Geir Instanes

Corrosion and erosion monitoring in plates and pipes using constant group velocity Lamb wave inspection

Recent improvements in tomographic reconstruction techniques generated a renewed interest in short-range ultrasonic guided wave inspection for real-time monitoring of internal corrosion and erosion in pipes and other plate-like structures. Emerging evidence suggests that in most cases the fundamental asymmetric A0 mode holds a distinct advantage over the earlier market leader fundamental symmetric S0 mode. Most existing A0 mode inspections operate at relatively low inspection frequencies where the mode is highly dispersive therefore very sensitive to variations in wall thickness. This paper examines the potential advantages of increasing the inspection frequency to the so-called constant group velocity (CGV) point where the group velocity remains essentially constant over a wide range of wall thickness variation, but the phase velocity is still dispersive enough to allow accurate wall thickness assessment from phase angle measurements. This paper shows that in the CGV region the crucial issue of temperature correction becomes especially simple, which is particularly beneficial when higher-order helical modes are also exploited for tomography. One disadvantage of working at such relatively high inspection frequency is that, as the slower A0 mode becomes faster and less dispersive, the competing faster S0 mode becomes slower and more dispersive. At higher inspection frequencies these modes cannot be separated any longer based on their vibration polarization only, which is mostly tangential for the S0 mode while mostly normal for the A0 at low frequencies, as the two modes become more similar as the frequency increases. Therefore, we propose a novel method for suppressing the unwanted S0 mode based on the Poisson effect of the material by optimizing the angle of inclination of the equivalent transduction force of the Electromagnetic Acoustic Transducers (EMATs) used for generation and detection purposes.

CONSTANT GROUP VELOCITY ULTRASONIC GUIDED WAVE INSPECTION FOR CORROSION AND EROSION MONITORING IN PIPES

This paper describes a novel ultrasonic guided wave inspection technique for the monitoring of internal corrosion and erosion in pipes, which exploits the fundamental flexural mode to measure the average wall thickness over the inspection path. The inspection frequency is chosen so that the group velocity of the fundamental flexural mode is essentially constant throughout the wall thickness range of interest, while the phase velocity is highly dispersive and changes in a systematic way with varying wall thickness in the pipe. Although this approach is somewhat less accurate than the often used transverse resonance methods, it smoothly integrates the wall thickness over the whole propagation length, therefore it is very robust and can tolerate large and uneven thickness variations from point to point. The constant group velocity (CGV) method is capable of monitoring the true average of the wall thickness over the inspection length with an accuracy of 1% even in the presence of one order of magnitude larger...

Acoustic formulation of elastic guided wave propagation and scattering in curved tubular structures

Recently, the use of guided wave technology in conjunction with tomographic techniques has provided the possibility of obtaining point-by-point maps of corrosion or erosion depth over the entire volume of a pipeline section between two ring arrays of ultrasonic transducers. However, current research has focused on straight pipes and little work has been done on pipe bends and other curved tubular structures which are also the most susceptible to developing damage. Tomography of curved tubes is challenging because of the complexity and computational cost of the 3-D elastic model required to accurately describe guided wave propagation. Based on the definition of travel-time-preserving orthogonal parametric representations of curved tubes, this paper demonstrates that guided wave propagation and scattering can be approximated by an equivalent 2-D acoustic model which is inhomogeneous and elliptically anisotropic. Numerical methods to solve the full wave equation and predict ray paths and travel times are introduced and applied to the case of a bend. Particular emphasis is given to the shortest-path ray tracing method, which is applied to the 2-D model to compute ray paths and predict travel times of the fundamental flexural mode, A0, propagating across a curved pipe. Good agreement is found between predictions and experiments performed on a 220-mmdiameter (8-in-diameter) (D) pipe with 1.5D bend radius. The 2-D model also reveals the existence of an acoustic lensing effect which leads to a focusing phenomenon also confirmed by the experiments. The computational efficiency of the 2-D model makes it ideally suited for tomographic algorithms.

Guided Wave Tomography of Pipe Bends

Detection and monitoring of corrosion and erosion damage in pipe bends are open challenges due to the curvature of the elbow, the complex morphology of these defects, and their unpredictable location. Combining model-based inversion with guided ultrasonic waves propagating along the elbow and inside its walls offers the possibility of mapping wall-thickness losses over the entire bend and from a few permanently installed transducers under the realm of guided wave tomography (GWT). This paper provides the experimental demonstration of GWT of pipe bends based on a novel curved ray tomography algorithm and an optimal transducer configuration consisting of two ring arrays mounted at the ends of the elbow and a line of transducers fixed to the outer side of the elbow (extrados). Using realistic, localized corrosion defects, it is shown that detection of both the presence and progression of damage can be achieved with 100% sensitivity regardless of damage position around the bend. Importantly, this is possible for defects as shallow as 0.50% of wall thickness (WT) and for maximum depth increments of just 0.25% WT. However, due to the highly irregular profile of corrosion defects, GWT generally underestimates maximum depth relative to the values obtained from 3-D laser scans of the same defects, leading in many cases to errors between 3% WT and 8% WT.

Experimental Validation of a Fast Forward Model for Guided Wave Tomography of Pipe Elbows

Ultrasonic guided wave tomography (GWT) methods for the detection of corrosion and erosion damage in straight pipe sections are now well advanced. However, successful application of GWT to pipe bends has not yet been demonstrated due to the computational burden associated with the complex forward model required to simulate guided wave propagation through the bend. In a previous paper [Brath et al., IEEE Trans. Ultrason., Ferroelectr., Freq. Control, vol. 61, pp. 815–829, 2014], we have shown that the speed of the forward model can be increased by replacing the 3-D pipe bend with a 2-D rectangular domain in which guided wave propagation is formulated based on an artificially inhomogeneous and elliptically anisotropic (INELAN) acoustic model. This paper provides further experimental validation of the INLEAN model by studying the traveltime shifts caused by the introduction of shallow defects on the elbow of a pipe bend. Comparison between experiments and simulations confirms that a defect can be modeled as a phase velocity perturbation to the INLEAN velocity field with accuracy that is within the experimental error of the measurements. In addition, it is found that the sensitivity of traveltime measurements to the presence of damage decreases as the damage position moves from the interior side of the bend (intrados) to the exterior one (extrados). This effect is due to the nonuniform ray coverage obtainable when transmitting the guided wave signals with one ring array of sources on one side of the elbow and receiving with a second array on the other side.

First Field Results of Guided Wave Tomography for Continuous Monitoring of Corrosion and Erosion Damage in Pipelines

The effective life management of pipelines in the Oil and Gas industry requires monitoring techniques that can probe an extended section of a pipe and can sample its state with relatively high frequency so as to implement corrosion mitigation in a timely fashion. Due to the typically low corrosion rates, 1 mm/yr or less, the monitoring technique must be sensitive to wall-thickness changes that are in the order of a few tens of micrometers. Ultrasonic guided wave tomography (GWT) with permanently installed sensors offers an attractive compromise between sensitivity and area coverage by combining the long range propagation characteristics of guided ultrasonic waves with the principles of model-based inversion. Here, the pipe section to be monitored is delimited by two ring arrays of ultrasonic transducers that encircle the pipe and measure guided wave signals after traveling inside the pipe wall from one array to the other. The signals are interpreted by advanced GWT algorithms to form a wall thickness map of the entire pipe section. In this paper we review the principle of operation of GWT, discuss its performance, and present the first long term field results obtained for a pipe in a deepwater rig in the Gulf of Mexico. The field results show that GWT based on EMAT transduction provides highly stable wall thickness estimations even in the presence of multiphase flow inside the pipe undergoing a wide range of pressure and temperature fluctuations.