Acoustic Surface Roughness Measurement in Corrosive Pipelines
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Solution Overview
Problem
Conventional methods for measuring surface roughness in corrosive environments, such as pipelines transporting fluids like carbon dioxide, hydrogen, and ammonia, are limited by their speed and ability to detect defects, particularly in non-planar and contaminated surfaces, and often require contact, which is impractical for field inspections.
Innovation Solution
A non-contact acoustic measurement system that emits and detects acoustic signals to determine surface roughness by comparing the characteristics of the emitted and reflected signals, using a 'smart pig' equipped with guide disks and a surface preparation device to clean the interior surface of pipelines, allowing for fast and robust inspection of roughness parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional contact methods are used to measure surface roughness, then measurement precision can be achieved, but the measurement process is slow and impractical for field inspections
Solution Approach 1:
The patent replaces mechanical contact measurement systems with an acoustic wave-based measurement system. The system uses acoustic waves to interact with the surface and measures roughness parameters through acoustic signal analysis, eliminating the need for physical contact while maintaining measurement capability and enabling faster inspection speeds suitable for field applications.
2Reliability
If conventional methods are used to inspect non-planar and contaminated surfaces, then some defects can be detected, but the ability to detect defects is significantly limited
Solution Approach 1:
The acoustic measurement system replaces mechanical contact probes that struggle with non-planar and contaminated surfaces. Acoustic waves can penetrate and interact with surfaces regardless of their planarity or contamination level, allowing reliable defect detection in challenging conditions where conventional mechanical methods fail.
3Measurement precision
If contact-based roughness measurement is performed in corrosive environments, then surface roughness can be measured, but the measurement process becomes impractical for field inspections
Solution Approach 1:
The system substitutes mechanical contact measurement with non-contact acoustic measurement, eliminating the need for physical contact with the surface. This makes the measurement process practical for field inspections in corrosive environments where contact probes would be damaged or contaminated, while preserving measurement precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and accurate measurement of surface roughness in corrosive environments, overcoming limitations of conventional methods by providing a fast and robust inspection process that can detect defects and corrosion levels in complex pipeline surfaces.
Implementation Method 1
an acoustic receiver configured to detect a second acoustic signal that comprises a reflection of the first acoustic signal from the surface
Data Source
AI summary
Systems and methods for evaluating a roughness of a surface are disclosed. The system includes an acoustic emitter configured to emit an acoustic signal and an acoustic receiver configured to detect a reflection of the emitted acoustic signal from the surface and provide a data signal comprising a portion of the reflected signal. The system also includes a processor configured to receive the data signal and determine the roughness based in part on a difference between the emitted acoustic signal and the reflected acoustic signal.