Non-intrusive pipe wall diagnostics

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Solution Overview

Problem

Existing pipe diagnostic systems are inadequate for online detection of corrosion and fouling in industrial processes, particularly in environments with high noise and vibration, and may introduce potential leak points or require offline access to the pipe.

Innovation Solution

A heat-flow based pipe diagnostic system that couples a sensor capsule with temperature-sensitive elements to the exterior of a pipe, using a heat transfer calculation to estimate process fluid temperature and detect changes indicative of fouling or corrosion without requiring access to the pipe interior.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If acoustic detection system is used for corrosion and fouling detection, then pipe diagnostics can be provided without interior access, but detection reliability deteriorates in environments with high process noise and vibration

Engineering Contradiction:

Improvepipe diagnostics without interior accessVSAvoiddetection reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces acoustic detection with optical detection using light. The optical system uses a light source and photodetector to measure light transmission through the pipe wall, substituting the acoustic field with an optical field that is not affected by mechanical vibrations and noise, thereby resolving the contradiction between ease of operation and reliability in high-noise environments

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the detection parameter from acoustic properties to optical properties (light absorption and transmission). By measuring how light passes through the pipe wall and changes with fouling or corrosion, the system achieves reliable detection independent of acoustic interference, resolving the reliability issue while maintaining non-intrusive operation

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If pipe diagnostic system requires access to interior of pipe, then accurate assessment of pipe condition can be achieved, but system must be taken offline and potential leak points are created

Engineering Contradiction:

Improvepipe condition assessment accuracyVSAvoidsystem continuity and leakage risk

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

Instead of placing sensors inside the pipe to directly observe the interior condition, the patent inverts the approach by placing sensors on the exterior of the pipe. The optical system measures light transmission through the pipe wall, allowing interior condition assessment from the exterior, thus eliminating the need to take the system offline and avoiding creation of leak points

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces the pipe wall itself as an intermediary medium. By measuring light transmission through this intermediary, the system indirectly assesses interior conditions (fouling, corrosion) without direct interior access, maintaining system continuity and eliminating leakage risks while achieving diagnostic precision

Inventive Principle:

Principle #24Intermediary (Mediator)

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 online, vibration-resistant pipe diagnostics that can detect fouling and corrosion without generating leak points, allowing for timely maintenance scheduling and reducing the risk of pipe failure.

Implementation Method 1

employ a heat transfer calculation with the transmitter reference measurement and the indication to generate an estimated process fluid temperature

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

at least one temperature sensitive element disposed therein. The measurement circuitry is coupled to the sensor capsule and is configured to measure an electrical characteristic of the at least one temperature sensitive element

Methodology Applied

Scientific EffectTemperature sensitive element response: Thermistor

Data Source

PatentUS10760742B2Non-intrusive pipe wall diagnostics

Publication Date: 2020.09.01 ROSEMOUNT INC

AI summary

A pipe diagnostic system includes a sensor capsule, measurement circuitry and a controller. The sensor capsule is configured to be coupled to an exterior surface of a pipe and has at least one temperature sensitive element disposed therein. The measurement circuitry is coupled to the sensor capsule and is configured to measure an electrical characteristic of the at least one temperature sensitive element and provide an indication of the measurement. The controller is coupled to the measurement circuitry and is configured to obtain a transmitter reference measurement and employ a heat transfer calculation with the transmitter reference measurement and the indication to generate an estimated process fluid temperature. The controller is further configured to obtain an indication of process fluid temperature and provide a pipe diagnostic indication based on a comparison of the estimated process fluid temperature and the obtained indication of process fluid temperature.