Non-Intrusive Pipe Wall Diagnostics Using External Thermal Sensing

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Solution Overview

Problem

Existing pipe diagnostic systems are inadequate for online, non-invasive detection of internal pipe conditions, particularly in environments with high noise and vibration, and may introduce leakage points, while also relying on offline access for assessment and ineffective corrosion detection.

Innovation Solution

A heat-flow based pipe diagnostic system that uses a sensor capsule with temperature-sensitive elements coupled to the exterior of the pipe to measure electrical characteristics, calculate process fluid temperature, and provide diagnostic indications by comparing estimated and actual temperatures, allowing for online monitoring without internal access or potential leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If acoustic detection system is used for corrosion and fouling detection, then pipe diagnostic capability is provided, but detection reliability deteriorates in environments with high process noise and vibration

Engineering Contradiction:

Improvedetection reliabilityVSAvoidprocess noise and vibration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the acoustic detection system with a thermal detection system. Instead of using acoustic sensors to detect pipe conditions, the invention uses temperature sensors to measure temperature differences across the pipe wall. This substitution of detection mechanism eliminates sensitivity to acoustic noise and vibration, providing reliable operation in harsh industrial environments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces thermal energy as an intermediary medium for detection. By measuring heat transfer through the pipe wall rather than acoustic waves, the system creates an intermediate measurement path that is not affected by process noise and vibration. The temperature difference across the pipe wall serves as the intermediary indicator of pipe condition.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If pipe diagnostic system requires access to interior of pipe, then direct assessment of internal conditions is achieved, but system must be taken offline and potential leakage points are created

Engineering Contradiction:

Improvedirect assessment accuracyVSAvoidsystem availability and leak-free operation

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent inverts the detection approach by placing sensors on the exterior of the pipe rather than requiring interior access. Instead of inserting diagnostic equipment inside the pipe, the system measures temperature differences from the outside surface, eliminating the need to take the system offline and avoiding creation of leakage points.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The pipe itself serves as the measurement path. The natural heat transfer through the pipe wall provides the measurement medium, eliminating the need for separate access paths or insertion equipment. The system uses the pipe's own thermal properties for self-diagnosis without requiring external intervention that could compromise integrity.

Inventive Principle:

Principle #25Self-service

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 non-invasive, online detection of pipe fouling and corrosion, reducing maintenance downtime and preventing pipe failure by accurately assessing internal pipe conditions without disrupting the process fluid flow or introducing leakage points.

Implementation Method 1

The sensor capsule 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

Methodology Applied

Scientific EffectTemperature sensitive element detection: Thermistor

Implementation Method 2

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

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentEP3769075B1Non-intrusive pipe wall diagnostics

Publication Date: 2024.08.21 ROSEMOUNT INC

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AI summary

A pipe diagnostic system (200) includes a sensor capsule (206), measurement circuitry (228) and a controller (222). The sensor capsule (206) is configured to be coupled to an exterior surface of a pipe (100) and has at least one temperature sensitive element disposed therein. The measurement circuitry (223) is coupled to the sensor capsule (206) 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 (222) is coupled to the measurement circuitry (223) and is configured to obtain a transmitter reference measurement (502) and employ a heat transfer calculation (506) with the transmitter reference measurement and the indication to generate an estimated process fluid temperature. The controller (222) is further configured to obtain an indication of process fluid temperature and provide a pipe diagnostic indication (512) based on a comparison of the estimated process fluid temperature and the obtained indication of process fluid temperature.