A Magnetic Flux Leakage Detector for Ferromagnetic Pipeline Welds with a Magnetization Direction Perpendicular to the Direction of Travel
Abstract
:1. Introduction
2. Magnetization Structure Design
2.1. Detection Probe Magnetic Circuit Design
2.2. Numerical Simulation of the Magnetized Structure
3. Development of Continuous Non-Contact Magnetic Flux Leakage Scanning Technology for Pipeline Welds
3.1. Design of a Continuous Non-Contact Magnetic Flux Leakage Scanner for Pipeline Welds
3.2. Working Principle of the Continuous Non-Contact Magnetic Flux Leakage Scanner for Pipeline Welds
4. Experimental Study on the Magnetic Flux Leakage Detection of Pipeline Welds
5. Quantitative Analysis of Pipeline Weld Defects
6. Discussion
- (1)
- The traditional pipeline magnetic flux leakage detection device uses a detection system mode in which the magnetization direction is parallel to the direction of travel. However, due to the structural characteristics of the weld, the traditional detection system mode is not applicable. Since the weld magnetic flux leakage detection device needs to travel along the direction of the weld, the detector designed in this paper rotates the magnetizer 90 degrees along the direction of the weld seam so that the magnetization direction is perpendicular to the direction of travel, breaking through the technical barrier of traditional magnetic flux leakage detection devices not being suitable for weld detection.
- (2)
- Currently, the device can detect pipeline weld defects such as cracks and corrosion, and the detection sensitivity can reach a 20% wall reduction. But it cannot detect rough surfaces, geometrical distortions, uneven weld beads, etc., in pipeline welds. For pipeline bend welds, since the detection device has a certain size, the detection device cannot pass through smaller bends, so it can only detect pipeline bend welds within a certain size range. In the future, consideration will be given to improving the detection device to break through the current limitations.
- (3)
- The quantitative research method of pipeline weld defects proposed in this paper, which is based on the integration of mathematical morphology and the chain code algorithm, studies the quantification of crack defects from the geometric dimension changes in a single depth direction of the crack defects (dimensions in other directions remain unchanged), which has certain limitations. Future work will investigate methods to quantify the three-dimensional dimensions of defects.
7. Conclusions
- (1)
- The magnetization direction of the detector designed in this paper is perpendicular to the direction of travel. Correspondingly, the sensor arrangement has also been changed. The sensors are arranged inside the sensor box parallel to the bottom surface of the pole shoes. The sensor array direction is parallel to the magnetization direction and perpendicular to the traveling direction. Through the above technological innovation, pipeline weld inspection based on the magnetic flux leakage method has been realized, broadening the scope of existing inspection objects.
- (2)
- In order to match the contour of the weld, a sensor box that matches the reinforcement of the weld was designed. On one hand, it reduces the influence of fluctuations in the distance between the sensor and the pipe weld; that is, the lift-off value. On the other hand, it ensures that the lift-off value between the sensor and the pipe and the weld is equal, thereby improving the sensitivity of the detection signal.
- (3)
- A quantitative research method for pipeline weld defects based on the integration of mathematical morphology and chain code algorithms was proposed, and a pipeline weld defect inversion software system was developed. Through the developed software, the mathematical morphological processing of magnetic flux leakage images of pipeline weld defects was realized, the chain code information of the defect boundary was extracted, and parameters such as defect length and defect area were measured. The minimum accuracy of measuring length by this method was 80%, and a preliminary quantitative study of pipeline weld defects was realized. This research content provides new ideas for quantitative research on pipeline weld defects.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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X80 Pipeline Parameter | ||
---|---|---|
Pipeline diameter/mm | 1219 | |
Pipeline wall thickness/mm | 18.4 | |
Weld width/mm | 22 | |
Weld reinforcement/mm | 2 | |
Defect parameter | ||
Length 40 mm, Width 1 mm | ||
No. | Depth | Value/mm |
1 | Weld reinforcement + 20% of pipeline wall thickness | 5.68 |
2 | Weld reinforcement + 40% of pipeline wall thickness | 9.36 |
3 | Weld reinforcement + 60% of pipeline wall thickness | 13.04 |
4 | Weld reinforcement + 80% of pipeline wall thickness | 16.72 |
5 | 20% of pipeline wall thickness | 3.68 |
6 | 40% of pipeline wall thickness | 7.36 |
7 | 60% of pipeline wall thickness | 11.04 |
8 | 80% of pipeline wall thickness | 14.72 |
No. | Length/mm | No. | Length/mm | ||
---|---|---|---|---|---|
1 | Real defect length/mm | 40 | 5 | Real defect length/mm | 40 |
Defect length displayed by chain code/mm | 2 × 16 | Defect length displayed by chain code/mm | 2 × 18 | ||
Relative error /% | 20 | Relative error /% | 10 | ||
2 | Real defect length/mm | 40 | 6 | Real defect length/mm | 40 |
Defect length displayed by chain code/mm | 2 × 19 | Defect length displayed by chain code/mm | 2 × 18 | ||
Relative error /% | 5 | Relative error /% | 10 | ||
3 | Real defect length/mm | 40 | 7 | Real defect length/mm | 40 |
Defect length displayed by chain code/mm | 2 × 21 | Defect length displayed by chain code/mm | 2 × 18.5 | ||
Relative error /% | 5 | Relative error /% | 7.5 | ||
4 | Real defect length/mm | 40 | 8 | Real defect length/mm | 40 |
Defect length displayed by chain code/mm | 2 × 22 | Defect length displayed by chain code/mm | 2 × 21 | ||
Relative error /% | 10 | Relative error /% | 5 |
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Cui, W.; Xiao, Z.; Feng, Z.; Yang, J.; Zhang, Q. A Magnetic Flux Leakage Detector for Ferromagnetic Pipeline Welds with a Magnetization Direction Perpendicular to the Direction of Travel. Sensors 2024, 24, 5158. https://doi.org/10.3390/s24165158
Cui W, Xiao Z, Feng Z, Yang J, Zhang Q. A Magnetic Flux Leakage Detector for Ferromagnetic Pipeline Welds with a Magnetization Direction Perpendicular to the Direction of Travel. Sensors. 2024; 24(16):5158. https://doi.org/10.3390/s24165158
Chicago/Turabian StyleCui, Wei, Zhongmin Xiao, Ziming Feng, Jie Yang, and Qiang Zhang. 2024. "A Magnetic Flux Leakage Detector for Ferromagnetic Pipeline Welds with a Magnetization Direction Perpendicular to the Direction of Travel" Sensors 24, no. 16: 5158. https://doi.org/10.3390/s24165158