Phased Array Ultrasonic Inspection of Swing Check Valve Clapper Wear
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Solution Overview
Problem
Existing non-intrusive inspection techniques for valves, such as ultrasonic and magnetic methods, fail to provide comprehensive information on the operational status of swing-type check valves, particularly regarding wear on hinge pins, which can lead to catastrophic failures if not detected in time.
Innovation Solution
The use of phased array sequence scanning with water wedges to non-invasively test swing-type check valves, allowing for visualization of the valve's operation by transmitting and receiving ultrasonic signals through piezo-electric crystals mounted on the water wedges, enabling detection of fluid presence and air pockets, and creating a computer-generated image of the valve's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional non-intrusive inspection techniques (ultrasonic, magnetic) are used, then the valve can be tested without disassembly, but comprehensive information on operational status including hinge pin wear cannot be obtained
Solution Approach 1:
The inspection process is divided into multiple sequential scanning positions along the valve body, with each position capturing specific operational information. The clapper is monitored at different locations (fully open, fully closed, intermediate positions) to comprehensively assess hinge pin wear and operational status without disassembly.
Solution Approach 2:
The invention transitions from traditional single-point ultrasonic measurement to multi-dimensional phased array scanning. By moving the transducer array along the valve body and capturing reflections from multiple angles and positions, the system creates a comprehensive three-dimensional view of clapper movement and hinge pin condition.
2Measurement precision
If the valve is disassembled for detailed inspection, then comprehensive information on internal components including hinge pin wear can be obtained, but the valve must be taken apart which reduces operational availability
Solution Approach 1:
The invention replaces mechanical disassembly with non-contact ultrasonic phased array scanning. The transducer array electronically steers and focuses ultrasonic beams to monitor clapper movement and detect hinge pin wear through acoustic reflections, eliminating the need for physical disassembly while maintaining detection precision.
Solution Approach 2:
The ultrasonic waves serve as an intermediary between the inspection system and the internal valve components. The phased array transducers transmit ultrasonic signals through the valve body and clapper, and the reflected waves carry information about hinge pin wear and clapper position without requiring direct physical contact or disassembly.
3Loss of information
If phased array ultrasonic scanning is used, then comprehensive visualization of valve operation and detection of wear can be achieved, but the device complexity increases
Solution Approach 1:
The phased array transducer system performs multiple functions: it monitors clapper position, detects hinge pin wear, identifies air pockets, and visualizes valve operation. A single multi-element transducer array replaces what would otherwise require multiple separate inspection devices and methods.
Solution Approach 2:
The system creates a visual copy or representation of the valve's internal operation through computer-generated images based on ultrasonic reflection data. This graphical output provides an intuitive visualization of clapper movement and potential issues without requiring physical access to the components.
4Reliability
If air pockets are not detected, then the valve may operate undetected with improper fluid filling, but traditional inspection methods cannot identify air pocket locations
Solution Approach 1:
The phased array system performs periodic scanning at multiple positions along the valve body during valve operation. By repeatedly scanning through different sequences and positions, the system can detect air pockets that may move or change position during operation, improving reliability of detection.
Solution Approach 2:
The system uses feedback from ultrasonic reflection patterns to identify air pockets. When reflections indicate abnormal acoustic impedance changes consistent with air pockets, the system adjusts scanning parameters and provides visual feedback to operators about the location and severity of air pocket issues.
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 allows for the reliable non-intrusive inspection of swing-type check valves, detecting operational issues like wear and air pockets, enabling timely maintenance and preventing failures, while providing a visual representation of the valve's operation for operators.
Implementation Method 1
transmitting and receiving ultrasonic signals through piezo-electric crystals mounted on the water wedges
Implementation Method 2
phased array sequence scanning with water wedges to non-invasively test swing-type check valves, allowing for visualization of the valve's operation
Implementation Method 3
phased array sequence scanning
Data Source
AI summary
Computers with proper programs generate signals in phased array sequence. In pulsers with delays, signals are fed through a multiplexor into multiple water wedges that are attached to a valve being tested. For a sequential operation of the valves from the open to the closed position, ultrasonic signals are transmitted through fluid contained in the valve and reflected back through piezo-electric crystals to the multiplexor. By summation and merger of the signals, an image can be developed of the operation of the valve to determine if the valve is operating properly. By using multiple water wedges and pass visualization software, the operator can see exactly how the valve is functioning, which information can be stored for inspections or maintenance.