Tank Bottom Plate Corrosion Mapping With Acoustic Emission Robot Scanning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current on-line testing technologies for storage tank bottom plates, such as acoustic emission and storage tank bottom plate testing robots, face limitations in detecting the entire bottom plate due to signal propagation distance and cannot determine real-time corrosion severity.
Innovation Solution
An acoustic emission internal testing method and device using a storage tank robot equipped with acoustic emission sensors and an underwater acoustic transducer to calculate attenuation coefficients and determine step distances, allowing comprehensive testing and evaluation of corrosion state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If acoustic emission sensors are installed on the outer wall plate at a certain distance from the bottom plate, then the testing can be performed on-line without cessation of production, but the acoustic emission signal propagation distance is limited and cannot cover the whole bottom plate of large storage tanks
Solution Approach 1:
An underwater acoustic transducer is introduced as an intermediary device to generate acoustic emission signals within the liquid medium. This transducer acts as a signal source that enables the acoustic emission sensors to detect corrosion signals more effectively through the liquid medium, extending the detection range to cover the entire bottom plate area.
Solution Approach 2:
The patent utilizes the liquid medium (hydraulic environment) inside the storage tank as a transmission medium for acoustic signals. By installing sensors on the outer wall and using the liquid as the propagation medium, the system achieves extended signal transmission distance and complete coverage of the bottom plate area.
2Measurement precision
If ultrasonic, magnetic flux leakage, or pulsed eddy current sensors are used on a testing robot to measure wall thickness, then the corrosion regions can be located, but these methods cannot determine whether corrosion is still occurring or its severity
Solution Approach 1:
The patent changes the detection parameter from static structural measurements (wall thickness) to dynamic acoustic emission parameters (signal intensity, activity, frequency). By monitoring these acoustic parameters, the system can determine not only the location but also the activity and severity of ongoing corrosion processes.
Solution Approach 2:
The patent uses acoustic emission signal characteristics (intensity, activity levels, frequency patterns) as indicators to differentiate between active and inactive corrosion, and to assess corrosion severity. Different corrosion states produce distinct acoustic signal patterns that can be identified and classified.
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 omni-directional scanning and real-time evaluation of corrosion on large liquid-carrying storage tank bottom plates, overcoming range limitations and providing accurate corrosion detection.
Implementation Method 1
acoustic emission technology relies upon a certain number of sensors, which are installed in a circumferential direction of the outer wall plate of the storage tank at a certain distance from the bottom plate to detect the acoustic emission signal generated by the storage tank bottom plate due to corrosion
Implementation Method 2
calculating an attenuation coefficient of the acoustic emission signal when propagated by the underwater acoustic transducer through a medium according to the acoustic emission signal and relative positions of the underwater acoustic transducer and the acoustic emission sensors
Data Source
AI summary
An acoustic emission internal testing method and device for detecting corrosion of a large liquid-carrying storage tank bottom plate. An acoustic emission sensor is configured to collect an acoustic emission signal generated by an underwater acoustic transducer, and to calculate an attenuation coefficient of the acoustic emission signal when propagated by the underwater acoustic transducer through a medium, thereby determining a step distance of the storage tank robot. After the storage tank robot travels every step distance on a storage tank bottom plate, the acoustic emission sensor collects an acoustic emission signal generated by the storage tank bottom plate. Finally, the position where the storage tank bottom plate is corroded and the corrosion degree are determined according to intensity characteristic parameters and activity characteristic parameters of the acoustic emission signal collected after the storage tank robot travels every step distance.