Research on heat exchanger tube sheet to shell fillet weld testing and engineering application using total focusing phased array technique

Abstract According to structure of the heat exchanger tube sheet to shell fillet weld, the total focusing phased array technique was adopted to settle down this testing difficulty. Firstly, the inspection background and detection difficulties of the fillet weld was introduced in this paper. Secondly, the sound field simulation and typical flaw response simulation was carried out using CIVA software, and the special blocks were manufactured on the base of the simulation result. Thirdly, the total focusing phased array testing study was carried out in laboratory, and the drilled holes, grooves, as well as the typical flaws of incomplete fusion, incomplete penetration and crack in blocks were successfully detected. Finally, the total focusing technique engineering application of one heat exchanger in chemical device was put into effect, the incomplete fusion and incomplete penetration flaws were successfully detected. The total focusing phased array technique was successfully applied to the heat exchanger inspection project, the research result of this paper have high practical value for ensuring the safe and reliable operation of heat exchanger, and can be popularized and applied in the engineering project.