1. Introduction
The pipeline system is a cost-effective way of transporting oil and gas, widely used in the petrochemical industry. As an essential part of changing the flow direction of the pipeline system, elbows are prone to erosion damage under the erosion of the internal conveying medium [
1,
2,
3]. Therefore, it is necessary to accurately predict the remaining wall thickness.
Traditional nondestructive testing techniques have some limitations [
4,
5,
6,
7]. For example, magnetic particle testing can only detect ferromagnetic materials [
8] and requires a low environment temperature; eddy current testing [
9] can only detect conductive metal materials and non-metallic materials that can generate eddy currents; and radiographic testing [
10] has high detection costs and slow detection speeds. Compared with these techniques, ultrasonic-guided wave detection has the advantages of small energy attenuation, an extensive detection range, and a fast detection speed. Therefore, it is more suitable for detecting the erosion degree of the elbow [
11,
12,
13,
14].
The pulse signal is generally used to excite axisymmetric guided waves to detect structural damage, and the position and depth of defects are judged by the amplitude and receiving time of echo signals. This method has a good detection effect on symmetrical parts [
15,
16]. However, when detecting the elbow, the following problems exist: the axisymmetric guided wave will produce non-axisymmetric reflection in the bending part of the elbow and mode conversion will occur, which increases the difficulty of identifying the corresponding mode from the echo signal; in some frequency ranges, it is difficult to ensure that a single axisymmetric mode is excited; axisymmetric guided waves are less effective in detecting axial and circumferential defects; when the test piece can only be contacted in a limited space, it is difficult to install sensor arrays required to excite axisymmetric guided waves [
17,
18]. Some scholars have tried to use non-axisymmetric guided waves to detect circular tube structures [
19], cracks in rivet holes [
20], and straight pipes [
21,
22] and have achieved good results. Therefore, we consider using non-axisymmetric guided waves to detect the erosion degree of elbow erosion.
The LFM signal has a large time-bandwidth product, a long detection distance, and a high-range resolution, widely used in radar, electronic communication, and fault diagnosis [
23,
24,
25,
26,
27]. Its characteristics are suitable for detecting the erosion degree of the elbow. However, the strong coupling of the LFM signal in the time–frequency domain makes it difficult to separate the signal from the noise. Fractional Fourier transform (FrFT) has chirp basis decomposition characteristics, suitable for LFM signal filtering [
28,
29,
30,
31]. Some scholars have successfully detected cracks in reinforced concrete using the method of horizontal fusion of CODA waves and multi-ultrasonic sensor signals [
32,
33]. Inspired by this, we consider arranging multiple sensors on the elbow to receive signals and use machine learning algorithms to establish the internal relationship between the signals and the erosion degree.
Least squares support vector machine algorithm (LSSVM) has a fast solution speed and good robustness [
34], and its characteristics are suitable for predicting the erosion degree of the elbow. The regularization parameter and kernel parameter affect the performance of LSSVM, and the determination of the values of these two parameters by empirical or grid methods suffers from subjectivity and arbitrariness, making the results inaccurate. Particle swarm optimization (PSO) is an evolutionary algorithm with fast convergence speed, a simple solution process, and global search capability, which can effectively optimize the above two parameters [
35,
36].
Based on the above discussion, to solve the problem that it is difficult to predict the erosion degree of the elbow qualitatively with the existing ultrasonic detection technology, this paper combined the non-axisymmetric guided wave detection with the FrFT filtering of the LFM signal, using the PSO–LSSVM algorithm to obtain the intrinsic relationship between the time domain energy of the signals and the erosion degree, and finally realize the accurate prediction of the erosion degree of the elbow.
The LFM signal excites the PZT sensor pasted on the outer arch of one end of the elbow to generate a non-axisymmetric guided wave and collect signals through four PZT sensors arranged at the other end. The time domain energy value of the signal filtered by FrFT and the corresponding remaining wall thickness of the erosion area are used as samples to train the PSO–LSSVM model. Finally, the same test sample is used to test the model’s accuracy in predicting the erosion degree and compare it to the nonlinear regression analysis method, BP neural network, and LSSVM. The results show that the method proposed in this paper is more accurate than other methods, and it has a guiding significance for real-time monitoring of the elbow erosion.
3. Experimental Setup
3.1. Experimental Device
The ultrasonic testing system for elbow erosion is shown in
Figure 4. It mainly comprises a function signal generator, a high-precision digital oscilloscope, a handheld grinder, and an ultrasonic thickness gauge. The detection object is a 90° metal elbow with a nominal diameter of DN = 50.8 mm and an average wall thickness of 4 mm.
3.2. Experimental Program
The most severe erosion area is located near the outlet end of the elbow and the overall defect morphology is symmetrical about the center plane of the elbow, showing a parabolic shape [
47,
48]. Therefore, we used a handheld grinder to make oval-shaped pits to simulate the actual erosion area during the experiment. The depth of grinding is roughly the same each time, and the average value of multiple measurements of the central area of the bottom of the erosion pit is measured with an ultrasonic thickness gauge [
42].
In practical applications, other parts are usually installed at both ends of the elbow. The collected signal energy will be small if only one end is installed with a sensor to excite and receive signals. Therefore, we chose to paste a PZT on the outer arch of one end as a signal exciter, start from the outer arch at the other end, and paste a PZT every 90° along the circumferential direction of the pipe as a signal receiver. The PZT receiver at the outer arch point is defined as PZT-A; the inner bending point is PZT-D; and the left and right ends of the connection between PZT-A and PZT-D are PZT-B and PZT-C, respectively. The artificially simulated erosion area and the PZT pasting position are shown in
Figure 5. The PZT specifications and materials used in the test are the same, and the properties of the PZT material are shown in
Table 1 [
42].
By conducting a large-scale frequency sweep test on the sample, it is determined that the excitation frequency of the LFM signal is 60–200 kHz, the signal amplitude is 10 V, the sweep time is 0.1 s, and the sampling frequency is 2 MHz. The form of the excitation signal is shown in
Figure 6. During the grinding test, the sample’s artificially simulated erosion thinning process is shown in
Table 2 (C0 is the unpolished state).
3.3. Time Domain and Energy Analysis of Signals
Taking the signal received by PZT-A as an example,
Figure 7a is the offset diagram of the received signal under different erosion degrees, and
Figure 7b is the time domain signal synthesis diagram of erosion degrees C0, C2, C4, and C6. It can be found that there is no significant difference in the time domain signal waveform and amplitude under different erosion degrees. It is difficult to directly obtain the relationship between the erosion degree and the received signals in the time domain, and further analysis is required.
Taking the signal collected by PZT-A when the erosion degree is C0, the STFT is performed on the signals before and after FrFT filtering, and the time–frequency diagram is obtained, as shown in
Figure 8. The noise signals in the original signal are effectively filtered out, and the LFM signal is well preserved. This shows that FrFT can effectively filter out the noise in the acquisition signal, thereby reducing the error caused by the noise.
Calculate the time domain energy value of the signals after FrFT filtering and represent them with
EiA,
EiB,
EiC, and
EiD (
i = 0~6 represents seven erosion degrees. A, B, C, and D represent the four receiving positions). Take the average value of the time domain energy at the same erosion degree and position, and construct a graph as shown in
Figure 9.
As the erosion degree increases, the reflected guided wave at the erosion area gradually increases and the time domain energy of the signal at point A of the outer arch generally shows a downward trend, but there are also cases of abnormal energy (such as when the erosion degree is C1). The erosion area is on the shortest path between the guided wave exciting point and the outer arch PZT-A. In erosion degree C0, the metal oxide layer on the inner surface of the erosion area reduces the time domain energy of the signal received by PZT-A. In erosion degree C1, the metal oxide layer in this area is removed. Therefore, the time domain energy of the signal collected by the outer arch back PZT-A is higher than that of erosion degree C0.
After the non-axisymmetric guided wave is excited, the guided wave will form a wavefront in the elbow and propagate to the surroundings. The sources of the guided wave signals received by PZT-B and PZT-C are complex, and the erosion area is not on the minimum path between the two PZT sensors and the excitation point. Therefore, there is no apparent correspondence between the energy values of PZT-B and PZT-C acquisition signals and the surface morphology and depth of the erosion area. With increasing erosion, the guided wave is refracted and reflected in the erosion area, and its propagation path changes. For the elbow measured in this test, the specific performance is that the time domain energy of the signal received by PZT-D of the inner bend gradually increases.
The above results show that, for the elbow in this test, there is a correspondence between the time domain energy of the signals received by PZT-A on the back of the outer arch and PZT-D on the inner bend and the erosion degree. However, it is difficult to accurately predict the erosion degrees of the elbow from the energy point of view alone.
5. Comparison and Analysis
5.1. Other Methods
In order to further verify the effectiveness and accuracy of the method proposed in this paper in predicting the erosion degree of the elbow, we use the same experimental data as input and predict the remaining thickness using the nonlinear regression analysis method, LSSVM algorithm, and BP neural network.
When using the nonlinear regression analysis method, the independent variables are the time domain energy values of the signals after FrFT filtering received by the four PZT receivers, and the regression model formula is defined as follows:
where
C,
a1,
a2,
a3, and
a4 are the regression coefficients and
t is the predicted remaining thickness value. Substitute the training set data into Equation (12) to establish the nonlinear relationship between 109 groups of the independent variable and the remaining thickness. This set of multiple regression equations is solved to obtain the values of each regression coefficient and establish the nonlinear regression empirical equation for the prediction of the remaining thickness of the elbow:
In the LSSVM algorithm, the kernel function is the radial basis function shown in Equation (10). The value ranges of the regularization parameter and the kernel function parameter are set to be [0, 300] and [0, 200], respectively. The grid method is used to fold the value range of the two parameters ten times to obtain their optimal value and input it into the LSSVM. The LSSVM model is trained using the training set data.
When building the model based on the BP neural network, the input is the feature matrix of the training set samples and the output is the predicted value of the remaining thickness. The model uses a three-layer neural network, and its related parameter settings are shown in
Table 5.
5.2. Results and Discussion
Input the sample data into the above models to obtain the prediction accuracy of each model and compare it to PSO–LSSVM, as shown in
Figure 12. The results show that the prediction accuracy of the training set samples by the four methods is higher than that of the test set samples under the same circumstances, indicating that the above models all have good regression fitting performance. PSO–LSSVM has the highest prediction accuracy for training and test samples, at 99.4178% and 98.1864%, respectively.
In order to verify the applicability of the method proposed in this paper, we used the same experimental method to test the two other elbows (the nominal diameters of elbow 2 and elbow 3 are 50.8 mm and 108 mm, respectively, and the average thicknesses are 4 mm and 8 mm, respectively) and analyzed the extracted data.
Figure 13 shows the accuracy of the above four prediction models for the remaining thickness of the two elbows. Both the nonlinear regression model and the LSSVM model have lower accuracy in predicting the remaining thickness of the elbows. The prediction accuracy of the BP neural network model on the test set data of Elbow 2 and Elbow 3 is 86.8205% and 97.1253%, respectively, which shows that its predictive ability is not stable enough. The PSO–LSSVM model has the highest and most stable prediction accuracy for the remaining thickness of these two elbows, reaching 94.7167% and 99.119%, respectively.
In order to test the accuracy of the prediction of the new erosion degree, we conducted a test on a DN219 elbow. We extracted 20 sets of data under eight erosion degrees for analysis. The remaining wall thickness values are shown in
Table 6. The sample set under each erosion degree is randomly divided into the training set and test set according to the ratio of 4:1. Three different training sets and test set sample features are used to verify the method proposed in this paper, as shown in
Table 7.
The accuracy rates of each model are shown in
Figure 14. It can be seen that, under these three verification methods, the accuracy rates of PSO-LSSVM are 99.9593%, 94.0039%, and 81.2976%, respectively, which are still higher than those of the other methods.
Measurement errors during experimentation, ambient noise, and sample parameters used to train the model can affect predictions. The measurement error mainly comes from the influence of the PZT sensor pasting process. Therefore, during the test, it should be ensured that the glue layer between the PZT sensor and the elbow is as thin as possible under the premise of insulation, and it should be ensured that the sensor has been firmly pasted on the elbow before the test. FrFT can filter the error caused by environmental noise in the method proposed, so it does not need to be considered. Increasing the erosion state and the number of samples contained in the model training samples can improve the model’s accuracy.