The advantages and disadvantages of radiography and automated ultrasound control (AUZK) with coherent data processing are considered. The informativeness and sensitivity of these methods are compared. The possibilities of measuring the size of defects in radiography and in AUZK are analyzed. It is argued that for practical purposes, the detectability and error in determining the geometric dimensions of defects in AUZK with coherent data processing is quite sufficient. An example of using a system with coherent data processing for monitoring austenitic welded joints of pipelines of considerable thickness — up to 45 mm is given. The pipelines were used in the construction of a catalytic cracking complex. The timing of the work showed that the performance of the AUZC of one welded joint Ø 508 × 34 mm did not exceed 60 minutes, with the possibility of carrying out other installation work.
The article describes an approach to measuring the equivalent area of discontinuities in ultrasonic testing using phased arrays by calculating generalized ARD diagrams. The description of the calculation model, experimental results of checking the accuracy of calculations, information about the application of the proposed technology in the software of AUGUR series systems are given. The idea of generalized ARD diagrams (FAR-ARD) is to construct a three-dimensional function that establishes the relationship between the amplitudes of echo signals reflected from a flat-bottomed hole with a diameter d removed at a distance r from the beam entry point with an input angle of degrees for a given focusing law.
The method of automated control based on the use of a headlight-flaw detector for recording echo signals with subsequent restoration of the image of reflectors by projection in spectral space in three-dimensional mode (3D-PSP) is considered.A special setting of the flaw detector allows you to simulate the operation of many single-element converters with different input angles. This approach makes it possible to obtain images of reflectors with high resolution and a high signal-to-noise ratio at a depth of more than 100 mm. The procedure of calibration of an antenna array on a prism operating in the simulation mode of several piezoelectric converters with different input parameters is considered. The results of the control of the fragment of the ITER divertor support workpiece when obtaining images by the classical method of headlights and using three-dimensional processing are presented, demonstrating the effectiveness of the developed control technology.
The article examines the measurement errors of the main parameters of piezoelectric converters by the AUGUR 5.4 calibration system. Some influence functions are investigated. The real measurement error has been experimentally determined when testing the system with an assessment of precision in terms of repeatability and reproducibility. The acceptability of the measurement error of the main parameters of piezoelectric converters in accordance with the requirements of GOST 23702-90 is shown. The sufficiency of the normalized metrological characteristics of the system to ensure the uniformity of measurements is shown
The description of the AUGUR 5.4 piezoelectric transducer calibration system developed at the ECHOPLUS Company is given. The method of calculating all parameters of converters in accordance with GOST 23702-90 and EN 12668-2 is described in detail. Examples of piezoelectric converter passports are given.
The technology of automated ultrasonic inspection of annular welded joints of the unit for welding coolant collectors to the nozzles of steam generators Du1200 of VVER-1000 type reactors using systems with coherent data processing of the Augur series is considered. Acoustic control schemes, characteristics of piezoelectric transducers (PEP) and features of their use in monitoring are given. The results of testing the technique on a test sample showed the possibility of measuring the actual dimensions of defects. The data of measurements of the sizes of real cracks at three Russian nuclear power plants are presented and examples of coherent images of defects in the field of welded joints and galtel junction are given.
The description of the method of ultrasonic inspection of the internal welded joint of welding a branch pipe (branch) to the cowling (trunk) of a welded tee with reinforcing pads from the outer surface of the branch pipe is given. The method is based on three-dimensional coherent processing of automated ultrasonic inspection data obtained during scanning by transducers at a considerable distance from the controlled weld joint, along the pipe surface, where there are no overlays. The results of the control of tees with artificial and real defects are presented, demonstrating the capabilities of the method. The possibility of carrying out control at the sensitivity level regulated by the regulatory documents of the Gazprom is shown.
In Russia, a large number of industrial potentially hazardous facilities are operated in petrochemical production, energy and, first of all, nuclear, pipeline transport, defense equipment and many other industries. Accidents that occur lead to human casualties, environmental disasters, and significant material losses. In order to improve operational safety and reduce accidents, more and more attention is being paid to equipment diagnostics, which makes it possible to assess their operability at an early stage, prevent the occurrence of emergencies and, if possible, extend the service life of facilities. Abroad, they produce and offer for sale a large range of diagnostic devices that allow solving many diagnostic tasks. However, they are quite expensive, as a rule, they are not adapted to the Russian market, they are not equipped with methods of application to various objects, they do not allow creating a complex technology that includes the use of several methods and devices and gives the most objective and complete information about the object. In this paper, a comprehensive technology for diagnosing a wide range of potentially dangerous objects is analyzed, ensuring their safe operation even when they exhaust their resource by applying new and improving known methods and devices for non-destructive evaluation of the technical condition of the object.
A generalized sequence of actions for automated ultrasonic inspection of welded joints with measurement of defect sizes using the AUGUR system is considered. The main features of each control stage are described. It is shown that the effective application of the measurement mode requires calibration of acoustic transducers, analysis of surface irregularities, coherent data processing and detailed analysis of the images obtained.
The complex technology of control of welded joints is considered, which allows the analysis of the quality of welds through the analysis of the effect of defects on the strength of the seam. This technology consists of three stages. The first stage: manual or automated ultrasonic testing according to standard control methods in order to search for defects. The second stage: automated expert ultrasound using Augur series systems in order to determine the type and size of defects. The third stage: strength calculation of the working life of the weld, taking into account information about the parameters of defects and other characteristics that affect the resource. The features of Augur series systems that use coherent processing (FT-SAFT type) of recorded pulse ultrasonic field data are briefly considered. An example of an image of a crack in a pipeline with a diameter of 890 mm is given. It is noted that the use of systems with coherent data processing of the Augur series makes it possible to carry out periodic monitoring of welds during their operation. An example of periodic monitoring of a defect in a welded seam of a stainless steel pipeline with a diameter of 325 mm is given. The results of expert control of welds of pipelines of various types in the nuclear power industry and control of oil pipelines are presented. It is shown that the use of the above-described technology of comprehensive assessment of the state of welds can significantly reduce the amount of unjustified repair of seams due to knowledge of the degree of their danger and, thereby, reduce repair costs; increase the operational reliability of industrial products by eliminating the most dangerous defects missed during routine inspection. The use of automated Augur systems makes it possible to minimize the disadvantages inherent in manual control by ensuring 100% control volume, to ensure documentation of the results; to monitor the defect, analyze its development during operation and prepare seam repairs on a planned basis.