METHOD FOR DETERMINING THE GEOMETRY OF A DEFECT AND FOR DETERMINING A LOAD LIMIT
20220163325 · 2022-05-26
Inventors
Cpc classification
G01N29/2412
PHYSICS
G01B21/20
PHYSICS
International classification
Abstract
A method is provided for determining the geometry of one or more real, examined defects of a metallic and in particular magnetizable object, in particular a pipe or a tank, by means of at least two reference data sets of the object generated on the basis of different, non-destructive measuring methods.
Claims
1. A method for determining the geometry of one or more real, examined defects of a metallic object by at least two reference data sets of the object generated on the basis of different, non-destructive measuring methods, wherein the object is displayed at least partially on or through an at least two-dimensional object grid in an EDP unit, the method comprising the steps of: determining at least one starting defect geometry as the initial defect geometry, determining respective prediction data sets as initial prediction data sets on the basis of the initial defect geometry by simulation or assignment of a measurement that matches the respective reference data set, iteratively adjusting the initial defect geometry to the geometry of the one or more real, examined defects by the EDP unit and by at least one particularly competing expert routines, generating a respective expert defect geometry in the respective at least one expert routine by at least one separate algorithm and based on the initial defect geometry, determining respective expert prediction data sets based on the respective expert defect geometry by simulation or assignment of a measurement that matches the respective reference data set, making available the expert defect geometry on which the respective expert prediction data sets are based to at least one of the at least one expert routine as a new initial defect geometry for further adjustment to the geometry of the one or more real, examined defects, when the expert prediction data sets of a respective expert routine are more similar to the respective reference data sets than the initial prediction data sets and/or a fitness function that takes into account the at least two expert prediction data sets is improved, the expert prediction data sets belonging to the new initial defect geometry are used as new initial prediction data sets, wherein the iterative adjustment by means of the expert routines takes place until a stop criterion is met.
2. The method according to claim 1, wherein a data set based on an MFL, eddy current, EMAT, or ultrasonic measuring method is used as the first reference data set and a data set generated based on another and different of said measuring methods is used as the other reference data set.
3. The method according to claim 1, wherein the initial defect geometry is determined on the object grid, an at least two-dimensional defect grid and/or via a parameter representation.
4. The method according to claim 1, wherein at least one simulation parameter obtained from a calibration run of the inspection device belonging to the measuring method and/or at least one material-specific parameter of the object are used for the measuring method-specific generation of the initial and/or expert prediction data sets.
5. The method according to claim 1, wherein the at least one expert routines run in competition with one another in such a way that the resources of the EDP unit to a respective expert routine are distributed as a function of a success rate.
6. The method according to claim 1, wherein initial and/or expert prediction data sets are generated on the basis of a forward model for simulating the respective non-destructive measuring method.
7. The method according to claim 1, wherein the starting defect geometry is generated by means of a look-up table, by one of the expert routines, and/or by a machine learning algorithm.
8. The method according to claim 7, wherein the starting defect geometry is generated by inversion of at least parts of the reference data sets using at least one neural network trained for this task.
9. The method according to claim 1, wherein, to determine the object grid, anomaly-free areas and anomaly-afflicted areas of the object are first classified on the basis of at least parts of the reference data sets, wherein an initial object grid is created particularly on the basis of previously known information about the object, the initial object grid is used to calculate prediction data sets for the respective non-destructive measuring methods, at least parts of the prediction data sets are compared with respective parts of the reference data sets while excluding the anomaly-afflicted areas, and, depending on at least one degree of accuracy, either the initial object grid is used as the object grid describing the geometry of the object or an iterative adjustment of the initial object grid to the geometry of the object in the anomaly-free areas is carried out by means of the EDP unit.
10. The method according to claim 9, wherein, in the iterative adjustment of the initial object grid, a new initial object grid is created and new prediction data sets are calculated for it, and at least parts of the new prediction data sets are compared to corresponding parts of the reference data sets, excluding the anomaly-afflicted areas until an object stop criterion is met, and the initial object grid then present is used as the object grid describing the geometry of the object.
11. The method according to claim 9, wherein an anomaly-free area is assigned to at least one predefined local element of the object during the classification and this element is used in the creation of the initial object grid or inserted into the initial object grid.
12. The method according to claim 11, wherein the local element is described by means of a parametric geometry model.
13. The method according to claim 1, wherein the initial defect geometry or a pointer referring thereto is stored in a memory area of the EDP unit that is accessible to all expert routines.
14. The method according to claim 1, wherein the stop criterion is assumed to be a substantial change in the initial defect geometry, in the geometry of the object and/or defect grid, in the initial prediction data set and/or in at least one expert prediction data set, which change does not occur after a plurality of iterations.
15. The method according to claim 1, wherein a comparison of the variation of the expert prediction data set to the measurement spread of the real data set is used as the stop criterion.
16. The method according to claim 1, wherein an expert routine is assigned one or more algorithms for generating and/or adjusting the expert defect geometry including machine learning, stochastic optimization, empirical and/or numerical model functions.
17. The method according to claim 16, wherein an algorithm is generated randomly in an expert routine or is selected and/or changed by a selection function.
18. The method according to claim 1, wherein different and defect-specific variations for generating the expert defect geometry are carried out in the expert routine(s).
19. The method according to claim 18, wherein, in the expert routines, a parameter representation of a respective defect, derived from or assigned to the initial defect geometry, is varied to generate the expert defect geometry.
20. The method according to claim 19, wherein a defect classification algorithm imaged preferably using a neural network classifies the defects of the initial defect geometry.
21. A method for determining a load limit of an object that is under pressure at least during operation, wherein a data set describing one or more defects is used as an input data set in a calculation of the load limit, wherein the input data set is generated first according to a method according to claim 1.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0079] Reference is now made more particularly to the drawings, which illustrate the best presently known mode of carrying out the invention and wherein similar reference characters indicate the same parts throughout the views.
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DETAILED DESCRIPTION OF THE DRAWINGS
[0089] Individual features of the exemplary embodiments described below can, in combination with the features of the independent claims, also lead to further developments according to the invention.
[0090] In the prior art, the evaluation of, for example, MFL data of a pipe according to
[0091] According to an exemplary embodiment of the method according to the invention, the surface of a pipe is represented by a 2D mesh surface. The defect geometry can be parameterized as a vector of depth values D that lie on a defect grid 5 (
[0092] Herein, i is the number of data sets to be treated simultaneously (real or simulated data sets), Y.sub.cal.sup.i is the result of a simulation of the corresponding i-th measurement, Y.sub.m.sup.i is the measured data of the respective reference data sets, and R(x.sub.1 . . . x.sub.n) is a regularization term, which can be used in the case of ambiguities, e.g. due to several minima, and can be used as follows:
R(x.sub.1 . . . x.sub.n)=α∥(x.sub.1 . . . )x.sub.n∥,
where α is a scaling term.
[0093] The process sequence according to the invention is described at least in sections below according to
[0094] For example, several runs of the same MFL pipeline pig can be combined as input data sets according to box 2. Both data sets 1 can be filtered beforehand for the purpose of better merging and adjusted to one another (method step 3), for example to reduce any artifacts or background noise. In addition, another data set 4 is processed based on another measuring method as an additional reference data set in the associated box 3 and filtered for the purpose of matching to identical grid structures, such that, according to method section 6, two matched reference data sets are available that were created on the basis of different non-destructive measuring methods.
[0095] Data sets that are precisely matched to one another can be treated jointly, wherein the method according to the invention implements the simultaneous treatment of the data sets by using a fitness function that takes into account the data sets to be considered together.
[0096] In step 7, the reference data sets present in step 6 are accessed, for which purpose a starting defect geometry is first determined as the initial defect geometry in step 8. As described above, this takes place based on a neural network into which the reference data sets are read as input data sets.
[0097] The solution of the neural network is then made available as one or more initial defect geometries x.sub.1 . . . x.sub.n to the individual expert modules. In advance, the number of parameter values that describe the defect geometries can be kept as small as possible, with the aim of reducing computing time. This is achieved, for example, by a dynamic grid adjustment. Since the number of depth values corresponds to the number of node points in the defect grid 5, the number of nodes can at the same time also be the number of defect parameters. Starting with a comparatively coarse grid, this is gradually refined in relevant areas.
[0098] The refinement shown in the relevant grid area in
[0099] After a defect grid made available centrally to all expert routines has now been selected, a new expert defect geometry is then calculated in step 14 for specific defects in the respective expert routines, and it is checked under 14.1 whether this needs to be made available to the other expert routines. This is the case if, for example, a fitness function has been improved as described above and no stop criterion has yet ended the defect finding process. In this case, the iteration continues with the defect geometry or geometries made available to all expert routines. Otherwise, the method is ended in 14.2. with the determination of the defect geometries and, in particular, the specification of the accuracy of the solution. In addition, the burst pressure can be calculated based on the defect geometries found.
[0100] According to the method according to the invention, the sequence of the work flow of a group of expert routines 11 which are in competition with one another is simulated on the EDP unit. For this purpose, the program can have various modules which can set data in specific areas of the EDP unit independently of one another and particularly not synchronized with one another, so that they can be further processed there. This particularly takes place under the supervision of a monitoring routine 9 (
[0101] The number of computation slots 13 available to an expert routine 11 and the simulation routines subsequently made available can vary in such a way that a first expert routine, for example, can utilize up to 50% of the total available for the computation slots and computing time available to simulation routines.
[0102] As shown, the initial defect geometries are stored in the memory area 12. This can be a memory area accessible to the expert routines 11. Log files of the expert routines 11 and monitoring routine 9 as well as instructions to the expert routines 11 can also be stored there, which are then independently implemented by them. For example, this can be an interrupt command that is set when the stop criterion is reached.
[0103] The expert routines 11 are preferably independent program modules which generate new expert defect geometries and place them in the simulation routines 16. Furthermore, the fitness function presented at the beginning can be generated in the expert routines 11 based on the expert prediction data sets and compared to the initial prediction data sets stored in the area 12. If the expert prediction data sets are overall more similar to the reference data sets than the data sets stored in area 12, these expert prediction data sets are then used as new initial prediction data sets.
[0104] For example, a new defect geometry is generated randomly in the expert routines 11. Machine learning algorithms or empirical rules can be used for this. Advantageously, however, the implementation of at least two basic expert routines working in a defect-specific manner based on the type of defect is provided to further improve the convergence of the solutions, as described below.
[0105] These search strategies, which are preferably always implemented in a method according to the invention, are based on an assumed probability distribution p(x, y) of grid points, the depth value of which results in a maximum reduction in the fitness function to determine a corrosion-based defect geometry. The probability function is used to identify N grid points (x.sub.n, y.sub.n). Instead of grid points x.sub.n, y.sub.n, the parametric representation of the group of defects (x.sub.1 . . . x.sub.n) already used above can be assumed as the subject of the probability distribution, with N grid points (x, y) or (x.sub.n, y.sub.n).
[0106] At each of the points under consideration, the depth function, which in the present case describes the depth D of the corrosion at the grid point, is changed by ΔD, wherein the sign of the change is distributed randomly. The number of selected points N can also be chosen randomly:
[0107] When selecting the probability function p(x, y), different expert strategies can be implemented, for example:
[0108] This algorithm implements a variation of the defect depth, in which the grid points with the greatest depth are preferred. Another strategy for a corrosion-based development of the expert defect geometry may be as follows:
[0109] Such an algorithm varies the defect geometry at positions at which the simulated MFL measurement signal H.sub.the best has the greatest difference to the measured signal H.sub.m for the best known solution.
[0110] On this basis, different expert routines or their algorithms can be set up by varying the number of grid points to be considered and the ΔD. As an example, the following six expert routines can be used for the development of corrosion-based defects:
[0111] The following functional rules can be used for an expert routine that is suitable for the variation of a crack-based defect:
[0112] the depth of the defect is randomly reduced or increased by a specific amount, preferably e.g. 1 or 2% of the wall thickness of the object,
[0113] the position of all points of the crack is varied in a randomly selected direction, and/or
[0114] a line describing the crack is lengthened or shortened by the position of the grid nodes on the object grid or defect grid.
[0115] An expert routine that describes a laminating defect can work according to the following functional rules:
[0116] on the basis of the 2D parameter description of a laminating defect, the values associated with the grid nodes are varied step by step by 5% in one direction or the other with the aim of varying the position of the lamination; this can only be done for a subset of the known of the 2D description of the lamination or the laminating defect,
[0117] randomly selected points (grid nodes) with values not equal to zero, which are in the vicinity of points with values of zero, can be set to zero (reduction of the extent of the lamination),
[0118] randomly selected grid points with values of zero, which are located in the vicinity of grid points with values not equal to zero, can be set to the corresponding neighborhood value, whereby the lamination is increased, and/or
[0119] all values in the grid can be moved in a randomly selected direction, which is accompanied by a change in the position of the lamination along the pipeline surface.
[0120] As described, the monitoring routine 9 shown in
wherein ΔF is the reduction of the fitness function F by the result of the respective expert routine, and in this case N is the number of simulations required for this. An assessment of the n expert routines can be assumed as
[0121] The number of computation slots N.sub.S for an expert routine in one iteration then is
N.sub.S=int(R.sub.nN.sub.all),
wherein N.sub.all is the number of all available slots.
[0122] The respective non-destructive measurements for the expert defect geometries are simulated in the simulation routines 16. An expert routine can iterate until it finds a solution whose expert prediction data sets are better than the initial prediction data sets stored in area 12. If this is the case, the expert routine 11 can attempt to achieve other better solutions on the basis of the already improved solution.
[0123] A resulting error E for the individual observations of the simulated and measured data sets can result from the errors of the respective data sets in the individual calculations:
E=Σ.sub.i∥Y.sub.cal.sup.i(D)−Y.sub.m.sup.i∥,
wherein Y.sub.m.sup.i and Y.sub.cal.sup.i represent the above-described respective measured and simulated measuring fields at the defect geometries (x.sub.1 . . . x.sub.n).
[0124] To demonstrate the efficiency of the proposed method, a large number of test scenarios were carried out, wherein the data of two MFL inspection runs that were carried out with magnetizations that are linearly independent of one another are used below, according to
[0125] An initial defect geometry was determined on the EDP unit via the neural network, which geometry was then iteratively improved until a stop criterion was reached. The result of the method according to the invention is shown in
[0126] The above-mentioned burst pressure of 4744.69 kPa results based on the conventional consideration with the determination of the defect geometry established in the prior art and shown in the result in
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[0129] One or more reference data sets are created on based on one or more measurements with one or more non-destructive measuring methods.
[0130] An object grid representing the intact geometry of the object is created based on the anomaly-free areas and using the simulation routine. For this purpose, information from previous measurement runs in the object with no or fewer defects can also be used. For this purpose, the object grid can be created in the anomaly-free areas and then completed by extrapolating and/or interpolating into the anomaly-afflicted areas. It is also conceivable to carry out an interpolation and/or extrapolation based on the reference data sets from the anomaly-free areas into the anomaly-afflicted areas.
[0131] The object grid is created using an iterative process. A first initial object grid is guessed, estimated or, for example, specified based on an estimated object geometry. This is adjusted in an iterative process. An initial object grid can, for example, have a weld seam according to the one shown in cross section in
[0132] A parametric description of the weld seam by means of a parametric geometry model can in particular also be used to accelerate the method.
wherein Y.sub.m.sup.i—is the measured signal of the i-th measurement, Y.sub.cal.sup.i is the calculated signal for the i-th measurement. Values for the parameters can be determined using derivative-free optimization algorithms, for example by means of random search. The parameters can be changed in fixed steps, preferably defined as a function of the wall thickness, to accelerate the method. For example, a change can be made in steps that are 1% of the wall thickness.
[0133] Based on the method according to the invention, the condition of a pipe and thus the pressure that can be specified for safe operation of the pipeline can be specified much more realistically, while operational reliability is still ensured. Such a result can be made available to the pipeline operators more quickly than in the prior art using the method according to the invention with the expert routines competing for resources of the EDP unit.