Magnetostrictive Sensor for Tank Bottom Inspection
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Solution Overview
Problem
Conventional magnetostrictive sensor technology is not practical or cost-effective for nondestructive testing of large above-ground storage tank bottom surfaces, as bonding magnetostrictive material to the tank bottom is impractical due to the large surface area and thickness of the tank bottom.
Innovation Solution
A specially designed magnetostrictive sensor is placed on the lip of the tank, using a shear wave couplant to facilitate the inspection of the tank bottom without the need for bonding, employing a horseshoe-shaped magnet and excitation coil to generate and detect ultrasonic guided waves for defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetostrictive material is bonded to the tank bottom for inspection, then inspection capability is improved, but the complexity and cost increase due to large surface area and thickness requirements
Solution Approach 1:
A ferromagnetic coating is applied to the tank bottom surface to serve as an intermediary layer. This coating enables the magnetostrictive sensor to function on nonferromagnetic tank bottoms without requiring direct bonding of magnetostrictive material to the entire tank bottom surface, thus reducing complexity while maintaining inspection capability
Solution Approach 2:
The magnetostrictive material is extracted from the tank bottom bonding requirement and concentrated into a portable sensor unit. This allows the sensor to be moved and scanned across different locations on the tank bottom, eliminating the need for extensive material bonding while maintaining comprehensive inspection coverage
2Area of stationary object
If magnetostrictive material is bonded to the tank bottom, then inspection coverage is improved, but the cost and time for material application increase
Solution Approach 1:
The inspection system transitions from a static bonded configuration to a dynamic portable sensor that can be scanned across the tank bottom. This allows comprehensive coverage of large areas without the time-consuming process of bonding material to the entire surface, as the sensor can be rapidly moved and repositioned
Solution Approach 2:
The portable magnetostrictive sensor unit serves multiple inspection locations universally. Instead of requiring dedicated bonded material for each inspection point, the same sensor can be moved to inspect different areas of the tank bottom, reducing both material application time and overall inspection costs
3Ease of operation
If a portable sensor is used instead of bonded material, then ease of operation is improved, but measurement precision may be affected
Solution Approach 1:
The mechanical bonding system is replaced with a portable sensor system that uses magnetic field interaction through the ferromagnetic coating. This substitution maintains measurement precision for detecting corrosion and cracks while dramatically improving ease of operation, as the sensor can be easily positioned and scanned without bonding procedures
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 cost-effective nondestructive testing of the tank bottom by allowing the sensor to be scanned around the edge of the tank, providing long-range inspection capabilities for detecting corrosion and cracking without the need for extensive material bonding, thus overcoming the impracticality of bonding magnetostrictive material to the tank bottom.
Implementation Method 1
Magnetostriction is a property of ferromagnetic materials that causes them to change shape when subjected to a magnetic field. Magnetostrictive materials can convert magnetic energy into kinetic energy
Implementation Method 2
The combination of a magnetized magnetostrictive material and an excitation coil produces a magnetostrictive sensor (MsS) probe
Implementation Method 3
employing a horseshoe-shaped magnet and excitation coil to generate and detect ultrasonic guided waves for defect detection
Data Source
AI summary
A method of testing for defects in the bottom of an above ground storage tank, the tank bottom having a lip extending outwardly from the tank wall around the circumference of the tank. A special magnetostrictive sensor is designed to be placed on this lip. The sensor is placed over a strip of magnetostrictive material, which generally conforms in length and width to the bottom of the probe, with a couplant being applied between the strip and the lip surface. The sensor is then operated in pulse echo mode to receive signals from defects in the bottom of the tank. It is incrementally moved around the circumference of the tank.