david padfield - aog · what is acoustic emission monitoring? • the process of detecting sound...
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ACOUSTIC EMISSION GLOBAL INSPECTION TECHNIQUE
DAVID PADFIELD
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What is Acoustic Emission Monitoring?
• The process of detecting sound produced by
discontinuities (cracking) within a structure when the
structure has stress applied to it or when it is leaking or
corroding.
• The sound is used to determine the structure’s condition.
• Applied to monitoring corrosion in aircraft, storage
tanks, pipelines, ships and bridges made from steel or
aluminium.
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AE Standards ASME - American Society of Mechanical Engineers • Acoustic Emission Examination of Fiber-Reinforced Plastic Vessels, Article 11, Subsection A,
Section V, Boiler and Pressure Vessel Code • Acoustic Emission Examination of Metallic Vessels During Pressure Testing, Article 12,
Subsection A, Section V, Boiler and Pressure Vessel Code • Continuous Acoustic Emission Monitoring, Article 13 Section V
ASTM - American Society for Testing and Materials • E569-97 Standard Practice for Acoustic Emission Monitoring of Structures During Controlled
Stimulation • E650-97 Standard Guide for Mounting Piezoelectric Acoustic Emission Sensors • E749-96 Standard Practice for Acoustic Emission Monitoring During Continuous Welding • E750-98 Standard Practice for Characterizing Acoustic Emission Instrumentation • E976-00 Standard Guide for Determining the Reproducibility of Acoustic Emission Sensor
Response • E1067-96 Standard Practice for Acoustic Emission Examination of Fiberglass Reinforced Plastic
Resin (FRP) Tanks/Vessels • E1106-86(1997) Standard Method for Primary Calibration of Acoustic Emission Sensors • E1118-95 Standard Practice for Acoustic Emission Examination of Reinforced Thermosetting
Resin Pipe (RTRP) • E1139-97 Standard Practice for Continuous Monitoring of Acoustic Emission from Metal Pressure
Boundaries • E1211-97 Standard Practice for Leak Detection and Location Using Surface-Mounted Acoustic
Emission Sensors • E1316-00 Standard Terminology for Nondestructive Examinations • E1419-00 Standard Test Method for Examination of Seamless, Gas-Filled, Pressure Vessels
Using Acoustic Emission • E1781-98 Standard Practice for Secondary Calibration of Acoustic Emission Sensors • E1932-97 Standard Guide for Acoustic Emission Examination of Small Parts • E1930-97 Standard Test Method for Examination of Liquid Filled Atmospheric and Low Pressure
Metal Storage Tanks Using Acoustic Emission • E2075-00 Standard Practice for Verifying the Consistency of AE-Sensor Response Using an
Acrylic Rod • E2076-00 Standard Test Method for Examination of Fiberglass Reinforced Plastic Fan Blades
Using Acoustic Emission
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AE Standards ASNT - American Society for Nondestructive Testing • ANSI/ASNT CP-189, ASNT Standard for Qualification and Certification of
Nondestructive Testing Personnel. • CARP Recommended Practice for Acoustic Emission Testing of Pressurized Highway
Tankers Made of Fiberglass reinforced with Balsa Cores. • Recommended Practice No. SNT-TC-1A.
Association of American Railroads • Procedure for Acoustic Emission Evaluation of Tank Cars and IM-101 tanks, Issue 1,
and Annex Z thereto, “ Test Methods to Meet FRA Request for Draft Sill Inspection program, docket T79.20-90 (BRW) ,” Preliminary 2
Compressed Gas Association • C-1, Methods for Acoustic Emission Requalification of Seamless Steel Compressed
Gas Tubes.
European Committee for Standardization • DIN EN 14584, Non-Destructive Testing – Acoustic Emission – Examination of
Metallic Pressure Equipment during Proof Testing; Planar Location of AE Sources. • EN 1330-9, Non-Destructive Testing – Terminology – Part 9, Terms Used in Acoustic
Emission Testing. • EN 13477-1, Non-Destructive Testing – Acoustic Emission – Equipment
Characterization – Part 1, Equipment Description. • EN 13477-2, Non-Destructive Testing – Acoustic Emission – Equipment
Characterization – Part 2, Verification of Operating Characteristics. • EN 13554, Non-Destructive Testing – Acoustic Emission – General Principles.
Institute of Electrical and Electronics Engineers • IEEE C57.127, Trial-Use guide for the Detection of Acoustic Emission from Partial
Discharges in Oil-Immersed Power Transformers.
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AE Standards International Organization for Standardization • ISO 12713, Non-Destructive Testing - Acoustic Emission Inspection
– Primary Calibration of Transducers. • ISO 12714, Non-Destructive Testing - Acoustic Emission Inspection
– Secondary Calibration of Acoustic Emission Sensors. • ISO 12716, Non-Destructive Testing - Acoustic Emission Inspection
– Vocabulary • ISO/DIS 16148, gas Cylinders – Refillable Seamless Steel gas
Cylinders – Acoustic Emission Examination (AEE) for Periodic Inspection.
Japanese Institute for Standardization • JIS Z 2342, Methods for Acoustic Testing of Pressure Vessels
during Pressure Tests and Classification of Test Results.
Japanese Society for Nondestructive Inspection • NDIS 2106-79, Evaluation of performance Characteristics of
Acoustic Emission Testing Equipment. • NDIS 2109-91, Methods for Absolute calibration of Acoustic
Emission Transducers by Reciprocity Technique. • NDIS 2412-80, Acoustic Emission Testing of Spherical Pressure
Vessels of High Tensile Strength Steel and Classification of Test Results.
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Acoustic Emission (AE)
Transient elastic waves generated by the rapid release of energy from localised sources within a material
(extract from ASTM E610.82)
Primarily “Clustering”
Am
pli
tud
e
Threshold
Duration
Rise
time
Decay
time
AE Counts = 7
Time
An AE hit
Energy
Parameters measured include:
AE event counts
Amplitude
Duration
Rise time
Decay time
Energy
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• Sensors – 20kHz to 500kHz
• Preamplifier
• Band pass filters tuned to sensors
10 - 1000kHz
• Location of acoustic signals
• “Clever” Software that can be
taught.
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Sensor Preamplifier Filter
DiSP AE
Card Computer
AE Equipment
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AE Testing – Tank Set Up
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Sensors
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Tank Bottom Sensor Positioning
• Sensors mounted 0.5 m to 2 m
above knuckle, usually 1m and 2m
• 3 to 24 sensors used depending on
size
• Cables from sensors are run back
to AE computer
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Primary sensors
Guard sensors
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Example of Bad Tank
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INDUSTRIAL CORROSION
Tank Bottoms - AE Test Procedure
• Tank conditioned – Isolate tank for 6-12 hours
– Large crude tanks 24 hrs, Small tanks 6 hrs
– Valves closed, heaters off, agitators switched off, ultrasonic depth gauges off, fluid flow in attached pipes stopped.
– Insulated tanks require 300 mm square holes removed to mount sensors
• Sensors mounted tank wall around the circumference
• Tank monitored for a pre-determined time – 1hr min
• Data processed to eliminate unwanted noise
• Data evaluated and sources located
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AE Testing – Experimental
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2 Mild steel specimens
Pipe & Flat bar immersed in 3%
Salt (NaCl) solution
Test initially for 120 hours
Monitoring paused for 4 weeks
then monitored for 17 hours
Dewatering then monitoring for
20 hours
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AE Corrosion Monitoring – Results
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Bar
Pipe
First 120 hours
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AE Corrosion Monitoring – Dry Results
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Bar
Pipe
After removal of corroding solution specimens were
allowed to dry and were monitored over a 17 hour period.
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AE Corrosion Monitoring – Results
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Wet Results
Duration maximum about 10,000 μsec
Dry Results
Higher amplitude signals
Correlation plots Duration (microS) vs Amplitude (dB)
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Acoustic Emission of FRP
• Storage tanks
• Pipelines
• Structures
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FRP Vessels
• Slow fill
• High Amplitude Events
indicate damage
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FRP Vessels
• Corrosion of FRP
• Disbonding of fibres
from matrix
• Lamination growth
• Gross fibre breakage
from damage
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AE Application to Fibre Composites
• Kaiser Effect – Need to exceed previously applied
load to get more AE.
• When testing FRP load
is applied twice if
significant AE detected
• 2nd load to see if first time to load or failure
occurring
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Pressure Vessel Monitoring
• Done to established Standards (ASME) (AS3788)
and Evaluation Criteria.
• Sensors mounted on vessel and system calibrated
Sensors • Number of sensors
determined by the size of
the vessel to be tested.
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• Tested to ISO / ASTM
Standards
• Sensors mounted on
ends of cylinders so AE
source can be detected
and located
• 2 sensors per cylinder
• Connected to AE
Monitoring equipment by
co-axial cable up to 100m
long.
Sensor Mounting on Gas Storage Cylinders
Sensors
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Pressure
Time
Normal operating pressure
100%
95%
90%
85%
Possible pipe or vessel fill or pressurisation sequence
On new tanks/vessels best done in conjunction with hydrotest
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AE Event and cluster location on cylinder 1
Test Results
Clusters
Located AE
Events
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Permanent Monitoring – HRH Piping • An array of sensors placed either in areas of interest, or
intermittently along a susceptible pipeline would enable short or long-term monitoring.
• 20m pipe monitored with multiple sensors, gives location, intensity, time of activity, etc
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Is it the Answer? Pros
• Global (whole structures)
• Permanent Installation
• Detects & Locates
• Relatively quick
• Easy for the Asset operator
• Prioritises
• Cost saving. • Safety
• Environmental
• Standards recognition
• Permanent record
Cons
• Limited quantification
• External stress required
• Complimentary method
• Requires Skilled personnel
• Some equipment Isolation
• Background noise
• Attenuation