EP2406624A1 - Capteur sans fil et système de gestion de données et procédé de surveillance de l'intégrité de structures mécaniques - Google Patents

Capteur sans fil et système de gestion de données et procédé de surveillance de l'intégrité de structures mécaniques

Info

Publication number
EP2406624A1
EP2406624A1 EP10753941A EP10753941A EP2406624A1 EP 2406624 A1 EP2406624 A1 EP 2406624A1 EP 10753941 A EP10753941 A EP 10753941A EP 10753941 A EP10753941 A EP 10753941A EP 2406624 A1 EP2406624 A1 EP 2406624A1
Authority
EP
European Patent Office
Prior art keywords
response signal
mechanical structure
ultrasonic wave
transducers
wall
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP10753941A
Other languages
German (de)
English (en)
Other versions
EP2406624A4 (fr
Inventor
Eugene B. Silverman
Nischom K. Silverman
Paul Baity
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP2406624A1 publication Critical patent/EP2406624A1/fr
Publication of EP2406624A4 publication Critical patent/EP2406624A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/22—Details, e.g. general constructional or apparatus details
    • G01N29/24—Probes
    • G01N29/2481—Wireless probes, e.g. with transponders or radio links
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/22—Details, e.g. general constructional or apparatus details
    • G01N29/28—Details, e.g. general constructional or apparatus details providing acoustic coupling, e.g. water
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/34—Generating the ultrasonic, sonic or infrasonic waves, e.g. electronic circuits specially adapted therefor
    • G01N29/348—Generating the ultrasonic, sonic or infrasonic waves, e.g. electronic circuits specially adapted therefor with frequency characteristics, e.g. single frequency signals, chirp signals
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
    • G01N29/50—Processing the detected response signal, e.g. electronic circuits specially adapted therefor using auto-correlation techniques or cross-correlation techniques
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/26—Scanned objects
    • G01N2291/269—Various geometry objects

Definitions

  • the invention relates to electrical communications, and more specifically to acoustic wave systems and devices.
  • Measurement techniques commonly found in the industry include eddy current instruments, guided wave ultrasound, phased array ultrasound and direct ultrasound thickness measurements, to name a few.
  • the use of ultrasound can be conveniently categorized as an ultrasound testing (UT) method. See Krautkramer, Josef and Krautkramer, Herbert, Ultrasonic Testing of Materials, 4th/revised edition, Springer Verlag, November 1990.
  • UT ultrasound testing
  • IPI In-Line Inspection
  • tools or smart pigs, are intelligent sensing devices that are introduced into the line at a specialized entry point and most commonly conveyed by product flow along the length of the pipe.
  • Intrusive methods include electrical resistance probes and coupons.
  • the coupon is the original form of intrusive corrosion monitoring. It can typically consist of a strip of metal made of material similar to the pipeline. It is weighed, then inserted it into an access point and left for several months for exposure to the product. The operator then removes the coupon and weighs it again to see what percentage is missing. As in any invasive technique, this approach to corrosion monitoring can be disruptive to pipeline operations. See Lawson, K.M., and N. G. Thompson. "The Use of Coupons for Monitoring the Cathodic Protection of Buried Structures.," CORROSION/98, paper no. 672. Houston, TX: NACE, 1998.
  • the most common non-intrusive device is external monitoring such as eddy current testing and ultrasonic testing (UT) as cited earlier.
  • UT ultrasonic testing
  • a portable device pulse-receiver
  • voltage is applied across a piezoelectric crystal to generate an ultrasonic sound wave that propagates through the metal.
  • the time it takes to travel through the metal and back to the transducer is directly proportional to its thickness.
  • the devices are quick, easy to use and inexpensive, and operators do not have to shut off flow or risk breeching the pipeline in order to take a reading.
  • Measurement tools typically require a power source that must be either available locally or accompanied with the person taking the measurement;
  • the present invention solves before-mentioned problems by providing an ultrasonic sensor system with minimal power requirements which enables the system to be operated and monitored wirelessly and remotely.
  • a first aspect of the invention is a method for inspecting a wall of a mechanical structure, including obtaining an infinite response from a sample material having a front face, a thickness, and a back wall, by transmitting into a sample material an ultrasonic wave having a frequency and duration and being generated by one or more transducers, wherein the thickness of the sample material is sufficiently great that only a wave corresponding to the front face of the sample is received back; transmitting an ultrasonic wave generated by one or more transducers into the wall of a mechanical structure to be inspected at a time (T), wherein the ultrasonic wave has the same frequency and duration as the ultrasonic wave transmitted into the sample material; receiving a response signal back from the wall to be inspected; and correlating the response signal to the infinite response, thereby creating correlated data.
  • T time
  • a second aspect of the invention is a mechanical structure monitoring system, including one or more transducers for transmitting a broadband long pulse ultrasonic wave into a mechanical structure to be monitored and for receiving a response signal back from the mechanical structure, wherein the mechanical structure has a front face, a thickness, and a back wall; a central processing unit for eliminating noise from the response signal wave form; a means for transmitting the response signal waveform to a remotely-located server and for receiving data back from the remotely-located server; and a user terminal for accessing the transmitting means thereby allowing a user to pulse or energize the transducer in order to transmit the broadband long pulse ultrasonic wave into the mechanical structure to be monitored.
  • a feature of the invention is that it can use traditional high resolution ultrasound compression waves although the application can be applied to alternative non-destructive techniques such as shear waves, phased arrays, guided wave ultrasound, eddy current and electromagnetic acoustic transducers.
  • Another feature of the invention is that single or multiple transducers can be pulsed in any order of interest to the user and, as an alternative feature, would provide for a configuration of a multitude of sensors that can be arranged in an array.
  • an array of transducers can be arranged in the shape of a circle, oval, square or rectangular matrix or along one or more axes for a length or shape determined by the monitoring area of interest.
  • An advantage of the invention is that the system employs low power ultrasonic electronics, thereby making the system intrinsically safe (IS).
  • IS system intrinsically safe
  • "Intrinsically safe” equipment is defined as "equipment and wiring which is incapable of releasing sufficient electrical or thermal energy under normal or abnormal conditions to cause ignition of a specific hazardous atmospheric mixture in its most easily ignited concentration.”
  • sensors can be located in remote locations with or without a local source of power, and sensors can be located in air or submerged in a liquid such as an aboveground or belowground storage tank, or under water such as an offshore platform.
  • a feature of the invention is that it provides thickness measurements with resolution capabilities equal to traditional ultrasound compression waves or similar to phased array or guided wave ultrasound.
  • the sensors can provide measurements on structures with or without coatings, and the sensors can be attached to a structure with the use of glues, clamps, weldments or other forms of permanent or removable attachment methods.
  • Another feature of the invention is that it provides for the ability to integrate a wide range of sensors that would benefit the user when located in remote monitoring locations.
  • These sensors may include seismic monitoring, monitoring of volatile organic compounds in the atmosphere or local environment, moisture, temperature, nitrogen oxides, carbon dioxide, carbon monoxide, accelerometers used to measure natural or man-made vibrations, and similar sensors used for the remote monitoring of naturally occurring or manmade events.
  • An advantage of the invention is that it can be monitored remotely via a wireless network accessible through the World Wide Web or in an alternative configuration accessible within a local wireless network, cellular network or local area network.
  • the system allows the user who is logged onto the system to remotely pulse or energize the transducer.
  • Another advantage of the invention is that it can be packaged for use in non- explosive atmospheres and in locations requiring electronics designed for operation in explosive atmospheres.
  • Another advantage of the invention is that real time monitoring and control capability is possible from a remote location, either above or below ground; data can be integrated directly into mechanical integrity database management programs for real time or offline analysis; data trending with failure prediction information is readily accessible to the user; and, the system provides early failure warning based on a material loss threshold or, in an alternative configuration, thresholds of special interest to the user.
  • Fig. 1 is a graph plotting an example of a typical long pulse broadband ultrasound wave, or "chirp,” transmitted to inspect a wall of a mechanical structure;
  • Fig. 2 is a graph showing received calibration data
  • Fig. 3 is an enlarged view of the graph in Fig. 2 showing the desired section of the calibration signal, which is also known as the infinite response;
  • Fig. 4 is a graph showing an ultrasound signal received back from a 0.201 inch thick piece of metal
  • Fig. 5 is an enlarged view of the graph in Fig. 4 showing the desired section of the calibration signal
  • Fig. 6 is a graph showing the received signal from Fig. 5 after the noise is eliminated, thereby creating correlation (or "correlated") data;
  • Fig. 7 is an enlarged view of the correlation data from Fig. 6;
  • Fig. 8 is a graph plotting an example of a long pulse broadband ultrasound wave, (or "chirp"), transmitted to inspect a wall of a mechanical structure;
  • Fig. 9 is a graph of another example of a long pulse broadband ultrasound wave, (or "chirp"), transmitted to inspect a wall of a mechanical structure;
  • Fig. 10 is a graph showing a return signal
  • Fig. 11 is a graph showing a calibration wave (or "infinite response").
  • Fig. 12 is a graph correlating the return signal from Fig. 10 with the infinite response from Fig. 11 ;
  • Fig. 13 is a graph plotting a response signal from a corroded plate
  • Fig. 14 is a graph showing the response signal from Fig. 13 after correlation with an infinite response:
  • Fig. 15 is a graph showing a response signal when the one or more transducers are tilted when delivering a chirp to a mechanical structure
  • Fig. 16 is a graph showing the response signal from Fig. 15 after correlation with an infinite response
  • Fig. 17 is a graph showing a response signal from a tank having sludge with water on top;
  • Fig. 18 is a graph showing the response signal from Fig. 17 after correlation with an infinite response
  • Fig. 19 is a front perspective drawing of an embodiment of a transducer array mounted on a test pipe
  • Fig. 20 is an example of a graphic user interface for a system of monitoring thickness of a mechanical structure over time
  • Fig. 21 is a schematic showing a mechanical structure monitoring system network.
  • Fig. 1 there is shown an exemplary broadband long pulse ultrasound wave or signal which can be used to inspect a wall of a mechanical structure.
  • Mechanism as used in this application can mean any structure that contains a wall or surface the integrity or thickness of which needs to be monitored from time to time.
  • Non- limiting examples of mechanical structures can include tank or tankers, ships, plates of steel, pipes, bridges or trusses of bridges, wind turbines, off-shore oil platforms, and pylons.
  • An ultrasonic wave such as that shown in Fig.
  • the duration of the transmit signal can be proportional to the distance from the transducer to the wall of the mechanical structure to be inspected. For example, the closer the transducer to the wall, the shorter the preferred duration of the transmit signal; and conversely, the further the transducer from the wall, the longer the preferred duration of the transmit signal.
  • the duration of the transmit signal shown in Fig. 1 was about 35 ⁇ seconds.
  • the preferred transmit signal is a chirp.
  • a “chirp" signal is a signal in which the frequency increases (“up-chirp") or decreases (“down-chirp”) with time. As used herein, the term “chirp” can be used interchangeably with "sweep signal.”
  • an infinite response (also known as a "calibration signal”) can be generated by transmitting a chirp signal into a thick piece of metal sample material.
  • the back wall deflection of the chirp signal is delayed until the 2126 sample shown in the graph.
  • the saturated area in the graph is the transmit time, and the middle signal is the correlation signal which can be used for correlating a response signal to the infinite response.
  • the delay between the correlation data and the back wall deflection allows the correlation data to be isolated for later use.
  • the sample material is sufficiently thick that a wave corresponding to the back wall of the sample material is not received back, which is why the calibration signal is also known as an "infinite response.”
  • the calibration signal is also known as an "infinite response.”
  • “calibration signal” and “infinite response” are synonymous and may be used interchangeably.
  • Fig. 3 shows the desired part of the calibration signal which can be used for correlation with a response signal from a mechanical structure to be inspected. There preferably will be a calibration signal for each transducer and transmit signal used.
  • Fig. 4 shows another example of a calibration signal received back from a piece of metal having a thickness of about 0.201 inch. As shown in Fig. 3, the saturated area is the transmit time and the second signal is the desired calibration signal.
  • Fig. 5 shows the calibration signal received from the metal sample material of Fig. 4. The portion of the received signal shown in Fig. 5 can be captured by the ultrasound AD/DA board, and normally would be integer data with a -8192 to +8191 range for a 14 bit AD converter. The data can be packaged in a binary file in a row and column format.
  • a calibration signal is correlated with a response signal received back from a mechanical structure to be inspected
  • correlation data as shown in the graph in Fig. 6 is created.
  • the graph shows a typical A-Scan plot with the big impulse being the reflection back from the front face and the remaining pulses are reflections from the front and back faces.
  • FIG. 7 An enlarged view of the correlation data from Fig. 6 is shown in Fig. 7. An operator can place cursors on the adjacent peaks to measure time or thickness.
  • Fig. 8 and 9 show alternative broadband long pulse ultrasound waves that can be used in the present invention.
  • these ultrasound signals are chirp signals in which the frequency changes over time.
  • Fig. 10 shows a response signal received back from a wall of a mechanical structure to be tested.
  • the response signal can be correlated with a calibration signal resulting in correlated data, which is reflected in the graph in Fig. 11.
  • the calibration signal was obtained by recording the infinite response from a thick (approximately 4 inches) block of steel sample material. There is no contribution in the correlated data from internal reflections - only the reflection from the front face - because of the thickness of the sample material.
  • the peaks in the correlated data in Fig. 12 can be analyzed to determine the thickness of the mechanical structure to be inspected.
  • Figs. 13 and 14 show a response signal received back from a plate in a mechanical structure to be inspected and correlated data, respectively. Much of the noise has been removed from the correlated data, which reveal corrosion and/or pitting in the plate.
  • Figs. 15 through 18 show response signals and correlation data for mechanical structures where (i) the transducer was tilted and the plate was corroded (figs. 15 and 16) and (ii) there was sludge between the transducer and the tank floor (figs. 17 and 18).
  • Fig. 19 shows an example of one possible embodiment of a sensor 1901 containing a transducer array mounted on a 6-inch diameter pipe 1901.
  • the sensor 1901 also can include sensor for monitoring humidity, temperature, moisture, structural vibration, wind, atmospheric volatile organic compounds, or seismic activity.
  • the system can include one or more transducers for transmitting a broadband long pulse ultrasonic wave into a mechanical structure to be monitored and for receiving a response signal back from the mechanical structure, wherein the mechanical structure has a front face, a thickness, and a back wall.
  • the system can also include additional environmental sensors, such as sensors for monitoring humidity, temperature, moisture, structural vibration, wind, atmospheric volatile organic compounds, or seismic activity.
  • a central process unit can be included either onsite in the sensor array or at a remote site for eliminate noise from a response signal received back from a mechanical structure to be inspected.
  • a means for transmitting the response signal to a remotely located server and for receiving data back from the remote serve can be included.
  • Non-limiting examples of transmitting means include a wired or wireless connection to the Internet or other local area network with secure encrypted data transmission.
  • the system of the present invention requires not more than about 12 volts of electrical force and can operate with as little as 5 volts of electrical force. This low power requirement allows the invention to be wirelessly operated remotely. As a result, the system can be powered by the sun or a battery for extended periods of time.
  • the system can further include auxiliary power means and/or a battery backup for powering the one or more transducers and environmental sensors.
  • the system can be an Internet-accessible system that allows the user to pulse a remotely located ultrasonic sensor that is permanently attached to a corroded pipe.
  • the manner of attachment of the sensor to the pipe can be achieved in a number of ways including the use of epoxy glue, a dry couplant, or compliant material that holds the transducer tightly against the structure to be monitored through the use of a clamp that ensures that the transducer remains snugly fastened on the structure.
  • the sensor can be operated for over 16 hours without a charge and for several days through a solar powered array.
  • the data can be collected and transmitted through a wireless network to the World Wide Web where the data can be stored on a Web Server located on a local computer, transmitted and stored on a remote Web Server hosted by an Internet Service Provider and accessed by another remote computer through a password- protected terminal logged onto the Internet.
  • a transducer can be pulsed or energized by the user and data can be acquired, collected, stored and displayed without the user having direct access to the ultrasonic sensor mounted on the pipe.
  • Fig. 20 shows an example a graphical user interface located at a user terminal for accessing the transmitting means thereby allowing the user to pulse or energize the transducer in order to transmit the broadband long pulse ultrasonic wave into the mechanical structure to be inspected.

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  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Engineering & Computer Science (AREA)
  • Signal Processing (AREA)
  • Computer Networks & Wireless Communication (AREA)
  • Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)

Abstract

La présente invention a pour objet un procédé et un appareil pour l'inspection d'une paroi d'une structure mécanique comprenant les étapes consistant à obtenir une réponse infinie à partir d'un matériau échantillon ayant une face avant, une épaisseur, et une paroi arrière, par la transmission dans un matériau échantillon d'une onde ultrasonore ayant une fréquence et une durée et produite par un ou plusieurs transducteurs, l'épaisseur du matériau échantillon étant suffisamment grande pour que seule une onde correspondant à la face avant de l'échantillon soit reçue en retour; à transmettre une onde ultrasonore produite par un ou plusieurs transducteurs dans la paroi d'une structure mécanique à inspecter à un instant (T), l'onde ultrasonore possédant les mêmes fréquence et durée que l'onde ultrasonore transmise dans le matériau échantillon; à recevoir en retour un signal de réponse à partir de la paroi à inspecter; et à corréler le signal de réponse à la réponse infinie, ce qui crée des données corrélées. Le système peut être actionné à distance et sans utilisation de fil, et des données peuvent être transmises et reçues par l'intermédiaire d'Internet ou d'un réseau local, soit sans fil, soit de façon câblée. (figure illisible)
EP10753941.3A 2009-03-13 2010-03-15 Capteur sans fil et système de gestion de données et procédé de surveillance de l'intégrité de structures mécaniques Withdrawn EP2406624A4 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US15995009P 2009-03-13 2009-03-13
PCT/US2010/027357 WO2010107712A1 (fr) 2009-03-13 2010-03-15 Capteur sans fil et système de gestion de données et procédé de surveillance de l'intégrité de structures mécaniques

Publications (2)

Publication Number Publication Date
EP2406624A1 true EP2406624A1 (fr) 2012-01-18
EP2406624A4 EP2406624A4 (fr) 2017-12-06

Family

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Family Applications (1)

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EP10753941.3A Withdrawn EP2406624A4 (fr) 2009-03-13 2010-03-15 Capteur sans fil et système de gestion de données et procédé de surveillance de l'intégrité de structures mécaniques

Country Status (4)

Country Link
EP (1) EP2406624A4 (fr)
BR (1) BRPI1006453A2 (fr)
CA (1) CA2755405A1 (fr)
WO (1) WO2010107712A1 (fr)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB201211515D0 (en) * 2012-06-28 2012-08-08 Pipelines 2 Data P2D Ltd Methods and apparatus for acoustic assessment of fluid conduits
US20160327519A1 (en) 2014-01-02 2016-11-10 Pipelines 2 Data (P2D) Limited Methods and apparatus for acoustic assessment from the interior of fluid conduits
US10908130B2 (en) * 2014-10-01 2021-02-02 Sensor Networks, Inc. Asset integrity monitoring using cellular networks

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5203823A (en) * 1989-02-28 1993-04-20 Mitsubishi Denki Kabushiki Kaisha Detecting apparatus
JP3130223B2 (ja) * 1994-11-18 2001-01-31 三菱電機株式会社 検出方法及び検出装置
DE59708827D1 (de) * 1996-04-18 2003-01-09 Ramseier Hans Ulrich Charakterisierung von objekten mittels ultraschall
BR0314672A (pt) 2002-09-24 2005-08-02 Ast Services Llc Sistema de inspeção, circuito de acionamento, e, veìculo de inspeção
US20080262347A1 (en) * 2007-04-20 2008-10-23 Geoffrey Batchelder Method and apparatus for monitoring integrity of an implanted device

Non-Patent Citations (1)

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Title
See references of WO2010107712A1 *

Also Published As

Publication number Publication date
WO2010107712A1 (fr) 2010-09-23
CA2755405A1 (fr) 2010-09-23
EP2406624A4 (fr) 2017-12-06
BRPI1006453A2 (pt) 2018-02-27

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