Stepwise Cracking Severity in Pressurized Vessels Using Ultrasonic Imaging
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Solution Overview
Problem
Existing non-destructive testing methods fail to effectively evaluate the severity of step-wise cracking in pressurized vessels, which can lead to safety issues due to crack propagation under increasing internal pressure.
Innovation Solution
A computer-implemented method using ultrasonic testing to capture images of a vessel's circumferential wall, identify adjacent cracks, determine crack intensity paths, and classify the severity of crack propagation based on computational analysis, enabling operations such as repair or shutdown decisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional non-destructive testing methods are used to detect cracks, then crack presence can be identified, but the severity and propagation likelihood of step-wise cracking cannot be effectively evaluated
Solution Approach 1:
The patent segments the crack evaluation process into multiple components: individual crack detection, crack clustering into groups based on spatial proximity, path angle calculation, and severity classification. This segmentation allows traditional NDT to be enhanced with additional analytical layers that evaluate not just crack presence but also their potential for step-wise propagation through the vessel wall thickness.
Solution Approach 2:
The patent introduces a new dimensional parameter - the path angle - which measures the orientation of crack clusters relative to the vessel wall thickness direction. This angular dimension, combined with crack length and clustering patterns, transforms the evaluation from simple 2D crack detection to a 3D assessment that predicts propagation likelihood through the third dimension of wall thickness.
2Reliability
If detailed analysis of multiple crack parameters is performed, then crack severity can be assessed, but the complexity of the evaluation process increases
Solution Approach 1:
The patent replaces complex manual evaluation mechanics with automated computational algorithms. The system automatically detects cracks, clusters them based on spatial coordinates, calculates path angles, determines crack lengths, and assigns severity classifications - all through computer-implemented methods that reduce human burden while maintaining or improving assessment reliability.
Solution Approach 2:
The patent transforms multiple physical crack parameters (length, orientation, spatial distribution, clustering patterns) into a simplified severity classification system. By changing the parameters from continuous measurements to discrete severity levels, the system maintains comprehensive analysis while reducing the complexity of interpretation and decision-making.
3Reliability
If crack propagation risk is evaluated to prevent vessel failure, then safety is improved, but operational downtime for inspection and repair increases
Solution Approach 1:
The patent performs preliminary assessment of crack propagation risk during scheduled inspections by analyzing path angles and crack cluster patterns. This preliminary evaluation identifies which vessels require immediate attention versus those that can continue operation, optimizing the timing of repairs and minimizing unnecessary operational downtime while maintaining safety.
Solution Approach 2:
The patent creates a computational model or 'copy' of the crack propagation scenario by calculating virtual paths and probabilities based on current crack configurations. This computational copying allows risk assessment without physical experimentation or trial-and-error inspection, enabling rapid evaluation that minimizes inspection time and operational disruption.
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 rapid analysis of crack severity and propagation likelihood, allowing for timely remedial actions to prevent vessel damage, thereby enhancing safety and operational efficiency.
Implementation Method 1
ultrasonic testing (UT) involves passing ultrasonic waves through the metal, receiving reflections of the ultrasonic waves, and converting the reflected waves into images
Data Source
AI summary
To determine severity of stepwise cracking in a pressurized vessel, a computer system receives an image collection of an area of a circumferential wall of the vessel. The image collection includes images distributed across the area, and represent respective cracks on the wall within the area. From among the images, the computer system identifies subsets of images, each including images of adjacent cracks. For the at least two images in each subset, the computer system determines multiple distances, each between an end of an image in each subset and an end of each other image in a subset. Based on the determined multiple distances, the computer system determines a probability of a crack propagating through cracks in each subset. Based on the crack intensity path determined for each subset of the multiple subsets, the computer system determines an operation to be performed on the vessel.