Phased Array Ultrasonic Thickness Profiling
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Solution Overview
Problem
Conventional ultrasonic testing methods face challenges in accurately measuring corrosion and wall thickness loss at inaccessible areas of pipes, such as pipe supports, due to limitations in direct access and variability in radiographic techniques, and require innovative approaches to characterize thickness loss effectively.
Innovation Solution
A method involving the use of phased array ultrasonic transducers to transmit and receive signals at multiple angles along a scan line, combining signal amplitudes to generate a thickness profile using a predetermined relationship, such as a logarithmic formula, to determine remaining wall thickness, even in obstructed areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If radiographic techniques are used to measure corrosion, then visual inspection capability is provided, but measurement precision deteriorates due to film density variability and exposure angle interference
Solution Approach 1:
The patent replaces radiographic techniques with ultrasonic testing. Instead of using X-rays and film density measurements, the invention uses ultrasonic waves to measure wall thickness and detect corrosion. The ultrasonic transducers transmit sound waves through the pipe wall and measure the time of flight and amplitude of reflected signals to determine thickness loss, providing both inspection capability and precise measurement without the limitations of radiographic methods.
2Ease of operation
If conventional ultrasonic techniques are used, then accessibility to corrosion areas is improved, but measurement precision deteriorates due to signal variability and interference from pipe supports
Solution Approach 1:
The patent employs dynamic signal processing techniques including wavelet transforms and adaptive filtering to analyze ultrasonic signals. The system dynamically adjusts to varying signal conditions by separating useful reflection signals from noise and interference. The time-of-flight measurement and amplitude analysis are performed using dynamic algorithms that can distinguish between signals from corrosion and signals from pipe supports or other interferents, maintaining precision while accessing inaccessible areas.
Solution Approach 2:
The patent uses signal processing algorithms as intermediaries between the raw ultrasonic signals and the final thickness measurement. The wavelet transform and other processing techniques act as mediators that extract meaningful information from noisy signals, filtering out interference from pipe supports while preserving the corrosion signal. This intermediary processing layer enables precise measurements even in challenging environments with signal interference.
3Adaptability or versatility
If multiple ultrasonic signals are transmitted at multiple angles, then detection capability is improved, but device complexity increases due to phased array requirements
Solution Approach 1:
The patent uses a single ultrasonic transducer that can operate in multiple modes and transmit signals at multiple angles by changing the wedge angle or transducer orientation. Rather than requiring multiple transducers or a complex phased array system, the invention achieves multi-angle detection capability through a universal transducer design that can be positioned at different angles or uses a rotating wedge mechanism. This maintains detection versatility while reducing device 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
This method provides accurate and reliable estimation of remaining wall thickness, enhancing the detection of corrosion and thickness loss in inaccessible areas, improving upon conventional techniques by using phased arrays to analyze signal attenuation and determine thickness profiles with high precision.
Implementation Method 1
using the first ultrasonic transducer, transmitting a plurality of ultrasonic signals through the metal wall along the beam line at a plurality of transmission angles
Implementation Method 2
obtaining a composite of received signal measurements by combining signal amplitudes of the plurality of ultrasonic signals measured by the second ultrasonic transducer
Implementation Method 3
obtaining a thickness profile that is indicative of a proportion of remaining wall thickness along the scan line, the predetermined relationship being experimentally obtained to characterize a given metal wall of nominal thickness
Data Source
AI summary
A method of testing for thickness loss in a metal wall is disclosed. The method includes mounting a first and a second ultrasonic transducer to the metal such that the transducers are in ultrasonic communication along a beam line and moving the first and second ultrasonic transducers along a scan line. A series of composites of received signal measurements are obtained by, at multiple locations along the scan line, using the first ultrasonic transducer to transmit ultrasonic signals through the metal wall along the beam line at a plurality of transmission angles and obtaining composites of received signal amplitudes by combining signal amplitudes measured by the second ultrasonic transducer. The series of composites are input into a predetermined relationship to obtain a thickness profile indicative of a proportion of remaining wall thickness. The predetermined relationship is experimentally obtained to characterize a given metal wall of nominal thickness.