Ferro-magnet material magnetic domain, the method for testing stress concentration region under the weak magnetic conditions is presented; the feasibility of the method is proved by experiments and an effective way in resolving the safety assessment of pipeline is provided.
In this thesis, the internal pipeline defect detection mechanism and detection model are researched. By applying magnetic dipole method in the different excitation direction, the defect magnetic field distribution is calculated. By applying the finite element method for the same specification defects under the conditions of high-saturation or near saturation to surface magnetic leakage distribution, the inner-outer defects surface magnetic field distribution in the weak magnetic field is emulationally calculated. Through the research of two kinds of device structures used in MFL detection, a solution to the traditional complex structures in the pipeline MFL detection equipment is proposed and so is it to the low capacity within the pipelines. And also by the research into the space weak magnetic fields detection, an efficient identification method to pipeline inner-outer defect distribution is offered.
The signal characteristics and the identification ability for the two kinds of structural defect MFL detection device (used in the magnetic poles of mid-region and magnetic poles of post-region detection) are experimentally analyzed; With the magnetic poles mid-region detection accuracy up to inner defect minimum identification surface diameter ofφ3mm, depth of 10% wall thickness of the pit defect, and outer defect minimum identification surface diameter ofφ3mm, depth of 20% wall thickness of pit defect, a through-hole up to diameter ofφ2mm can be detected, while with the magnetic poles post-region detection accuracy up to inner defect minimum identification surface diameter ofφ4mm, depth of 20% wall thickness of the pit defect, and outer defect minimum identification surface diameter ofφ4mm, depth of 40% wall thickness of pit defect, a through-hole up to diameter ofφ3.5mm can be detected. By comparing the experimental results, under the conditions of reducing appropriate testing requirements, magnetic post-region detection can be used as a simplified means for pipe inspection device.
The signal characteristics and the identification ability for the inner-outer defect identification under the conditions of weak magnetic field: detection is experimentally verified, which can efficiently detect inner surface diameter ofφ2mm, depth of 10% wall thickness of pit defect, while for the outer width of 10mm, 50% wall thickness of groove defect, there is no valid detection signal, therefore, such a method can be used as an effective way to identify inner-outer defect.
According to relative theories of ferromagnetics, the internal magnetic properties of ferromagnetic in the magnetic domain model are studied in this thesis; and the micro-mechanism of ferro-magnet material magnetic domain structure is analyzed. Through the research on the movement variation of magnetic domain structure, that is, the movement of domain wall and rotation of magnetic moment, the effects on the magnetic domain caused by outer magnetic field and outer stress is analyzed and so is variation caused by such material magnetic properties. Through theoretical analysis and simulation experiments, the stress concentration area detection method under a weak magnetic field conditions is presented in this paper, so as just to solve the problem of pre-judgment in defect regions of pipeline integrity evaluation.
Q235 stress model specimen is designed in the experiment. Stress region detection experiments are carried out under the conditions of non-external excitation, the weak magnetic fields and the strong magnetic fields. A standard specimens of non-stress concentration area under the geomagnetic condition and two standard specimens with different stress values are directly detected in such a magnetic method that stress concentration region signal characteristics under the condition of non-external excitation is obtained, with the result that the stress concentration region’s surface magnetic induction intensity in horizontal component and vertical component reaches 1.4Gs of the signal peak-peak value; stress concentration region signal characteristics under the condition of external excitation is obtained, by changing the relative position between specimen and excitation device, with the result that the stress concentration region’s surface magnetic induction intensity in horizontal component and vertical component reaches 14Gs-24Gs of the signal peak-peak value. Experiment results show that the stress concentration area is not sensitive under the conditions of strong magnetic fields and the stress concentration area under the condition of weak magnetic field can be detected and detection results have very good repeatability while under the conditions of non-excitation conditions, the stress concentration area can be measured, but the signal is greatly influenced by the external conditions, and after loading strong magnetic field, the effective signal itself disappears with unrecoverable nature. Experimental results show that the stress concentration region detection method under the conditions of weak magnetic field is feasible, the method of which can be used as an effective way to detection stress concentration region.
In this paper, theoretical analysis and experimental research verify the basic theoretical correctness and feasibility of the method.
本文研究了管道缺陷内检测机理和检测模型,应用磁偶极子方法对不同励磁方向下,缺陷处磁场分布进行了数学解析计算;应用有限元方法对同一规格缺陷在高饱和状态下、近饱和状态下表面漏磁场分布,空间弱磁场条件下的内外缺陷表面磁场分布情况进行了数值仿真计算。通过对漏磁检测装置两种结构的研究,提出了一种解决传统管道漏磁内检测设备结构复杂,管道通过能力低的方法;通过对空间弱磁场检测的研究,提出了识别管道缺陷内外壁分布的一种有效方法。
实验分析了两种结构装置的缺陷漏磁检测(磁极中间区域检测和磁极后部区域检测)信号特征和识别能力:磁极中间区域检测精度为内缺陷最小识别面积表面直径φ3mm,深度10%壁厚的凹坑缺陷,外缺陷最小面积识别表面直径φ3mm,深度20%壁厚的凹坑缺陷,可以检测到直径φ2mm的透孔;磁极后部区域检测精度为内缺陷最小面积识别表面直径φ4mm,深度20%壁厚的凹坑缺陷;外缺陷最小面积识别表面直径φ4mm,深度40%壁厚的凹坑缺陷;可以检测到直径φ3.5mm的透孔,通过比较实验结果可知磁极后部区域检测可以在适当降低检测要求的条件下,作为简化管道内检测装置的一种手段。
实验研究了空间弱磁场条件下内外缺陷识别的信号特征和识别能力:可以有效检测出内表面直径φ2mm,深度10%壁厚的凹坑缺陷;而对外表面宽度10mm,深度50%壁厚的凹槽缺陷无有效检测信号,该方法可以作为内外缺陷识别的有效途径。
根据铁磁学的相关理论,研究了磁畴模型下铁磁体的内部磁特性;分析了铁磁材料磁畴结构产生的微观机理,并通过对磁畴结构运动变化规律,即磁畴壁移动和磁矩转动规律的研究,分析了外加磁场和外加应力对磁畴的影响,以及由此引起的材料磁特性的变化;通过理论分析和仿真实验,针对管道完整性评价中缺陷区域的预判问题,提出了一种弱磁场条件下应力集中区域的检测方法。
实验设计了Q235(钢材号)应力模型试件,建立了在无外部励磁、弱磁场激励、强磁场激励条件下的实验方案。地磁条件下对没有形成应力集中区的标准试件和两条具有不同应力值的试件进行直接磁检测,得到了在无外部励磁的条件下应力集中区域的信号特征,应力集中区域表面磁感应强度水平分量和垂直分量信号峰峰值均达到1.4Gs;在外部励磁条件下,通过改变试件与励磁装置的相对位置,得到了在不同励磁条件下应力集中区域的信号特征,应力集中区域表面磁感应强度垂直分量信号峰峰值均可以达到14Gs-24Gs。实验结果表明:强磁场激励条件下应力集中区不敏感;弱磁场条件下应力集中区域可以检测,而且检测结果具有很好的重复性;无励磁条件下,应力集中区可以测量,但信号受外界条件影响很大,而且外加强磁场后,自身有效信号消失,不可恢复。实验证明了弱磁场条件下应力集中区域检测方法的可行性,该方法可以作为应力集中区域检测的有效途径。
通过理论分析和实验研究,验证了所采用基本理论的正确性和方法的可行性。
The internal pipeline detection is an important means to determine pipeline deformation, corrosion, cracks, and defective degrees, the result of which provides a scientific basis for the pipeline operation, maintenance, and its safety evaluation. In this thesis, with a focus study on pipeline defect inspection and pre-judgment method and with a main research into magnetic flux leakage (MFL) detection theory and application, the defect detection capability of inspection device used in two kinds of structure is analysed and inner-outer defect identification (ID/OD) method is proposed under the condition of weak magnetic field, which has laid a technical basis for the evaluation of the pipeline defect integrity. Based on the research into the micro-mechanism structure of Ferro-magnet material magnetic domain, the method for testing stress concentration region under the weak magnetic conditions is presented; the feasibility of the method is proved by experiments and an effective way in resolving the safety assessment of pipeline is provided.
In this thesis, the internal pipeline defect detection mechanism and detection model are researched. By applying magnetic dipole method in the different excitation direction, the defect magnetic field distribution is calculated. By applying the finite element method for the same specification defects under the conditions of high-saturation or near saturation to surface magnetic leakage distribution, the inner-outer defects surface magnetic field distribution in the weak magnetic field is emulationally calculated. Through the research of two kinds of device structures used in MFL detection, a solution to the traditional complex structures in the pipeline MFL detection equipment is proposed and so is it to the low capacity within the pipelines. And also by the research into the space weak magnetic fields detection, an efficient identification method to pipeline inner-outer defect distribution is offered.
The signal characteristics and the identification ability for the two kinds of structural defect MFL detection device (used in the magnetic poles of mid-region and magnetic poles of post-region detection) are experimentally analyzed; With the magnetic poles mid-region detection accuracy up to inner defect minimum identification surface diameter ofφ3mm, depth of 10% wall thickness of the pit defect, and outer defect minimum identification surface diameter ofφ3mm, depth of 20% wall thickness of pit defect, a through-hole up to diameter ofφ2mm can be detected, while with the magnetic poles post-region detection accuracy up to inner defect minimum identification surface diameter ofφ4mm, depth of 20% wall thickness of the pit defect, and outer defect minimum identification surface diameter ofφ4mm, depth of 40% wall thickness of pit defect, a through-hole up to diameter ofφ3.5mm can be detected. By comparing the experimental results, under the conditions of reducing appropriate testing requirements, magnetic post-region detection can be used as a simplified means for pipe inspection device.
The signal characteristics and the identification ability for the inner-outer defect identification under the conditions of weak magnetic field: detection is experimentally verified, which can efficiently detect inner surface diameter ofφ2mm, depth of 10% wall thickness of pit defect, while for the outer width of 10mm, 50% wall thickness of groove defect, there is no valid detection signal, therefore, such a method can be used as an effective way to identify inner-outer defect.
According to relative theories of ferromagnetics, the internal magnetic properties of ferromagnetic in the magnetic domain model are studied in this thesis; and the micro-mechanism of ferro-magnet material magnetic domain structure is analyzed. Through the research on the movement variation of magnetic domain structure, that is, the movement of domain wall and rotation of magnetic moment, the effects on the magnetic domain caused by outer magnetic field and outer stress is analyzed and so is variation caused by such material magnetic properties. Through theoretical analysis and simulation experiments, the stress concentration area detection method under a weak magnetic field conditions is presented in this paper, so as just to solve the problem of pre-judgment in defect regions of pipeline integrity evaluation.
Q235 stress model specimen is designed in the experiment. Stress region detection experiments are carried out under the conditions of non-external excitation, the weak magnetic fields and the strong magnetic fields. A standard specimens of non-stress concentration area under the geomagnetic condition and two standard specimens with different stress values are directly detected in such a magnetic method that stress concentration region signal characteristics under the condition of non-external excitation is obtained, with the result that the stress concentration region’s surface magnetic induction intensity in horizontal component and vertical component reaches 1.4Gs of the signal peak-peak value; stress concentration region signal characteristics under the condition of external excitation is obtained, by changing the relative position between specimen and excitation device, with the result that the stress concentration region’s surface magnetic induction intensity in horizontal component and vertical component reaches 14Gs-24Gs of the signal peak-peak value. Experiment results show that the stress concentration area is not sensitive under the conditions of strong magnetic fields and the stress concentration area under the condition of weak magnetic field can be detected and detection results have very good repeatability while under the conditions of non-excitation conditions, the stress concentration area can be measured, but the signal is greatly influenced by the external conditions, and after loading strong magnetic field, the effective signal itself disappears with unrecoverable nature. Experimental results show that the stress concentration region detection method under the conditions of weak magnetic field is feasible, the method of which can be used as an effective way to detection stress concentration region.
In this paper, theoretical analysis and experimental research verify the basic theoretical correctness and feasibility of the method.
引文
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