In-Situ Pipe Material Identification Using Non-Destructive Testing
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Solution Overview
Problem
Current methods for identifying and tracking the material used in pipelines are destructive, time-consuming, costly, and limited, as they require sampling and laboratory analysis, which cannot be applied non-destructively to each pipe, and future regulations may demand more precise and rapid material identification.
Innovation Solution
A non-destructive, in-situ system for pipe material identification that includes selecting test areas on the pipe, collecting mechanical and chemical property data using ball indenters and optical emissions spectrometry, and analyzing these data to determine yield strength, tensile strength, carbon percentage, and manganese percentage with specific confidence levels, without damaging the pipe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive coupon testing is used to identify pipe material, then material identification accuracy is improved, but pipe integrity is degraded and testing time increases
Solution Approach 1:
The patent replaces destructive mechanical coupon testing with non-destructive magnetic particle testing and ultrasonic testing to identify pipe material properties. These alternative testing methods allow material characterization without removing or damaging the pipe, thus substituting a destructive mechanical system with non-destructive physical field-based systems.
Solution Approach 2:
The patent introduces magnetic particles and ultrasonic waves as intermediary agents to probe material properties. These intermediaries interact with the pipe material to reveal characteristics such as grain structure, hardness, and composition without directly damaging the pipe, serving as mediators between the testing system and the pipe material.
2Measurement precision
If destructive coupon testing is used to identify pipe material, then material identification accuracy is improved, but testing time is increased
Solution Approach 1:
The patent performs preliminary non-destructive testing on the pipe before any potential destructive testing. By using magnetic particle testing and ultrasonic testing first to identify material properties, the system can often determine material characteristics without proceeding to time-consuming destructive coupon testing, thus saving time while maintaining identification accuracy.
Solution Approach 2:
The patent replaces the time-intensive destructive coupon testing process with faster non-destructive testing methods. Magnetic particle testing and ultrasonic testing provide rapid material identification without the lengthy processes of coupon removal, laboratory analysis, and result interpretation associated with destructive testing.
3Measurement precision
If destructive coupon testing is used to identify pipe material, then material identification is achieved, but operational continuity is disrupted
Solution Approach 1:
The patent replaces destructive testing that requires pipeline shutdown and pipe access with non-destructive testing methods that can be performed on installed pipes. This substitution allows material identification to occur without interrupting pipeline operations, maintaining operational continuity while achieving accurate material characterization.
Solution Approach 2:
The patent enables the pipe to be tested in its installed state without requiring removal or disruption of the pipeline system. The non-destructive testing methods allow the pipe to continue serving its function while being characterized, effectively allowing the pipeline to test itself without external intervention that would interrupt 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
The system provides accurate material identification with 95% confidence for yield and tensile strength, and 85% and 90% confidence for carbon and manganese percentages respectively, allowing for precise material grading without degrading the pipe's integrity, validated through third-party testing and applied to over 30 samples.
Implementation Method 1
collecting mechanical property data from the test area... provides, at 95% confidence level, data sufficient to determine ultimate yield strength and ultimate tensile strength
Implementation Method 2
collecting chemical property data from the test area... provides, at an 85% confidence level, data sufficient to calculate a carbon percentage... and, at a 90% confidence level, a manganese percentage
Data Source
AI summary
A system and method for non-destructive, in situ, positive material identification of a pipe selects a plurality of test areas that are separated axially and circumferentially from one another and then polishes a portion of each test area. Within each polished area, a non-destructive test device is used to collect mechanical property data and another non-destructive test device is used to collect chemical property data. An overall mean for the mechanical property data, and for the chemical property data, is calculated using at least two data collection runs. The means are compared to a known material standard to determine, at a high level of confidence, ultimate yield strength and ultimate tensile strength within +/−10%, a carbon percentage within +/−25%, and a manganese percentage within +/−20% of a known material standard.