Rolling Sensor Mounting for Pressure Vessel Integrity Testing
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Solution Overview
Problem
Pressure vessels have limited lifetimes due to cyclic and static fatigue, with uncertainties in calculating their remaining life, especially in applications with inconsistent pressure ranges and cycles, and the interaction between these fatigue types is not fully understood, complicating the assessment of structural integrity.
Innovation Solution
A sensor mounting system for pressure vessels that allows for in-field testing using phased array Modal Acoustic Emission (PA-MAE) sensors, with rail assemblies and rollers to position sensors in optimal orientations and densities, enabling accurate structural integrity assessment without removing the vessels from their deployment arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are positioned manually on pressure vessels, then measurement precision can be achieved, but device complexity and installation time increase significantly
Solution Approach 1:
The sensor mounting system is divided into separate functional components: a movable mounting structure with rollers for positioning, a sensor array for measurement, and a control system for coordination. This segmentation allows each component to be optimized independently while reducing overall system complexity through modular design.
Solution Approach 2:
A movable mounting structure acts as an intermediary between the sensor array and the pressure vessel surface. This intermediary component includes rollers that facilitate smooth movement and precise positioning of sensors along the vessel surface, eliminating the need for complex fixed mounting systems.
2Measurement precision
If multiple sensors are deployed to assess structural integrity, then measurement precision improves, but the number of components and installation complexity increase
Solution Approach 1:
Multiple sensors are merged into a single integrated sensor array that can be positioned simultaneously along the pressure vessel surface. The mounting structure holds multiple sensors in a coordinated arrangement, allowing them to function as a unified measurement system rather than separate individual sensors requiring independent mounting.
Solution Approach 2:
The movable mounting structure serves multiple functions: it positions the sensor array, maintains optimal sensor-to-surface contact, enables movement along the vessel length, and facilitates quick installation and removal. This multi-functionality reduces the need for additional specialized components for each sensor.
3Measurement precision
If pressure vessels are removed from service for testing, then measurement precision can be achieved, but loss of time and productivity decrease
Solution Approach 1:
The sensor mounting system is designed to be self-positioning through its movable structure with rollers that automatically adjust to maintain optimal contact with the vessel surface. The system can be quickly installed and removed without requiring disassembly of the vessel or complex installation procedures, allowing testing to be performed while the vessel remains in service or with minimal disruption to operations.
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 accurate, efficient, and comprehensive structural integrity testing of pressure vessels in real-world conditions, minimizing sensor locations and maximizing signal sensitivity, thereby improving the estimation of remaining vessel life and ensuring safety.
Implementation Method 1
The first roller is attached to the first elongated frame member and is configured to contact and roll upon a first surface of one of the first, second, third and fourth vessels
Implementation Method 2
A sensor mounting system for pressure vessels that allows for in-field testing using phased array Modal Acoustic Emission (PA-MAE) sensors
Data Source
AI summary
A sensor mounting assembly is configured for use with a vessel arrangement including at least four vessels. The assembly includes first and second elongated frame members, first and second rollers, and first and second sensors. The first sensor is attached to the first elongated frame member and is configured to contact the surface of the first vessel upon actuation in a first direction. The second sensor is attached to the second elongated frame member and is configured to contact the surface of the second vessel upon actuation in a second direction that is substantially orthogonal to the first direction. This disclosure also describes a method of mounting at least six sensors for use with a vessel arrangement including at least four vessels, the vessel arrangement disposed in a container in a two-by-two stacked configuration having a central space.