Non-destructive evaluation of ferromagnetic material thickness using Pulsed Eddy Current sensor detector coil voltage decay rate

© 2018 Elsevier Ltd A ferromagnetic material thickness quantification method based on the decay rate of the Pulsed Eddy Current sensor detector coil voltage is proposed. An expression for the decay rate is derived and the relationship between the decay rate and material thickness is established. Pipe wall thickness estimation is done with a developed circular sensor incorporating the proposed method, and results are evaluated through destructive testing. The decay rate feature has a unique attribute of being lowly dependent on properties such as sensor shape and size, and lift-off, enabling the method to be usable with any detector coil-based sensor. A case study on using the proposed method with a commercial sensor is also presented to demonstrate its versatility

Designing a pulsed eddy current sensing set-up for cast iron thickness assessment

© 2017 IEEE. Pulsed Eddy Current (PEC) sensors possess proven functionality in measuring ferromagnetic material thickness. However, most commercial PEC service providers as well as researchers have investigated and claim functionality of sensors on homogeneous structural steels (steel grade Q235 for example). In this paper, we present design steps for a PEC sensing set-up to measure thickness of cast iron, which is unlike steel, is a highly inhomogeneous and non-linear ferromagnetic material. The setup includes a PEC sensor, sensor excitation and reception circuits, and a unique signal processing method. The signal processing method yields a signal feature which behaves as a function of thickness. The signal feature has a desirable characteristic of being lowly influenced by lift-off. Experimental results show that the set-up is usable for Non-destructive Evaluation (NDE) applications such as cast iron water pipe assessment

Improved signal interpretation for cast iron thickness assessment based on pulsed eddy current sensing

© 2017 IEEE. This paper presents a novel signal processing approach for computing thickness of ferromagnetic cast iron material, widely employed in older infrastructure such as water mains or bridges. Measurements are gathered from a Pulsed Eddy Current (PEC) based sensor placed on top of the material, with unknown lift-off, as commonly used during non-destructive testing (NDT). The approach takes advantage of an analytical logarithmic model proposed in the literature for the decaying voltage induced at the PEC sensor pick-up coil. An increasingly more accurate and robust algorithm is proven here by means of an Adaptive Least Square Fitting Line (ALSFL) recursive strategy, suitable to recognize the most linear part of the sensor's logarithmic output voltage for subsequent gradient computation, from which thickness is then derived. Moreover, efficiency is also gained as processing can be carried out on only one decaying voltage signal, unlike averaging over multiple measurements as is usually done in the literature. Importantly, the new signal processing methodology demonstrates highest accuracies at the lower thicknesses, a circumstance most relevant to NDT evaluation. Experiments that verify the proposed method in real-world thickness assessment of cast iron material are presented and compared with current practices, showing promising results

Pulsed Eddy Current Sensing for Condition Assessment of Reinforced Concrete

© 2019 IEEE. Reinforced concrete (i.e., concrete wall-like structures having steel reinforcement rods embedded within) are commonly available as civil infrastructures. Such concrete structures, especially the walls of sewers, are vulnerable to bacteria and gas induced acid attacks which contribute to deterioration of the concrete and subsequent concrete wall loss. Therefore, quantification of concrete wall loss becomes important in determining the health and structural integrity of concrete walls. An effective strategy that can be formulated to quantify concrete wall loss is, locating a reinforcement rod and determining the thickness of concrete overlaying the rod via Non-destructive Testing and Evaluation (NDT E). Pulsed Eddy Current (PEC) sensing is commonly used for NDT E of metallic structures, including ferromagnetic materials. Since steel reinforcement rods that are commonly embedded in concrete also are ferromagnetic, this paper contributes by presenting experimental results, which suggest the usability of PEC sensing for reinforced concrete assessment, via executing the aforementioned strategy

Parameter analysis of pulsed eddy current sensor using principal component analysis

Pulsed eddy current (PEC) technique provides a means to inspect structures without surface contact. It is particularly useful when the structure’s surface is rough or inaccessible, such as insulated pipes in pipeline. Probe parameters of a PEC system, especially the sensing and excitation coil diameters, can significantly affect the PEC system’s performance. Thus, detailed analysis of these parameters is paramount in developing a PEC system. Currently, this is accomplished by establishing the trend of features with respect to the analyzed variables, e.g. sample thicknesses. However, prior to extracting these features, a number of configuration parameters have to be determined. For this reason, analyzing PEC performance over a range of coil diameter values is rather time-consuming as both the sensing and excitation coil diameters significantly affect the received signals. Principal component analysis (PCA) is proposed as an alternative to the feature extraction. The work here analyzes the trends contributed by the PCA scores for different values of sensing and excitation coil parameters. Results from both numerical simulations and experiments suggest that the sensitivity of the PEC probe is highly correlated with the excitation coil diameter, while the excitation-sensing coil distance is not significant in determining the sensitivity of the PEC probe. These findings are consistent with those reported in the literature, suggesting the potential of adopting PCA for an automated PEC performance analysis process

Gaussian process for interpreting pulsed eddy current signals for ferromagnetic pipe profiling

© 2014 IEEE. This paper describes a Gaussian Process based machine learning technique to estimate the remaining volume of cast iron in ageing water pipes. The method utilizes time domain signals produced by a commercially available pulsed Eddy current sensor. Data produced by the sensor are used to train a Gaussian Process model and perform inference of the remaining metal volume. The Gaussian Process model was learned using sensor data obtained from cast iron calibration plates of various thicknesses. Results produced by the Gaussian Process model were validated against the remaining wall thickness acquired using a high resolution laser scanner after the pipes were sandblasted to remove corrosion. The evaluation shows agreement between model outputs and ground truth. The paper concludes by discussing the implications or results and how the proposed method can potentially advance the current technological setup by facilitating real time pipe profiling

Decoupling the influence of wall thinning and cladding thickness variation pulsed eddy current using principal component analysis

Corrosion may develop and grow on steel pipes under layers of insulation and cladding. Inspection of the pipes through these protective layers is of paramount importance. Pulsed eddy current (PEC) is a primary non-destructive testing (NDT) technique candidate for this type of inspection as it requires no contact with the inspection material. To overcome the variability in PEC signals due to variations in the cladding thickness, a large measurement set is analysed in this paper using principal component analysis (PCA). The PCA approach decomposes the signal set into a number of uncorrelated variables that explain the maximum amount of the variance in the data set, in which, in this respect, efficiently separate the influences contributed by the difference in the material properties of cladding and pipe wall. The feasibility of using PCA to quantify simulated steel pipe wall independent of confounding cladding thickness variations is investigated. It is found that, with sufficient amount of data, the approach can effectively separate the influences contributed by the wall thickness variations from the cladding thickness variations

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)