Active Sensor Pipe Thickness Mapping
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Solution Overview
Problem
Conventional methods for inspecting pipe wall-thickness reduction and corrosion in power plants are inefficient, requiring extensive downtime and high costs, as they necessitate frequent measurements at multiple points and the use of expensive equipment.
Innovation Solution
An active sensor system comprising an oscillator and an optical fiber sensor that scans oscillatory waves over a desired frequency range, allowing for the detection of pipe thickness and identification of malfunctions over a wide area without stopping the plant, using a multi-point active sensor arrangement for accurate mapping and diagnosis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ultrasonic flaw detecting method is used to measure pipe thickness at multiple positions, then measurement precision is improved, but inspection time and device complexity increase significantly
Solution Approach 1:
The patent replaces the conventional mechanical ultrasonic testing system with an optical measurement system. Optical sensors measure pipe thickness through non-contact methods (such as optical lever or laser techniques), eliminating the need for mechanical probe contact and multiple manual measurement positions, thereby dramatically reducing inspection time while maintaining measurement precision.
Solution Approach 2:
The patent employs optical copying techniques where light patterns or images of the pipe surface are captured and analyzed to determine thickness variations. This optical copy method allows simultaneous measurement across multiple positions without physical contact, resolving the contradiction between comprehensive measurement and inspection time.
2Measurement precision
If conventional inspection methods are applied to detect pipe wall-thickness reduction, then detection accuracy is improved, but plant availability decreases due to required shutdowns
Solution Approach 1:
The patent enables continuous pipe inspection during plant operation by using optical sensors that can measure thickness through existing openings or surfaces without requiring plant shutdown. This continuous measurement capability maintains plant availability while providing accurate deterioration detection, as the optical system can operate uninterrupted during normal plant conditions.
Solution Approach 2:
The patent introduces optical sensors as intermediaries that can detect pipe thickness changes through non-intrusive means. These sensors act as mediators between the inspection requirement and the operating pipe, allowing measurement without direct contact or shutdown, thus maintaining both accuracy and plant availability.
3Ease of operation
If X-ray transmission method is used to detect pipe wall-thickness reduction without detaching heat insulation material, then inspection convenience is improved, but equipment cost increases significantly
Solution Approach 1:
The patent employs cost-effective optical sensors and simple optical components (such as light sources, detectors, and basic processing units) to achieve pipe thickness measurement. These inexpensive optical devices replace expensive X-ray equipment, providing the same operational convenience of non-contact measurement through heat insulation material while dramatically reducing apparatus cost.
Solution Approach 2:
The patent substitutes the expensive X-ray transmission system with a simpler optical measurement system. Optical methods use visible or infrared light that can pass through or reflect from the pipe surface and heat insulation material, eliminating the need for costly X-ray generators and detection systems while maintaining ease of operation.
4Measurement precision
If multiple point measurements are conducted to map pipe thickness distribution, then measurement precision is improved, but inspection complexity and time increase
Solution Approach 1:
The patent transitions from point-by-point measurement to area-wide simultaneous measurement by using optical systems that can capture thickness information across a two-dimensional surface or along a extended path. This dimensional expansion allows multiple position measurements to be performed concurrently rather than sequentially, reducing inspection complexity while maintaining mapping precision.
Solution Approach 2:
The patent employs optical sensors with multi-functional capabilities that can simultaneously perform thickness measurement, surface characterization, and spatial mapping. This universal optical system replaces multiple specialized measurement devices, achieving comprehensive pipe inspection with a single integrated system, thereby reducing overall complexity.
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 rapid, cost-effective inspection of pipe thickness and malfunction detection while the plant is operational, significantly reducing inspection time and steps, and providing accurate diagnostics for pipe deterioration and lifetime assessment.
Implementation Method 1
an oscillator capable of inputting oscillatory waves into the pipe and scanning a frequency of the oscillatory waves within a desired range
Implementation Method 2
an optical fiber sensor mounted on the pipe, the optical fiber sensor detecting the oscillatory waves generated in the pipe
Data Source
AI summary
An active sensor 10 is positioned on an outside of a pipe 60 so as to detect a thickness of the pipe. The active sensor comprises: an oscillator 15 capable of inputting oscillatory waves into the pipe and sweeping a frequency of the oscillatory waves within a desired range; and an optical fiber sensor mounted on the pipe, the optical fiber sensor detecting the oscillatory waves generated in the pipe.