Ultrasonic thickness reduction inspection method/apparatus
10309772 ยท 2019-06-04
Assignee
Inventors
Cpc classification
G01N2291/044
PHYSICS
G01N2291/0258
PHYSICS
G01N29/50
PHYSICS
G01N29/348
PHYSICS
International classification
G01N29/34
PHYSICS
G01N29/50
PHYSICS
G01N29/44
PHYSICS
Abstract
Chirp waves generated in a transmitting/receiving unit is supplied to ultrasonic sensors. Signals output from the ultrasonic sensors are supplied to the transmitting/receiving unit and summed in a signal processing/recording unit. The signal processing/recording unit performs mutual correlation processing between the summed signals and the chirp waves and calculates a peak generation time difference. Necessity of exchanging a pipe is determined by calculating and recording the thickness of a pipe from the calculated time difference and calculating a difference between thicknesses measured in the past and the present.
Claims
1. An ultrasonic thickness reduction inspection method, comprising: disposing a plurality of ultrasonic sensors on a surface of an inspection target; exciting the plurality of ultrasonic sensors by a frequency modulated wave signal in which a frequency is changed with time; supplying ultrasonic waves to an inside of the inspection target; receiving signals in which the plurality of ultrasonic sensors is excited by a plurality of echoes from the inside of the inspection target by the ultrasonic waves supplied to the inside of the inspection target; summing the plurality of received echo signals; calculating, from cross correlation between the signals summing the plurality of echo signals and the frequency modulated wave signal, a time difference between a first peak of the summed signals and a first peak of the frequency modulated wave signal; and detecting a change in a thickness of the inspection target based on the calculated time difference.
2. The ultrasonic thickness reduction inspection method according to claim 1, wherein the inspection target is a pipe, and the plurality of ultrasonic sensors is disposed side by side in a circumferential direction of the pipe.
3. The ultrasonic thickness reduction inspection method according to claim 1, wherein the inspection target is a pipe, and the plurality of ultrasonic sensors is disposed side by side in an axial direction of the pipe.
4. The ultrasonic thickness reduction inspection method according to claim 1, wherein the inspection target is a pipe, and the plurality of ultrasonic sensors is disposed side by side in a circumferential direction and an axial direction of the pipe.
5. The ultrasonic thickness reduction inspection method according to claim 1, wherein, by electromagnetic induction generated between a plurality of coils disposed opposite to each other, signals are received which are generated when the frequency modulated wave signals of the plurality of ultrasonic sensors are excited, and the plurality of ultrasonic sensors is excited by the plurality of echoes from the inside of the inspection target.
6. The ultrasonic thickness reduction inspection method according to claim 1, wherein a first coil connected to the plurality of ultrasonic sensors, a second coil disposed opposite to the first coil, a third coil electrically connected to the second coil via a metal protection material, and a fourth coil disposed opposite to the third coil are disposed, and by electromagnetic induction between the first coil and the second coil and electromagnetic induction between the third coil and the fourth coil, signals are received which are generated when the plurality of ultrasonic sensors is excited by frequency modulated wave signals, and the plurality of ultrasonic sensors is excited by the plurality of echoes from the inside of the inspection target.
7. An ultrasonic thickness reduction inspection apparatus, comprising: a plurality of ultrasonic sensors disposed on a surface of an inspection target; a transmitter/receiver configured to excite the plurality of ultrasonic sensors by a frequency modulated wave signal in which a frequency is changed with time, to supply ultrasonic waves to an inside of the inspection target, and to receive signals in which the plurality of ultrasonic sensors is excited by a plurality of echoes from the inside of the inspection target by the ultrasonic waves supplied to the inside of the inspection target; and a signal processor/recorder configured to sum the plurality of echo signals received by the transmitter/receiver, to calculate a time difference between a first peak of the summed signal and a first peak of the frequency modulated wave signal from cross correlation between signals summing the plurality of echo signals and the frequency modulated wave signal, and to detect a change in a thickness of the inspection target based on the calculated time difference.
8. The ultrasonic thickness reduction inspection apparatus according to claim 7, wherein the inspection target is a pipe, and the plurality of ultrasonic sensors is disposed side by side in a circumferential direction of the pipe.
9. The ultrasonic thickness reduction inspection apparatus according to claim 7, wherein the inspection target is a pipe, and the plurality of ultrasonic sensors is disposed side by side in an axial direction of the pipe.
10. The ultrasonic thickness reduction inspection apparatus according to claim 7, wherein the inspection target is a pipe, and the plurality of ultrasonic sensors is disposed side by side in a circumferential direction and an axial direction of the pipe.
11. The ultrasonic thickness reduction inspection apparatus according to claim 7, further comprising: a first coil connected to the plurality of ultrasonic sensors; and a second coil disposed opposite to the first coil and connected to the transmitter/receiver, wherein, by electromagnetic induction generated between the first coil and the second coil, signals are received which is generated when the plurality of ultrasonic sensors is excited by a frequency modulated wave signal, and the plurality of ultrasonic sensors is excited by the plurality of echoes from the inside of the inspection target.
12. The ultrasonic thickness reduction inspection apparatus according to claim 7, further comprising: a first coil connected to the plurality of ultrasonic sensors; a second coil disposed opposite to the first coil; a third coil electrically connected to the second coil via a metal protection material; and a fourth coil disposed opposite to the third coil and connected to the transmitter/receiver, wherein, by electromagnetic induction generated between the first coil and the second coil and electromagnetic induction between the third coil and the fourth coil, signals are received which are generated when the plurality of ultrasonic sensors is excited by a frequency modulated wave signal, and the plurality of ultrasonic sensors is excited by the plurality of echoes from the inside of the inspection target.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
DESCRIPTION OF THE PREFERRED EMBODIMENTS
(13) Hereinafter, embodiments of the present invention will be described in detail with reference to drawings.
EMBODIMENTS
First Embodiment
(14)
(15) Ultrasonic vibrators are incorporated in the ultrasonic sensors 101-1 to 101-12. Ultrasonic vibrators are formed by, for example, piezoelectric ceramic of such as lead zirconate titanate (PZT), a single crystal, a composite piezoelectric body combined with the material and polymer, or a polymer piezoelectric body represented by such as polyvinylidene fluoride (PVDF). The ultrasonic vibrator converts a voltage into an ultrasonic wave and sends it in a pipe, or converts an echo reflected in the pipe into an electric signal.
(16) To simplify a description, in
(17) The ultrasonic sensors 101-1 to 101-12 are connected in a circumferential direction by a wiring 108, and also a part of the wiring 108 is connected to a signal lead-out line 103 penetrating the insulating material 102. However, the signal lead-out line 103 does not necessarily penetrate the insulating material 102. For example, the signal lead-out line 103 may be led out to the outside from such as a space provided when the insulating material 102 is attached.
(18) A connection terminal 107 is attached at a tip of the signal lead-out line 103. The connection terminal 107 connects to a connection terminal 104 of a transmitting/receiving unit 105 during measuring and can transmit and receive an ultrasonic waveform signal from the transmitting/receiving unit 105. Regarding the other ultrasonic sensors disposed in an axial direction of the pipe 100, similarly, the connection terminal 104 of the transmitting/receiving unit 105 and a connection terminal of each of them are connected during measuring.
(19) The ultrasonic waveform signal received by the transmitting/receiving unit 105 is recorded in a memory (storage unit) after an appropriate signal processing is performed by a signal processing/recording unit 106. As described above, a plurality of ultrasonic sensors similar to the ultrasonic sensors 101-1 to 101-12 connected in a circumferential direction is disposed side by side in an axial direction of the pipe 100. An installation pitch of these ultrasonic sensors may be determined as requested. Typically, the installation pitch in the axial direction is approximately 5 to 10 cm.
(20) When a wall thickness of the pipe 100 is measured, a pulsar signal issued from the transmitting/receiving unit 105 simultaneously drives (excites) the plurality of ultrasonic sensors 101-1 to 101-12 connected by the wiring 108. The plurality of ultrasonic sensors 101-1 to 101-12 is excited by an echo from the inside of the pipe 100, and a signal summing ultrasonic waveform signals measured at the installation position is sent to the transmitting/receiving unit 105. Then, the summed sign is recorded after signal processing is performed to the signal. Such the signal processing will be described in detail with reference to
(21)
(22) A relative thickness of the pipe 100 at the positions where the ultrasonic sensors 101-1 to 101-12 are disposed is indicated at the right end in
(23) A waveform in which ultrasonic waveform signals 201-1 to 201-12 are summed, specifically summed ultrasonic waveform signal 202, is observed in the transmitting/receiving unit 105. A shape of the summed ultrasonic waveform signal 202 is variously changed depending on phase differences among ultrasonic waveform signals 201-1 to 201-12. Positive and negative peaks of the ultrasonic waveform signals 201-1 to 201-12 are mutually cancelled, and the strength of the summed ultrasonic waveform signal 202 is significantly reduced. As a result, the summed ultrasonic waveform signal 202 may be buried in noise and not be detected.
(24)
(25) Due to the phase differences, a peak strength of the summed ultrasonic waveform signal 202 becomes lower than a peak strength of the summed ultrasonic waveform signal 301. The thickest portion corresponds to a peak 302 or 304, and the thinnest portion corresponds to a peak 303 or 305.
(26) However, the peaks 303 and 305 are detected at almost the same time although positive and negative peaks are reversed. Therefore, it is difficult to accurately determine the occurrence of thickness reduction by comparing low strength sum signals.
(27) To solve this issue, in the present invention, a pulse wave using a pulse compression method is set to an input wave from the ultrasonic sensor 101-1 to the ultrasonic sensor 101-12. A pulse compression method is a technique to compress a pulse wave by a signal processing when a signal is received and to simultaneously obtain a high SN ratio and a high time resolution. A waveform is compressed by performing cross correlation processing between a transmitted pulse waveform and a received waveform after the signal is received. As a representative coded pulse wave, a chirp wave is used in which a frequency is changed (increased or decreased) with time. In embodiments described herein, the chirp wave is used. However, in the present invention, without being limited to a chirp wave, a signal of which an autocorrelation function is a delta function type can be also used. For example, various waveforms including a barker type, a complementary sequence, and an M sequence can be used.
(28) In a chirp wave pulse compression method, a frequency modulation signal in which a frequency is changed with time is used, and the method is widely used in such as the radar field. Specifically, while using a pulse waveform (chirp wave) in which a frequency is linearly changed with time is used as an input signal, a pulse width is compressed by signal processing when a signal is received, and a signal-to-noise ratio (SN ratio) and a high time resolution are simultaneously obtained. Compression of the pulse width can be realized by cross correlation processing of the input signal and the received signal.
(29)
(30) In
(31) A waveform in which cross correlation processing between the ultrasonic waveform signal 402 and the chirp wave 405 is performed is a compressed ultrasonic waveform signal 403. A peak appears at a time when cross correlation between the ultrasonic waveform signal 402 and the chirp wave 405 becomes highest. Therefore, echo peak positions of the ultrasonic waveform signals 401-1 to 401-12 are different. A plate thickness (wall thickness) is calculated by multiplying a peak position time of the compressed ultrasonic waveform signal 403 by a sonic speed (for example, a longitudinal wave sonic speed of a steel material forming a pipe 5,900 m/s).
(32)
(33) In
(34) Specifically, a peak of the ultrasonic waveform signals before summation is not mutually cancelled and not weakened. The compressed ultrasonic waveform signals 403 and 501 indicate a correlation degree with an input waveform, and a time expansion 505 thereof is reflected by a thickness distribution. For example, a right end peak 502 of the compressed ultrasonic waveform signal 403 is contributed by a signal component of the position where the thickness is 100%, and a left end peak 504 (first peak) is contributed by a signal component of the position where the thickness is 95%. A value obtained by multiplying a time difference 506 between the left end peaks 503 (the first peak) and 504 (the first peak) of the compressed ultrasonic waveform signal 501 in which thickness reduction is not detected by a sonic speed is equal to a thickness difference.
(35) A thickness reduction phenomenon is a phenomenon changing with time. Therefore, as illustrated in
(36)
(37) The signal processing/recording unit 106 includes a cross correlation processing unit 1061, a time difference comparison unit 1062, a thickness reduction zero waveform signal recording unit 1063, a calculation unit 1064, a thickness history recording unit 1065, a thickness comparison unit 1066, a determination unit 1067, and a display unit 1068.
(38) A signal summed by the summation unit 1054 of the transmitting/receiving unit 105 is supplied to the cross correlation processing unit 1061, and cross correlation processing is performed between the summed signal and a chirp waveform.
(39) Then, in the time difference comparison unit 1062, a generation time difference between the peak 503 of the signal 501 recorded in the thickness reduction zero waveform signal recording unit 1063 and the peak 504 of the summed signal 403 is calculated. Next, a time difference calculated by the time difference comparison unit 1062 is supplied to the thickness calculation unit 1064. The thickness of the pipe 100 is calculated. The calculated thickness value is recorded in the thickness history recording unit 1065 and supplied to the thickness comparison unit 1066. The thickness history recording unit 1065 records a history from a reference state (initial thickness) of the pipe 100. The thickness comparison unit 1066 calculates a difference between the thicknesses measured in the past and the present and a decrease ratio therebetween and supplies them to the determination unit 1067.
(40) The determination unit 1067 determines necessity of exchanging the pipe 100 based on the thickness difference calculated by the thickness comparison unit 1066 and causes the display unit 1068 to display a determination result and a thickness reduction state. The determination unit 1067 may cause the display unit 1068 to display only a thickness reduction state of the pipe 100.
(41) As described above, according to the first example of the present invention, a pipe thickness is calculated by supplying a chirp wave signal by a pulse compression method to an ultrasonic sensor, supplying ultrasonic waves to a pipe, and calculating a peak time difference by correlation between a summed waveform of an echo signal from the ultrasonic sensor and a signal in the case of no thickness reduction. Therefore, a pipe thickness reduction inspection method/apparatus capable of efficiently inspecting the occurrence and the distribution state of moderate pipe thickness reduction can be realized without inserting an inspection pig into a pipe.
(42) Specifically, moderate thickness reduction generated by such as FAC can be efficiently detected from a pipe external surface.
Second Embodiment
(43) Next, a second embodiment of the present invention will be described next.
(44)
(45) In
(46) A connection terminal 604 is attached at a tip of the signal lead-out line 603. The connection terminal 604 can transmit and receive an ultrasonic waveform signal from a transmitting/receiving unit 105 by connecting to a connection terminal 109 of the transmitting/receiving unit 105 during measuring. The ultrasonic waveform signal received by the transmitting/receiving unit 105 is recorded in a memory after appropriate signal processing is performed in a signal processing/recording unit 106.
(47) A plurality of ultrasonic sensors similar to the ultrasonic sensors 601-1 to 601-6 connected in an axial direction of the pipe 100 is disposed side by side in a circumferential direction of the pipe 100. An installation pitch in this case may be determined as requested. Typically, the installation pitch in an axial direction is approximately 5 to 10 cm.
(48) When a thickness is measured, a pulsar signal issued from the transmitting/receiving unit 105 simultaneously drives the plurality of ultrasonic sensors 601-1 to 601-6 connected by the wiring 602, and a signal summing ultrasonic waveform signals measured at each installation position is sent to the transmitting/receiving unit 105 and recorded after appropriate signal processing is performed. The transmitting/receiving unit 105 and the signal processing/recording unit 106 have a configuration as in the first embodiment. The signal processing is also configured as in the first embodiment. Therefore descriptions thereof will be omitted.
(49) Effects as in the first embodiment can be obtained in the second embodiment of the present invention.
(50) A connecting method of ultrasonic sensors is not limited to the method described in the first or second embodiments and can be arbitrarily determined. For example, ultrasonic sensors may be connected in a circumferential direction and an axial direction, and a part of or all of ultrasonic sensors may be connected. In addition, for example, there is a method in which a region which may cause thickness reduction is analyzed in a fluid analysis and measured fluid phenomenon, and a sensor in the region is connected.
Third Embodiment
(51) Next, a third embodiment of the present invention will be described next.
(52)
(53) The ultrasonic sensors 101-1 to 101-12 are connected in a circumferential direction, an axial direction, or an arbitrary direction of the pipe 100 by a wiring 108. Further, a part of the wiring 108 is connected to a coil 701 (first coil).
(54) On the other hand, another coil 702 (second coil) is connected to a transmitting/receiving unit 105, and the coils 701 and 702 are disposed opposite to each other by using an electromagnetic induction phenomenon from the outside of the non-metal insulating material 703, and a signal can be transmitted and received between the coils 701 and 702. During measuring, a transmitting/receiving apparatus 704 including the coil 702, the transmitting/receiving unit 105, and the signal processing/recording unit 106 is moved, and an ultrasonic wave signal can be transmitted and received without coming into contact with an insulating material.
(55) The transmitting/receiving apparatus 704 does not necessarily include all of the coil 702, the transmitting/receiving unit 105, and the signal processing/recording unit 106, and a part of them may be included. The other portions are similar to the first embodiment, and therefore a description will be omitted.
(56) In the third embodiment of the present invention, effects as in the first embodiment can be obtained, and also an ultrasonic sensor can transmit and receive a signal without coming into contact with an insulating material of the pipe 100.
Fourth Embodiment
(57) Next, a fourth embodiment of the present invention will be described next.
(58)
(59) The metal protection material 805 may be inserted into the non-metal insulating material 703. As with the configuration illustrated in
(60) A coil 804 (fourth coil) is connected to the transmitting/receiving unit 105. The transmitting/receiving unit 105 can transmit and receive a signal with the ultrasonic sensors 101-1 to 101-12 by using an electromagnetic induction phenomenon between coils 801 and 802 disposed opposite to each other and an electromagnetic induction phenomenon between coils 803 and 804 disposed opposite to each other. The other portions are similar to the third embodiment, and therefore a description will be omitted.
(61) In the fourth embodiment of the present invention, effects as in the third embodiment can be obtained, and also a noncontact inspection from the outside of an insulating material including metal disposed on an outer surface of a pipe.
(62) The embodiments described above indicate the case where the present invention is applied to a method and an apparatus for inspecting thickness reduction of a pipe. However, an inspection target of the present invention is not limited to a pipe. For example, the present invention can be applied to a method and apparatus for an ultrasonic thickness reduction inspection method/apparatus for a plate member having a large area.