The collection of articles includes the main works of the ECHOPLUS Company team dedicated to the creation of automated ultrasonic control systems for hazardous industrial facilities. It is noted that the use of coherent data processing methods in automated ultrasonic systems made it possible to make the transition from flaw detection to flaw detection with access to an assessment of the residual resource. The new technology has found wide application in leading sectors of the national economy, primarily in nuclear energy, Gazprom, Transneft, and Russian Railways. The results of the development of Augur series systems and their application in these areas are presented. It is shown that the use of automated systems gives a significant technical and economic effect.
The collection of articles includes the main works of the ECHOPLUS Company team dedicated to the creation of automated ultrasonic control systems for hazardous industrial facilities. It is noted that the use of coherent data processing methods in automated ultrasound systems made it possible to make the transition from flaw detection to flaw detection with access to the evaluation of the residual resource. The new technology has found wide application in the leading sectors of the national economy, primarily in the nuclear power industry, Gazprom, Transneft, Russian Railways. The results of the development of Augur series systems and their application in these areas are presented. It is shown that the use of automated systems gives a significant technical and economic effect.
The collection includes the most interesting works performed by the team of the ECHOPLUS Company in recent years. Simultaneously with the development and use of automated ultrasound systems with coherent data processing, the works devoted to the research, development and application of devices with phased antenna arrays are presented. New electronics, scanning systems, and image quality improvement algorithms are described. The basic principles of the construction of control methods using such systems are considered. The question of the ratio of radiography and ultrasound in non-destructive testing is investigated. It is shown that coherent automated ultrasonic inspection in some cases gives results no worse, and in combination better, than radiography. Examples of the use of data visualization tools and automation of ultrasound control are given. A new manual ultrasonic flaw detector "AUGUR-ART2020" is presented, which implements all modern and popular developments.
The experience of using the computer simulation program for the tasks of the CIVA ultrasound for the development of ultrasound control techniques is given.
The technology of automating the estimation of the parameters of the discontinuity identified using the AUZK system with coherent processing is described. To determine the parameters of the identified discontinuities, the main, stable signs characterizing the discontinuity are used; fuzzy logic is used to determine the type of discontinuity. The results of testing of this technology on the data of AUZK obtained by the Augur system during the control of austenitic welds are presented. It is shown that it is possible to determine the type of discontinuity (extended, non-stretched, volumetric, planar), its coordinates, real length and height. The results of automated determination of the discontinuity profile and destructive control were compared. The use of the considered technology allows to reduce the influence of the subjective factor on the control results and significantly reduce the time of data analysis.
The possibility of using linear interpolation of a two-dimensional spatial spectrum in the reconstruction of defect images by projection in spectral space (PSP) according to ultrasonic non-destructive testing is considered. Various interpolation algorithms are analyzed. The results of numerical and model experiments in which images were obtained using interpolation and in the absence of interpolation are presented. The effectiveness of the proposed algorithm for improving the quality of images obtained by the PSP method 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.
The issues of theory and practice of ultrasonic flaw detection based on the application of digital acoustic holography algorithms in relation to the operation of high-risk facilities are considered. The features of various algorithms for obtaining a coherent image are given, including: projections in spectral space, angular spectra, reference holograms, etc. The developed Augur series equipment and its modifications in relation to various control objects are described in sufficient detail. It is shown that the information about the type and size of defects obtained during holographic control is sufficient to assess the residual resource of the object. Based on the results of numerous metallographic studies, the error in measuring the size of defects, which is 1.5 mm, has been estimated. More than 10 years of experience in the application of Augur series systems, primarily at nuclear power facilities, is given; signs of defect types and algorithms for automatic determination of their parameters are formulated. The methodological foundations of holographic control of a wide range of welded joints have been developed, which made it possible to create and certify 13 specialized techniques. Of interest are systems for the diagnosis of railway carriage wheelsets using digital acoustic holography, in which a specially developed program for determining the residual life is used. Promising methods for improving the resolution and quality of defect images are described.
It is intended for developers and specialists in the field of diagnostics and operation of high-risk facilities, for training centers for specialists in the field of non-destructive testing.
The issues of theory and practice of ultrasonic flaw detection based on the application of digital acoustic holography algorithms in relation to the operation of high-risk facilities are considered. The features of various algorithms for obtaining a coherent image are given, including: projections in spectral space, angular spectra, reference holograms, etc. The developed Augur series equipment and its modifications in relation to various control objects are described in sufficient detail. It is shown that the information about the type and size of defects obtained during holographic control is sufficient to assess the residual resource of the object. Based on the results of numerous metallographic studies, the error of measuring the size of defects, which is 1.5 mm, is estimated. More than 10 years of experience in the use of Augur series systems, primarily at nuclear power facilities, is given; signs of types of defects and algorithms for automatic determination of their parameters are formulated. Methodological foundations of holographic control of a wide range of welded joints have been developed, which allowed the creation and certification of 13 specialized techniques. Of interest are systems for the diagnosis of wheel sets of railway cars using digital acoustic holography, in which a specially developed program for determining the residual resource is used. Promising methods of increasing the resolution and quality of defect images are described. It is intended for developers and specialists in the field of diagnostics and operation of high-risk facilities, for training centers for specialists in the field of non-destructive testing.