立式储罐声发射在线检测技术的试验研究和应用
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摘要
随着经济的快速发展，在我国石油及其产品的储存显得特别重要，而作为储存用的立式储罐是必不可少的重要设备之一。立式储罐在使用过程中，受到多种不利因素的影响，不可避免地受到各种损伤。为保证立式储罐的安全，要对立式储罐开展检测，常规的无损检测方法需要在停机开罐情况下进行，检测费用高、耗时长、劳动强度大，还会造成一定程度的环境污染，并且很难做到全面检验，检验结果对缺陷的活性不加区分。声发射技术具有动态检测、在线检测、整体检测、对活性缺陷敏感、检测经济、快速等优点，可提高检测的有效性，降低检测费用，减轻检测劳动强度。广大储罐使用单位迫切需要用这种先进的检测方法来对他们的储罐进行检测，检验单位也非常希望用这种更有效的检验方法来开展检测工作，提高检验装备。为此，开展立式储罐声发射在线检测技术的试验研究，加快声发射技术在立式储罐检验中的应用、推广，确保立式储罐的安全运行，具有重要的理论和实际意义。
立式储罐最容易发生问题的部位在储罐底部，储罐底部的缺陷中能产生声发射有效声源的最主要的两种缺陷是泄漏和腐蚀，本文针对现场立式储罐声发射检测的实际情况，选择以罐底板的腐蚀和泄漏为研究对象，开展立式储罐泄漏和腐蚀的声发射在线检测技术研究。主要内容是通过对立式储罐泄漏和腐蚀现象的分析，分析了立式储罐声发射的有效活动声源，通过制作模拟试验装置，进行了模拟试验，试验结果证明了立式储罐声发射检测技术的可应用性、有效活动声源的变化规律及有效声源的定位方法。以此为指导，开展了实际立式储罐的声发射在线检测应用研究，检测的结果用常规无损检测的方法进行开罐复验，结果证明了立式储罐的声发射在线检测是有效的、可行的。
研究和应用的结果表明，立式储罐声发射在线检测技术具有重要的应用价值，应大力加强声发射检测技术的研究和推广应用工作。
As the economic development goes so fast, the storage of petroleum and its products turns to be more and more important, so vertical storage tanks become absolutely necessarily important equipment. When we use the vertical tanks, they inevitably suffer from various damages such as corrosion, erosion, distortion, leak, etc. In order to guarantee the safety of vertical tanks, we need to test them periodically. Conventional non-destructive testing (NDT) methods can be used to inspect storage tanks only when they shut down and the bottom plates are cleaned thoroughly. Even so they have some disadvantages. For example, higher expenses, much more labor force and resulting environmental pollution to some extent. By using conventional methods, it's hard to get a complete testing result, because they can't find out active defects. However, AET has many advantages such as its dynamic property, sensitivity to active defects, whole monitoring one time, fast and economic inspection etc. It can greatly improve the efficiency of testing, and cut down labor force to minimum. Almost owners or users expect their storage tanks to be inspected by this advanced testing method. Meanwhile, the inspection companies also hope to apply this effective testing method to their work so that they can advance the level of inspection. Therefore, in order to make this technique effective enough to be used widely, it is necessary to do some experimental and theoretical study on the on-line inspection of vertical storage tanks.The bottom plates of vertical storage tanks are easier to break than other parts of them. The corrosion and leakage resulting from the break of tank bottom are main acoustic emission sources. This paper hereby did some research on the corrosion and leakage of tank bottom with the AET technology. This paper analyzed the mechanism of producing effective acoustic sources by analyzing the corrosion and leakage of storage tanks, and also verified source location methods and the reliability of AET technology by experimental study on test tanks or plates and field inspection of real tanks.The results from the experimental research and field applications have proved the great practicality of the AET technology, so we should apply this new testing method widely with our great effort.
立式储罐最容易发生问题的部位在储罐底部，储罐底部的缺陷中能产生声发射有效声源的最主要的两种缺陷是泄漏和腐蚀，本文针对现场立式储罐声发射检测的实际情况，选择以罐底板的腐蚀和泄漏为研究对象，开展立式储罐泄漏和腐蚀的声发射在线检测技术研究。主要内容是通过对立式储罐泄漏和腐蚀现象的分析，分析了立式储罐声发射的有效活动声源，通过制作模拟试验装置，进行了模拟试验，试验结果证明了立式储罐声发射检测技术的可应用性、有效活动声源的变化规律及有效声源的定位方法。以此为指导，开展了实际立式储罐的声发射在线检测应用研究，检测的结果用常规无损检测的方法进行开罐复验，结果证明了立式储罐的声发射在线检测是有效的、可行的。
研究和应用的结果表明，立式储罐声发射在线检测技术具有重要的应用价值，应大力加强声发射检测技术的研究和推广应用工作。
As the economic development goes so fast, the storage of petroleum and its products turns to be more and more important, so vertical storage tanks become absolutely necessarily important equipment. When we use the vertical tanks, they inevitably suffer from various damages such as corrosion, erosion, distortion, leak, etc. In order to guarantee the safety of vertical tanks, we need to test them periodically. Conventional non-destructive testing (NDT) methods can be used to inspect storage tanks only when they shut down and the bottom plates are cleaned thoroughly. Even so they have some disadvantages. For example, higher expenses, much more labor force and resulting environmental pollution to some extent. By using conventional methods, it's hard to get a complete testing result, because they can't find out active defects. However, AET has many advantages such as its dynamic property, sensitivity to active defects, whole monitoring one time, fast and economic inspection etc. It can greatly improve the efficiency of testing, and cut down labor force to minimum. Almost owners or users expect their storage tanks to be inspected by this advanced testing method. Meanwhile, the inspection companies also hope to apply this effective testing method to their work so that they can advance the level of inspection. Therefore, in order to make this technique effective enough to be used widely, it is necessary to do some experimental and theoretical study on the on-line inspection of vertical storage tanks.The bottom plates of vertical storage tanks are easier to break than other parts of them. The corrosion and leakage resulting from the break of tank bottom are main acoustic emission sources. This paper hereby did some research on the corrosion and leakage of tank bottom with the AET technology. This paper analyzed the mechanism of producing effective acoustic sources by analyzing the corrosion and leakage of storage tanks, and also verified source location methods and the reliability of AET technology by experimental study on test tanks or plates and field inspection of real tanks.The results from the experimental research and field applications have proved the great practicality of the AET technology, so we should apply this new testing method widely with our great effort.
引文
[1] 潘家华，郭光臣，高锡祺．油罐及管道强度设计．石油工业出版社，1986
[2] Ronnie K. Miller and Paul Mclntire eds, Vol. 5, Acoustic Emission Testing, Nondestructive Testing Handbook, American Society for Nondestructive Testing, 1987.
[3] 沈功田 戴光 刘时凤，“中国声发射技术进展”，中国第十届声发射学术研讨会论文集，大庆，2004：1～8。
[4] T. F. Drouillard, "Acoustic Emission: A Bibliography with Abstracts", Frances Laner, ed. New York, NY: IFI Plenum Data Company(1979).
[5] T. F. Drouillard, "Acoustic Emission -The First Half Century" , Progress in Acoustic EmissionⅦ, The Japanese Society forNDI, Japan, 1994.
[6] 耿荣生，“声发射技术发展现状—学会成立20周年回顾”，无损检测，1998，20(6)：151～154．
[7] 机电部通用机械研究所．在役储罐声发射检测评定方法．储罐．油气储运，1990，7(3)：26～30
[8] 高护生．腐蚀与防护学．陕西科学技术出版社，1994
[9] 耿荣生，傅刚强．金属点蚀过程声发射源机制研究．声学学报，2002，27(4)，369～372
[10] 许凤旗，董卫军．在线评估储油罐底部腐蚀状况的经济有效技术．中国第九届声发射学术研讨会论文集．成都．2001：122～126
[11] 傅玉华，周汉平，周吐清，刘刚．石油化工设备腐蚀与防治．机械工业出版社，1997
[12] 李光海．声发射检验技术进展．南昌航空工业学院学报，2001，15(2)：39～43
[13] 张俊哲．无损检测技术及其应用．科学出版社，1993
[14] 戴光 徐彦廷等译．美国《无损评价》(2004版)．化学工业出版社，2006
[15] 李家伟主编．无损检测手册．机械工业出版社，2001．
[16] 袁振明，马羽宽，何泽云．声发射技术及其应用．北京：机械工业出版社．1985
[17] 戴光 李伟 张颖．储罐的声发射在线检测技术与研究进展．中国第十届声发射学术研讨会论文集，大庆，2004：16～20．
[18] 徐彦廷．声源定位问题研究及误差分析．无损检测，1999：199～202
[19] 姚力．关于中压气罐检验中声发射检测针对性的讨论．中国第七届声发射学术研讨会论文集，北京，1997：121～123
[20] 徐彦廷，地上立式金属储罐在线声学检测与评价方法研究．中国第七届声发射学术研讨会论文集，成都，2001：84～89．
[21] 徐彦廷译．SPARTANAT 36通道声发射检测分析仪使用说明书．内部资料，2004．
[22] Acoustic Emission Testing, Vlo. 5, Nondestructive Testing Handbook, American Society for Nondestructive Testing. Edited by Ronnie K. Miller and Paul Mclntire. (1987): pp78
[23] Richard Nordstorm. Direct Tank Bottom Leak Monitoring with Acoustic Emission. Physical Acoustics Ltd. Cambridge, UK. 1993 July 250～253, 1993
[24] Ronnie K. Miller. Tank-Bottom Leak Detection in Above-Ground Storage Tanks by Using Acoustic Emission. Physical Acoustics Ltd. Cambridge, UK. 1993 July 823～829, 1993
[25] P. T. Cole. Acoustic Methods for the Evaluation of Tank Integrity and Floor Condition. Physical Acoustics Ltd. Cambridge, UK. 1993 July 1～7, 1993
[26] P. T. Cole and C. A. Husain. On-Line Acoustic Evaluation of Tank Floors and Walls. Physical Acoustics Ltd. Norman Way, Over Cambridge CB4 5QE, UK. 1993 July 1～7, 1993
[27] P. J. van de Loo and D. K. ronemeijer. Acoustic Emission tank testing: How to discriminate between the onset of corrosion and further stages of degradation?. European Conference on Acoustic Emission Testing, TUA Austria, Wien May 6～8, 1998
[28] P. J. van de Loo and B. Hdrmann. How Reliable is Acoustic Emission (AE) Tank Testing?. 7th ECNDT Copenhagen 1998 May 26～29, 1998
[29] American Petroleum Institute. A Guide to Leak Detection for Above-ground Storage Tanks
[30] William F. Hartman. Automatic Emission Testing of Above Ground Storage Tanks Physical Acoustics Corporation Princegon, NJ 08543-3135, May 1992
[31] Drouillard T F, "Acoustic Emission-The Frist Half Century", Progress in Acoustic Emission V Ⅱ, Proceedings of the 12th International Acoustic Emission Symposium, Sapporo, Japan, October 17-20, pp27～38
[32] 戴光．徐彦廷．李伟．张颖．地上立式金属储罐在线声学检测与评价方法研究．中国第九届声发射学术研讨会论文集，成都，2001：91～95
[33] 戴光等．球罐活性缺陷的评定方法．石油学报，1998，19(2)：17～20
[34] 沈功田等．压力容器声发射人工神经网络模式识别方法的研究．无损检测．2001，23(4)：144～149
[35] 关卫和等．大型立式储罐在线声发射检测与安全性评估．压力容器．22(1)：40～44
[36] 徐英等．球罐和大型储罐．北京．化学工业出版社，2005
[37] 徐至钧．大型储罐基础设计与地基处理．北京：中国石化出版社，1999
[38] 潘家华．油气储运工程论文集．北京：石油工业出版社，1993：105～186
[39] 陈湘球．罐顶对罐壁应力的影响．油气储运，1994，13(4)：19～22
[40] 刘玲莉译．地上污水储罐及处理罐的阴极保护．国外油气储运，1993，13(5)：20～25
[41] 胡士信．钢质储罐罐底外壁阴极保护应注意的几个问题．油气储运，1994，13(2)：51～55
[42] 袁振明．数字式声发射仪的发展．无损探伤，1999，(2)：1～5
[43] 郭光臣，董文兰，张志廉．油库设计与管理．东营．石油大学出版社，1991
[44] 曹怀祥．声发射检测在400m3球罐检验中的应用．无损检测，2000，22(11)：512～514
[45] 张远君．液体力学大全．北京．北京航空航天出版社．1991：336～350
[46] kambe，T．Minota，T．(1983)，Proc．Roy．Soc．A383，pp277～308
[47] 国家质量技术监督局．金属压力容器声发射检测及结果评价方法．北京．中国标准出版社．2001：1～7
[2] Ronnie K. Miller and Paul Mclntire eds, Vol. 5, Acoustic Emission Testing, Nondestructive Testing Handbook, American Society for Nondestructive Testing, 1987.
[3] 沈功田 戴光 刘时凤，“中国声发射技术进展”，中国第十届声发射学术研讨会论文集，大庆，2004：1～8。
[4] T. F. Drouillard, "Acoustic Emission: A Bibliography with Abstracts", Frances Laner, ed. New York, NY: IFI Plenum Data Company(1979).
[5] T. F. Drouillard, "Acoustic Emission -The First Half Century" , Progress in Acoustic EmissionⅦ, The Japanese Society forNDI, Japan, 1994.
[6] 耿荣生，“声发射技术发展现状—学会成立20周年回顾”，无损检测，1998，20(6)：151～154．
[7] 机电部通用机械研究所．在役储罐声发射检测评定方法．储罐．油气储运，1990，7(3)：26～30
[8] 高护生．腐蚀与防护学．陕西科学技术出版社，1994
[9] 耿荣生，傅刚强．金属点蚀过程声发射源机制研究．声学学报，2002，27(4)，369～372
[10] 许凤旗，董卫军．在线评估储油罐底部腐蚀状况的经济有效技术．中国第九届声发射学术研讨会论文集．成都．2001：122～126
[11] 傅玉华，周汉平，周吐清，刘刚．石油化工设备腐蚀与防治．机械工业出版社，1997
[12] 李光海．声发射检验技术进展．南昌航空工业学院学报，2001，15(2)：39～43
[13] 张俊哲．无损检测技术及其应用．科学出版社，1993
[14] 戴光 徐彦廷等译．美国《无损评价》(2004版)．化学工业出版社，2006
[15] 李家伟主编．无损检测手册．机械工业出版社，2001．
[16] 袁振明，马羽宽，何泽云．声发射技术及其应用．北京：机械工业出版社．1985
[17] 戴光 李伟 张颖．储罐的声发射在线检测技术与研究进展．中国第十届声发射学术研讨会论文集，大庆，2004：16～20．
[18] 徐彦廷．声源定位问题研究及误差分析．无损检测，1999：199～202
[19] 姚力．关于中压气罐检验中声发射检测针对性的讨论．中国第七届声发射学术研讨会论文集，北京，1997：121～123
[20] 徐彦廷，地上立式金属储罐在线声学检测与评价方法研究．中国第七届声发射学术研讨会论文集，成都，2001：84～89．
[21] 徐彦廷译．SPARTANAT 36通道声发射检测分析仪使用说明书．内部资料，2004．
[22] Acoustic Emission Testing, Vlo. 5, Nondestructive Testing Handbook, American Society for Nondestructive Testing. Edited by Ronnie K. Miller and Paul Mclntire. (1987): pp78
[23] Richard Nordstorm. Direct Tank Bottom Leak Monitoring with Acoustic Emission. Physical Acoustics Ltd. Cambridge, UK. 1993 July 250～253, 1993
[24] Ronnie K. Miller. Tank-Bottom Leak Detection in Above-Ground Storage Tanks by Using Acoustic Emission. Physical Acoustics Ltd. Cambridge, UK. 1993 July 823～829, 1993
[25] P. T. Cole. Acoustic Methods for the Evaluation of Tank Integrity and Floor Condition. Physical Acoustics Ltd. Cambridge, UK. 1993 July 1～7, 1993
[26] P. T. Cole and C. A. Husain. On-Line Acoustic Evaluation of Tank Floors and Walls. Physical Acoustics Ltd. Norman Way, Over Cambridge CB4 5QE, UK. 1993 July 1～7, 1993
[27] P. J. van de Loo and D. K. ronemeijer. Acoustic Emission tank testing: How to discriminate between the onset of corrosion and further stages of degradation?. European Conference on Acoustic Emission Testing, TUA Austria, Wien May 6～8, 1998
[28] P. J. van de Loo and B. Hdrmann. How Reliable is Acoustic Emission (AE) Tank Testing?. 7th ECNDT Copenhagen 1998 May 26～29, 1998
[29] American Petroleum Institute. A Guide to Leak Detection for Above-ground Storage Tanks
[30] William F. Hartman. Automatic Emission Testing of Above Ground Storage Tanks Physical Acoustics Corporation Princegon, NJ 08543-3135, May 1992
[31] Drouillard T F, "Acoustic Emission-The Frist Half Century", Progress in Acoustic Emission V Ⅱ, Proceedings of the 12th International Acoustic Emission Symposium, Sapporo, Japan, October 17-20, pp27～38
[32] 戴光．徐彦廷．李伟．张颖．地上立式金属储罐在线声学检测与评价方法研究．中国第九届声发射学术研讨会论文集，成都，2001：91～95
[33] 戴光等．球罐活性缺陷的评定方法．石油学报，1998，19(2)：17～20
[34] 沈功田等．压力容器声发射人工神经网络模式识别方法的研究．无损检测．2001，23(4)：144～149
[35] 关卫和等．大型立式储罐在线声发射检测与安全性评估．压力容器．22(1)：40～44
[36] 徐英等．球罐和大型储罐．北京．化学工业出版社，2005
[37] 徐至钧．大型储罐基础设计与地基处理．北京：中国石化出版社，1999
[38] 潘家华．油气储运工程论文集．北京：石油工业出版社，1993：105～186
[39] 陈湘球．罐顶对罐壁应力的影响．油气储运，1994，13(4)：19～22
[40] 刘玲莉译．地上污水储罐及处理罐的阴极保护．国外油气储运，1993，13(5)：20～25
[41] 胡士信．钢质储罐罐底外壁阴极保护应注意的几个问题．油气储运，1994，13(2)：51～55
[42] 袁振明．数字式声发射仪的发展．无损探伤，1999，(2)：1～5
[43] 郭光臣，董文兰，张志廉．油库设计与管理．东营．石油大学出版社，1991
[44] 曹怀祥．声发射检测在400m3球罐检验中的应用．无损检测，2000，22(11)：512～514
[45] 张远君．液体力学大全．北京．北京航空航天出版社．1991：336～350
[46] kambe，T．Minota，T．(1983)，Proc．Roy．Soc．A383，pp277～308
[47] 国家质量技术监督局．金属压力容器声发射检测及结果评价方法．北京．中国标准出版社．2001：1～7