Electromagnetic Sensor Array for Corrosion Detection Through Insulation
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Solution Overview
Problem
Existing pipeline inspection methods require the removal and subsequent replacement of insulation and weather protection, making them time-consuming and costly, and are not practical for pipes with small diameters or complex features, as they do not effectively detect corrosion and defects under these conditions.
Innovation Solution
The development of sensors and systems that utilize inductive and solid-state sensing element arrays to detect defects through the insulation and weather protection, using multiple excitation frequencies to estimate material properties and determine damage, allowing for non-invasive inspection and imaging of pipes without removing the protective layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional exterior inspection techniques are used, then corrosion and defects can be detected, but the insulation and weather protection must be removed and replaced, making the process time-consuming and costly
Solution Approach 1:
The patent replaces mechanical inspection methods (which require physical removal of insulation and weather protection) with electromagnetic sensing methods. The sensor system uses electromagnetic fields to detect corrosion and defects through the insulation and weather protection layers without mechanical removal, thereby eliminating the time-consuming removal and replacement processes while maintaining defect detection capability
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary to transfer information about the pipe condition from the inspection location to the sensor. The electromagnetic field penetrates through the insulation and weather protection layers, allowing defect detection without direct contact with the pipe surface, thus enabling inspection through protective layers without removal
2Measurement precision
If insulation and weather protection are removed for inspection, then accurate defect detection is possible, but the replacement of these protective layers adds to the expense
Solution Approach 1:
The patent replaces mechanical inspection methods that require removal of protective layers with electromagnetic sensing methods. The electromagnetic sensor system can detect corrosion and defects through the insulation and weather protection layers without removing them, eliminating material costs associated with removal and replacement while maintaining detection accuracy
Solution Approach 2:
The patent creates an electromagnetic model or representation of the pipe condition by measuring electromagnetic field interactions through the protective layers. This electromagnetic 'copy' or model allows assessment of the pipe condition without physically accessing or removing the protective layers, thereby avoiding material costs while preserving inspection accuracy
3Measurement precision
If interior inspection with PIG is performed, then wall thickness measurements can be made, but it is not practical for pipes with small diameters or complex features
Solution Approach 1:
The patent inverts the inspection approach by moving from interior inspection (PIG inside the pipe) to exterior inspection (sensor outside the pipe). The electromagnetic sensor is placed on the outer surface of the pipe and detects wall thickness and corrosion through the insulation and weather protection layers, enabling inspection of small diameter pipes and those with complex features that would be inaccessible to interior PIG inspection
Solution Approach 2:
The patent uses electromagnetic fields as an intermediary to bridge the gap between the exterior sensor and the pipe wall. The electromagnetic field penetrates through the insulation and weather protection layers to interact with the pipe wall, allowing wall thickness measurement from the exterior without requiring pipe interior access, thus enabling inspection of small diameter and complex geometry pipes
4Measurement precision
If multiple excitation frequencies are used, then material properties and damage can be characterized, but the sensor system becomes more complex
Solution Approach 1:
The patent changes the frequency parameter of the electromagnetic excitation to extract different material properties. By using multiple excitation frequencies, the system can characterize different aspects of the pipe and protective layer materials (such as conductivity, permeability, and thickness) without adding physical complexity to the sensor structure. The frequency variation is a software/control parameter change rather than a hardware complexity increase
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 detection and characterization of corrosion and other defects in pipelines, reducing the risk of catastrophic failure by providing accurate size and location information for maintenance or repair actions without disrupting the insulation and weather protection.
Implementation Method 1
The sensors may utilize inductive and/or solid state sensing element arrays operated in a magnetic field generated in part by a drive winding of the sensor
Implementation Method 2
Multiple excitation frequencies are used to generate the magnetic field and record corresponding sensing element responses
Data Source
AI summary
Detection of corrosion and other defects in piping is needed to prevent catastrophic pipeline failure. Sensors, systems and methods are provided to enable detection of such defects. These apparatus and methods are configured to characterize pipe protected by insulation and conductive weather protection. The sensors may utilize inductive and/or solid state sensing element arrays operated in a magnetic field generated in part by a drive winding of the sensor. Multiple excitation frequencies are used to generate the magnetic field and record corresponding sensing element responses. Relatively high excitation frequencies may be used to estimate the properties of the weather protection and sensor lift-off while lower frequencies may be used to detect internal and external pipe damage. Linear arrays may be moved to generate damage images of the pipe providing size and location information for defects. Two dimensional sensor arrays may be used to provide imaging without moving the sensor.