Screening of Corrosion in Storage Tank Walls and Bottoms Using an Array of Guided Wave Magnetostrictive Transducers

TL;DR

This paper introduces a new magnetostrictive transducer system for detecting corrosion in storage tanks from the outside, avoiding the need for dangerous internal inspections.

Contribution

A novel magnetostrictive transducer array and inspection method for long-range corrosion screening of storage tanks using guided waves.

Findings

Magnetostrictive transducers generate high SNR shear horizontal guided waves for long-range inspection.

The SwRI MST 8 × 8 probe enables corrosion mapping and defect width estimation using FMC and TFM.

Case studies and mockups validate the effectiveness of the system in real-world and simulated tank environments.

Abstract

Aboveground storage tanks are used to store various fluids and chemicals for many industrial purposes. According to API standard 653, the structural integrity of these tanks must be regularly assessed. The U.S. EPA requires each operator to have a Spill Prevention, Control and Countermeasure Plan (SPCC) for aboveground storage containers. The accepted practice for inspection of these tanks, particularly the tank bottoms, requires removing the tank from service, emptying the tank, and interior entry for direct inspection of the structure. The required inspection operations are hazardous due to the chemicals themselves as well as the requirement to operate within confined spaces. An inspection from outside the tank would have significant cost and time benefits and would provide a large reduction in the risks faced by inspection personnel. Guided wave (GW) testing is a promising candidate for screening of storage tank walls and bottoms from the tank exterior due to the ability of GWs to propagate over long distances from a fixed probe location. The lowest-order transverse-motion guided wave modes (e.g., torsional vibrations in pipes) are a good choice for long-range inspection because this mode is not dispersive; therefore, the wave packets do not spread out in time. A common weakness of guided wave inspection is the complexity of report generation in the presence of multiple geometry features in the structure, such as welds, welded plate corners, attachments and so on. In some cases, these features cause generation of non-relevant indications caused by mode conversion. Another significant challenge in applying GW testing is development of probes with high-enough signal amplitudes and relatively small footprints to allow them to be mounted on short tank bottom extensions. In this paper, a new generation of magnetostrictive transducers will be presented. The transducers are based on the reversed Wiedemann effect and can generate shear horizontal mode guided waves over a wide frequency range (20–150 kHz) with SNRs in excess of 50 dB. The recently developed SwRI MST 8 × 8 probe contains an array of eight pairs of individual magnetostrictive transducers (MsTs). The data acquisition hardware allows acquisition using Full Matrix Capture (FMC) and analysis software reporting of anomalies based on Total Focusing Method (TFM) image reconstruction. This novel inspection package allows generation of reports that map out corrosion locations and provide estimates of defect widths. Case studies of this technology on actual storage tank walls and bottoms will be presented together with validation of processing methods on mockups with known anomalies and geometry features.

Figures