the upcoming revolution in guided wave for pipe...

HCTL Open International Journal of Technology Innovations and Research (IJTIR) http://ijtir.hctl.org Volume 12, December 2014 e-ISSN: 2321-1814, ISBN (Print): 978-1-62951-791-9

Vimal Upadhyay and Prof. G. N. Pandey The upcoming revolution in guided wave for pipe inspections of 9

The Upcoming Revolution in Guided Wave for Pipe Inspection Vimal Upadhyay1 and Prof. G. N. Pandey2 [email protected] Abstract This paper will focus on fundamental principles associated with the imminent revolution in ultrasonic guided waves. This paper also outlined some selected major developments in guided waves during past decade. Only some applications in pipe, rail, butt joints, bonding and composites, imaging and tomography, material deterioration, ultrasonic vibration, de-icing, material integrity, structural health monitoring, and non-linear methods gave a birth to an idea of where we are heading. Keywords NDT 1, SHM 2, GW 3, Guided Wave Focusing 4, Near Zone 5, CUT 6, GUB 7.

Introduction Ultrasonic Guided Wave integrated with Non Destructive Evolution and Service Health Monitoring is growing rapidly for their use in industrial engineering. It is only way to inspect a large area of pipeline with limited accessibility of a tested piece from a sensor located at fixed position on a pipeline. With the beginning of guided wave in-service inspection taking off around fifteen years ago, there was a high expectation of reliable data because lack of theoretical mapping and computational power required in modelling analysis. There are many challenges came in light when we transfer technology from laboratory to field i.e. coating, buried structure, internal and external corrosion etc. most of these type problems overcome due to amazing innovation in guided wave technology in sensitivity and penetration power. Industrialists and researchers paradigm shift to guided waves from bulky waves due to less inspection time, large coverage, easy to solve new upcoming problems without prior solution potential. There is also paradigm move to service health monitoring from non destructive evaluation due to improve reliability and early warming of structural failure. Now a day’s low frequency guided waves are generally used in the survey of pipelines, for fault detection in the form of corrosion, erosion and metal loss. The principal advantage of using guided wave is that long range coverage in each direction i.e. 30 meter or more.

1Research Scholar, IIIT-Allahabad, Uttar Pradesh, India. 2Professor, IIIT-Allahabad, Uttar Pradesh, India.



Non Destructive Testing Service Health Monitoring

1. Off line evaluation 1. On line evaluation

2. Time based maintenance 2. Condition based maintenance

3. Find existing damage 3. Determine fitness & remaining life

4. Baseline generally not available 4. start with baseline

Table 1: Comparison between NDT and SHM

Brief Literature Review Guided Wave Technique Used in Pipeline/Pipe Inspection First time ultrasonic guided waves were used to tubing inspection by Rose et al 1993 [1], they follow the research results of Ditri and Rose (1992) [2] ,analytical simulation method of angular profiles developed by Li and Rose for hollow cylinders [3]. In 2002 phased array focusing technique for LGW propagation in cylindrical shells presented by Li and Rose [4]. Commercial applications of guided wave based on focusing techniques for in-service pipeline inspection were introduced by Rose and Mudge [5]. Sun et al. 2003 carried out the angular profile calculations and the phased array focusing technique for torsional guided wave propagation in hollow cylinders [6][25]. If the angular profiles show that ultrasonic energy is naturally concentrated at a circumferential location at a particular propagation distance, this phenomenon, which is called “natural focusing”, can be used to improve pipeline inspection [25][7, 8]. Thompson, et al. in 1972 studied circumferential waves for steel plates and pipeline inspection [9]. Van Velsor et al. 2009 developed enhanced coating disbond detection methods with guided wave physically based features [10]. Defect imaging and synthetic focusing methods were introduced by Hayashi et al. 2005 [11], Mu and Rose 2008 by focusing [12], and with coatings [13], Davies and Cawley 2009 [14], Mu et al. 2010 [15], and Velichko and Wilcox 2009 with post-processing [16]. Pavlakovic et al. in 1997 introduced a commercial software package for dispersion curve calculation: DISPERSE [17]. Demma et al. in 2001 studied mode conversion of longitudinal and torsional guided modes due to pipe bends [18]. Ma et al. in 2007 studied sludge and blockage detection inside pipes [19]. SAFEM efficient computational techniques were introduced for guided wave problems by Hayashi et al. 2002 [20]. Magnetostrictive methods were pioneered by Kwun et al. in 1998 covering guided wave inspection of pipe using magnetostrictive sensors [21]. Kim et al. in 2005 used magnetostrictive transducers with ferromagnetic strips 45˚ from the axis of a pipe [22].

Advantages of guided waves 1) Avoid removable of insulation, except probe mounting area.

2) No need to access all part of pipeline.

3) Whole pipeline tested (100% examination).

Another method is LRUT mostly used in corrosion and erosion determination are highly localized footprint area of search device. (In case of some devices it is not necessary to



remove insulation. However, this not helps in case of buried or sleeved pipelines. Furthermore, whole piece of test piece scanned). In case where access is costly or not easily possible, this type of surveys becomes unattractive due to costing. Partial inspection of this type situations cause leaks, failure. The benefit of LRUT is to examine whole part of test piece or pipe wall.

Characteristics of guided waves: 1) Range - 30meter in all direction from a single site point (up to 180 m has been

achieved).

2) Productivity – minimum 300 to 500 meter per day.

3) Able to distinguish pipe features, butt joints, welds and flaws.

4) Accuracy of longitudinal positioning ±100mm.

5) Detects internal and external material deterioration.

6) Diameter coverage range from 2 to 48-inch.

7) Working temperature range from -40 to +125°C.

Ultrasonic Bulk Waves Ultrasonic Guided Waves 1. Time Consuming 1. Fast 2. Point wise Scanning 2. Line Scanning 3. Unreliable 3. Reliable due to Volumetric Coverage 4. Training Required before using 4. No need for training

Table 2: Comparison between UBW and UGB

Conventional Ultrasonic Testing

Guided Wave Testing

1. High Frequency 1. Low Frequency 2. Short Wavelength 2. Long Wavelength 3. Sensitive to wall 3. Sensitive to Symmetry/Cross-Sectional

Area 4. Point to point measurement 4. Rapid Screening

Table 3: Comparison between CUT and GWT



Figure 1: Inspection with Working Steps

Technical Terms of GWT that Affect the Readings

1) Severity (past versus current activities comparison).

2) Bell Hole Inspection (access anomalies i.e. pipe surface condition and coating

condition).

3) Dead Zone (Probe cannot transmit or receive at same time; it is 1 feet in length).

Figure 2: dead zone shown in green [Source:

http://puc.sd.gov/commission/PSOT/Presentation/directassesstment.pdf ]

4) Near Field (region where the guided waves are forming, length 2-5 ft, features

detectable but sizing accuracy reduced).



Figure 3: Near Field shown in green [Source: http://puc.sd.gov/commission/PSOT/Presentation/directassesstment.pdf ]

5) Distance Amplitude Curve (percentage of cross sectional area).

6) Weld DACs are 23% ECL.

7) S/N ratio 2:1 needed for better confidence level.

8) Noise DAC=1/2(call DAC).

9) Inspection Range is a function of required sensitivity.

10) Sensitivity (detectable cross sectional area percentage).

11) Signal decay and amplitude decay (caused by branch connection, butt joints, and

corrosion, material itself etc.).

Figure 4: corrosion can also attenuate the sound significantly [Source: http://puc.sd.gov/commission/PSOT/Presentation/directassesstment.pdf ]



Phased array systems have risen to NDT field to a new height because there is no need for taking manual scanning results by putting a probe on different angles. Just recently, phased arrays for real time and synthetic focusing in practical pipe inspection applications have been introduced by Rose and Mudge [5]. Even more recently phased arrays for plate inspection were introduced by Li and Rose [23] and Giurgiutiu and Bao [24].

Figure 5: Step by step historical development in Phased Array

Guided Wave Technique of Focusing:

The term focusing referring to improve the signal to noise at a particular location by manipulating of sending and receiving guided wave signals. GWT focusing is a new development that increases the sensitivity, exact information to defect size, and confidence.

Figure 6: GWT Focusing Types with special features



Concluding Remarks

Day by day advances in guided wave techniques understanding, easy computation power and simulation process making them most suitable in-service inspection of pipes is a reality of today. Most of the applications of particular significance GW used in aircraft, pipelines, metal deterioration, rail, corrosion, bridges and erosions.

Technical Challenges and There Solutions in GWT:

Technical Challenges Solutions 1. Multi Nodes Application Environment

1. Guide wave Transducer Design & Mode Tuning to achieve single mode excitation and detection

2. Guided Wave Dispersion

2. Wave No./Frequency Domain Beam Steering

3. Skew Effects in Anisotropic Plates

3. Select a GW Mode & frequency that is insensitive to plate.

Table 4: Technical Challenges and There Solutions in GWT

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[15] Velichko, A. and Wilcox, P.D., “Post-processing of guided wave array data for high resolution pipe inspection,” J. Acoust. Soc. Am., 126(6), pp.2973-2982, 2009.

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[17] Demma, A., Cawley, P., Lowe, M.J.S., “Mode conversion of longitudinal and torsional guided modes due to pipe bends”, AIP Conference Proceedings, n 557A, p 172-9, 2001.

[18] Ma, J., Lowe, M.J.S., Simonetti, F., “Feasibility study of sludge and blockage detection inside pipes using guided torsional waves”, Measurement Science and Technology, v 18, n 8, p 2629-2641, August 1, 2007.

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[21] Kim, Y.Y., Park, C.I., Cho, S.H., Man, S.W., “Torsional wave experiments with a new magnetostrictive transducer configuration”, Journal of the Acoustical Society of America, v 117, n 6, p 3459-3468, June 2005.

[22] Grewal, D. S., ‘‘Improved Ultrasonic Testing of Railroad Rail for Transverse Discontinuities in the Rail Head Using Higher Order Rayleigh (M21) Waves,’’ Mater. Eval., 54, pp. 983–986, 1996.



[23] Giurgiutiu, V., Bao, J., “Embedded ultrasonic structural radar with piezoelectric wafer active sensors for the NDE of thin-wall structures”, ASME International Mechanical Engineering Congress and Exposition, Proceedings, p 31-38, 2002.

[24] Wilcox, P.D. , “Omni-Directional Guided Wave Transducer Arrays for the Rapid Inspection of Large Areas of Plate Structures,” IEEE Trans. Ultrason., Ferroelect., Freq., v 50(6), pp 699-709., 2003.

[25] Joseph L. Rose., “The Upcoming Revolution in Ultrasonic Guided Waves”, Nondestructive Characterization for Composite Materials, Aerospace Engineering, Civil Infrastructure,and Homeland Security 2011, edited by H. Felix Wu, Proc. of SPIE Vol. 7983, 798302 • © 2011 SPIE, DOI: 10.1117/12.897025 Proc. of SPIE Vol. 7983 798302-1.

[26] Vimal Upadhyay, Krishna Kant Agrawal, Mukesh Chand and Devesh Mishra, Ultrasonic Sensors Supervision of Petrochemical and Nuclear Plant, HCTL Open International Journal of Technology Innovations and Research, Volume 1, January 2013, Pages 41-49, ISSN: 2321-1814, ISBN: 978-1-62776-012-6.

[27] Vimal Upadhyay, Shuchi Sharma, Automated Crawler with Robotics Techniques and Sensors in Non Destructive Modeling for Pipeline Health Monitoring In Oil and Natural Gas Refineries, HCTL Open International Journal of Technology Innovations and Research, Volume 3, May 2013, Pages 32-41, ISSN: 2321-1814, ISBN: 978-1-62776-443-8.

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