Passive low frequency RFID for non-destructive evaluation and monitoring

Ph. D ThesisDespite of immense research over the years, defect monitoring in harsh environmental conditions still presents notable challenges for Non-Destructive Testing and Evaluation (NDT&E) and Structural Health Monitoring (SHM). One of the substantial challenges is the inaccessibility to the metal surface due to the large stand-off distance caused by the insulation layer. The hidden nature of corrosion and defect under thick insulation in harsh environmental conditions may result in it being not noticed and ultimately leading to failures. Generally electromagnetic NDT&E techniques which are used in pipeline industries require the removal of the insulation layer or high powered expensive equipment. Along with these, other limitations in the existing techniques create opportunities for novel systems to solve the challenges caused by Corrosion under Insulation (CUI). Extending from Pulsed Eddy Current (PEC), this research proposes the development and use of passive Low Frequency (LF) RFID hardware system for the detection and monitoring of corrosion and cracks on both ferrous and non-ferrous materials at varying high temperature conditions. The passive, low cost essence of RFID makes it an enchanting technique for long term condition monitoring. The contribution of the research work can be summarised as follows: (1) implementation of novel LF RFID sensor systems and the rig platform, experimental studies validating the detection capabilities of corrosion progression samples using transient feature analysis with respect to permeability and electrical conductivity changes along with enhanced sensitivity demonstration using ferrite sheet attached to the tag; (2) defect detection using swept frequency method to study the multiple frequency behaviour and further temperature suppression using feature fusion technique; (3) inhomogeneity study on ferrous materials at varying temperature and demonstration of the potential of the RFID system; (4) use of RFID tag with ceramic filled Poly-tetra-fluoro-ethyulene (PTFE) substrate for larger applicability of the sensing system in the industry; (5) lift-off independent defect monitoring using passive sweep frequency RFID sensors and feature extraction and fusion for robustness improvement. This research concludes that passive LF RFID system can be used to detect corrosion and crack on both ferrous and non-ferrous materials and then the system can be used to compensate for temperature variation making it useful for a wider range of applications. However, significant challenges such as permanent deployment of the tags for long term monitoring at higher temperatures and much higher standoff distance, still require improvement for real-world applicability.Engineering and Physical Sciences Research Council (EPSRC) CASE, National Nuclear Laboratory (NNL)

Design and Modelling of Passive UHF RFID Tags for Energy Efficient Liquid Level Detection Applications. A study of various techniques in the design, modelling, optimisation and deployment of RFID reader and passive UHF RFID tags to achieve effective performance for liquid sensing applications

Sewer and oil pipeline spillage issues have become major causes of pollution in urban and rural areas usually caused by blockages in the water storage and drainage system, and oil spillage of underground oil pipelines. An effective way of avoiding this problem will be by deploying some mechanism to monitor these installations at each point in time and reporting unusual liquid activity to the relevant authorities for prompt action to avoid a flooding or spillage occurrence. This research work presents a low cost energy efficient liquid level monitoring technique using Radio Frequency Identification Technology. Passive UHF RFID tags have been designed, modelled and optimized. A simple rectangular tag, the P-shaped tag and S-shaped tag with UHF band frequency of operation (850-950 MHz) has been designed and modelled. Detailed parametric analysis of the rectangular tag is made and the optimised design results analysed and presented in HFSS and Matlab. The optimised rectangular tag designs are then deployed as level sensors in a gully pot. Identical tags were deployed to detect 4 distinct levels in alternate positions and a few inches in seperation distance within the gully pot height (Low, Mid, High and Ultra high). The radiation characteristic of tag sensors in deployment as modelled on HFSS is observed to show consistent performance with application requirements. An in-manhole chamber antenna for an underground communication system is analysed, designed, deployed and measured. The antenna covers dual-band impedance bandwidths (i.e. 824 to 960 MHz, and 1710 to 2170 MHz). The results show that the antenna prototype exhibits sufficient impedance bandwidth, suitable radiation characteristics, and adequate gains for the required underground wireless sensor applications. Finally, a Linearly Shifted Quadrifilar Helical Antenna (LSQHA) designed using Genetic Algorithm optimisation technique for adoption as an RFID reader antenna is proposed and investigated. The new antenna confirms coverage of the RFID bandwidth 860-960 MHz with acceptable power gain of 13.1 dBi.Petroleum Technology Development Fund (PTDF) and National Space Research and Development Agency (NASRDA)

Radio frequency non-destructive testing and evaluation of defects under insulation

PhD ThesisThe use of insulation such as paint coatings has grown rapidly over the past decades. However, defects and corrosion under insulation (CUI) still present challenges for current non-destructive testing and evaluation (NDT&E) techniques. One of such challenges is the large lift-off introduced by thick insulation layer. Inaccessibility due to insulation leads corrosion and defects to be undetected, which can lead to catastrophic failure. Furthermore, lift-off effects due to the insulation layers reduce the sensitivities. The limitations of existing NDT&E techniques heighten the need for novel approaches to the characterisation of corrosion and defects under insulation. This research project is conducted in collaboration with International Paint®, and a radio frequency non-destructive evaluation for monitoring structural condition is proposed. High frequency (HF) passive RFID in conjunction with microwave NDT is proposed for monitoring and imaging under insulation. The small-size, battery-free and cost-efficient nature of RFID makes it attractive for long-term condition monitoring. To overcome the limitations of RFID-based sensing system such as effective monitoring area and lift-off tolerance, microwave NDT is proposed for the imaging of larger areas under thick insulation layers. Experimental studies are carried out in conjunction with specially designed mild steel sample sets to demonstrate the detection capabilities of the proposed systems. The contributions of this research can be summarised as follows. Corrosion detection using HF passive RFID-based sensing and microwave NDT is demonstrated in experimental feasibility studies considering variance in surface roughness, conductivity and permeability. The lift-off effects introduced by insulation layers are reduced by applying feature extraction with principal component analysis and non-negative matrix factorisation. The problem of thick insulation layers is overcome by employing a linear sweep frequency with PCA to improve the sensitivity and resolution of microwave NDT-based imaging. Finally, the merits of microwave NDT are identified for imaging defects under thick insulation in a realistic test scenario. In conclusion, HF passive RFID can be adapted for long term corrosion monitoring of steel under insulation, but sensing area and lift-off tolerance are limited. In contrast, the microwave NDT&E has shown greater potential and capability for monitoring corrosion and defects under insulation

Magnetic Flux Leakage techniques for detecting corrosion of pipes

Oil and gas pipelines are subjected to corrosion due to harsh environmental conditions as in refinery and thermal power plants. Interesting problems such as internal and external corrosion, emerging from the increasing demand for pipeline protection have prompted this study. Thus, early detection of faults in pipes is essential to avoid disastrous outcomes. The research work presented in this thesis comprises investigations into the use of magnetic flux leakage (MFL) testing for pipe in extreme (underwater and high temperature) conditions. The design of a coil sensor (ferrite core with coil) with a magnetic circuit is carried out for high temperature conditions. The sensor thus developed lays the ground for non-destructive evaluation (NDE) of flaws in pipes through the MFL technique. The research focusses on the detection and characterization of MFL distribution caused by the loss of metal in ferromagnetic steel pipes. Experimental verifications are initially conducted with deeply rusted pipe samples of varying thicknesses in air. AlNiCo magnets are used along with Giant Magneto Resistance (GMR) sensor (AA002-02). The experiment is further repeated for saltwater conditions in relation to varying electrical conductivity with radio frequency identification (RFID) technique. A further study carried out in the research is the correlation between magnetic and underwater data communication. The study has resulted in the development and experimental evaluation of a coil sensor with its magnetic response at room and high temperatures. This makes the system effective under high temperature conditions where corrosion metal loss needs to be determined

Magnetic Flux Leakage techniques for detecting corrosion of pipes

Oil and gas pipelines are subjected to corrosion due to harsh environmental conditions as in refinery and thermal power plants. Interesting problems such as internal and external corrosion, emerging from the increasing demand for pipeline protection have prompted this study. Thus, early detection of faults in pipes is essential to avoid disastrous outcomes. The research work presented in this thesis comprises investigations into the use of magnetic flux leakage (MFL) testing for pipe in extreme (underwater and high temperature) conditions. The design of a coil sensor (ferrite core with coil) with a magnetic circuit is carried out for high temperature conditions. The sensor thus developed lays the ground for non-destructive evaluation (NDE) of flaws in pipes through the MFL technique. The research focusses on the detection and characterization of MFL distribution caused by the loss of metal in ferromagnetic steel pipes. Experimental verifications are initially conducted with deeply rusted pipe samples of varying thicknesses in air. AlNiCo magnets are used along with Giant Magneto Resistance (GMR) sensor (AA002-02). The experiment is further repeated for saltwater conditions in relation to varying electrical conductivity with radio frequency identification (RFID) technique. A further study carried out in the research is the correlation between magnetic and underwater data communication. The study has resulted in the development and experimental evaluation of a coil sensor with its magnetic response at room and high temperatures. This makes the system effective under high temperature conditions where corrosion metal loss needs to be determined

Passive low frequencey RFID for detection and monitoring of corrosion under paint and insulation

PhD ThesisDespite decades of research, corrosion under insulation (CUI) still presents significant challenges for non-destructive testing and evaluation (NDT&E). One of the biggest challenges posed by CUI is the inaccessibility due to the large standoff distance intro-duced by thick insulation. The hidden nature of CUI may result in it going unnoticed for long periods of time leading to potentially catastrophic failures. Electromagnetic NDT&E techniques, which are widely employed in the pipeline industries in various forms, have large decrease in sensitivity primarily due to the insulation layer. Methods to overcome this typically involve either the removal of insulation or the use of high powered and expensive equipment. Limitations of existing NDT&E techniques create opportunities for novel approaches to tackle the challenges posed by CUI. This research project, funded by the Engineering and Physical Sciences Research Coun-cil (EPSRC) CASE studentship in collaboration with International Paint®, proposes the use of passive low frequency (LF) RFID hardware for the detection and monitoring of corrosion on insulated pipes. The battery-free, low cost nature of RFID makes it attrac-tive for long term condition monitoring. Experimental studies have been conducted us-ing carefully designed samples to demonstrate the detection capabilities of the proposed system. The contribution of the research can be summarised as follows: (1) experimen-tal feasibility study demonstrating the detection capabilities at large standoff distances; (2) demonstration of the increased sensitivity of the proposed system compared to tradi-tion eddy current (EC) method; (3) use of multivariate statistical analysis to identify the most dominant features and relate them to time-domain features of the RFID waveform; (4) application of principal component analysis (PCA) to overcome the dependence of the aforementioned features on the position of the reader coil; and (5) performed accel-erated CUI testing to demonstrate the potential of the RFID system in a realistic test scenario. This work concludes that passive LF RFID hardware can be used to detect corrosion on steel under thick insulation. In comparison to traditional EC method, the RFID based method shows greater sensitivity at large standoff distances. However, significant chal-lenges, particularly the high temperature survivability of RFID tags, limit the real-world applicability.Engineering and Physical Sciences Research Council (EPSRC) and Inter-national Pain

Substrate-integrated waveguide (SIW) microwave sensor theory and model in characterising dielectric material : A review

Microwave sensors offer appealing features such as susceptibility, quick response, and non-invasiveness, making them valuable tools for highly accurate measurements of material characterisation. A wide range of techniques, including cavity waveguide, planar transmission line, cavity waveguide perturbation, open-ended coaxial probe, and free-space transmission, have been employed to characterise materials that are essential for their cost-effectiveness, ease of manufacturing, high sensitivity, good quality factor (Q-factor), and compact size, allowing them to be applied to different material types. Among the microwave sensor types, the substrate-integrated waveguide (SIW) has emerged as a promising technology in order to characterise materials in an efficient manner. This paper presents a review of the current state and potential opportunities of SIW microwave sensors in the characterisation of dielectric materials. It provides insights into various design principles, techniques, and applications of SIW microwave sensors across different sectors, highlighting their advantages and limitations compared to conventional waveguide-based sensors. Furthermore, the paper summarises several fabrication methods that can be implemented for SIW microwave sensors to enable the production of efficient and reliable sensors. Additionally, the future directions provided in this paper aim to contribute to the ongoing development and optimisation of SIW-based microwave sensors for accurate and efficient dielectric material characterisation. Overall, this review article serves as a beneficial resource for new researchers seeking to understand the role of SIW microwave sensors in material characterisation. It outlines the current status, opportunities, and potential advancements of SIW sensors, shedding light on their significance and potential impact in the field of material characterisatio

Substrate-integrated waveguide (SIW) microwave sensor theory and model in characterising dielectric material: A review

Microwave sensors offer appealing features such as susceptibility, quick response, and non-invasiveness, making them valuable tools for highly accurate measurements of material characterisation. A wide range of techniques, including cavity waveguide, planar transmission line, cavity waveguide perturbation, open-ended coaxial probe, and free-space transmission, have been employed to characterise materials that are essential for their costeffectiveness, ease of manufacturing, high sensitivity, good quality factor (Q-factor), and compact size, allowing them to be applied to different material types. Among the microwave sensor types, the substrate-integrated waveguide (SIW) has emerged as a promising technology in order to characterise materials in an efficient manner. This paper presents a review of the current state and potential opportunities of SIW microwave sensors in the characterisation of dielectric materials. It provides insights into various design principles, techniques, and applications of SIW microwave sensors across different sectors, highlighting their advantages and limitations compared to conventional waveguide-based sensors. Furthermore, the paper summarises several fabrication methods that can be implemented for SIW microwave sensors to enable the production of efficient and reliable sensors. Additionally, the future directions provided in this paper aim to contribute to the ongoing development and optimisation of SIW-based microwave sensors for accurate and efficient dielectric material characterisation. Overall, this review article serves as a beneficial resource for new researchers seeking to understand the role of SIW microwave sensors in material characterisation. It outlines the current status, opportunities, and potential advancements of SIW sensors, shedding light on their significance and potential impact in the field of material characterisation

Optimising the Structure of Metal-Insulator-Metal Diodes for Rectenna Applications

The work in this thesis investigates the design and fabrication of metal-insulator-metal (MIM) diodes using an ultrathin organic insulator. The organic insulating layer was found to be compact, highly conformal, and uniform, effectively overcoming the main design challenge in MIM diodes. The fabricated diodes have strong nonlinear current-voltage characteristics with a zero-bias curvature coefficient and a voltage responsivity among the best values reported in the available literature. The fabrication process is simple and carried out at low temperature, which is cost effective, and can potentially be ported to large-area roll-to-roll manufacturing. An encapsulation method to prevent MIM junctions’ degradation has also been developed. Following the successful production of these MIM devices on a rigid substrate, with the fabrication only requiring low-temperature processing, the diodes were successfully fabricated on a flexible substrate with results similar to those fabricated on a rigid substrate. The flexible substrate diodes show no significant degradation in performance when stressed in a one-off bending experiment, although extreme mechanical stress testing does produce some loss in quality. Also, an elegant method for matching the impedance of an antenna to that of a MIM diode was successfully developed, for optimal external conversion efficiency where the diodes are used in a rectenna device. The responsivity of the impedance-matched rectenna is approaching an order of magnitude higher than that of a control device without a matching network. The fabrication, electrical characterisation and physical analysis of both the MIM diodes and rectennas are discussed in detail in this thesis