Remote Field Eddy Current Signals Research Articles

Radial Field Detector to Improve Sensitivity of Localized Defects in Remote Field Eddy Current Technique

ABSTRACT This paper presents the development of a cone-shaped radial magnetic-field-detector–based remote field eddy current (RFEC) probe for enhanced detection of localized defects in ferritic steel tubes. The performance of the radial coil detector has been evaluated for the detection of different types of defects such as through holes, flat bottom holes and notches of different sizes and orientations. The RFEC signals are observed to be corrupted by heavy noise due to spatial variations in material permeability. To remove the random noise from the nonstationary time series RFEC signals, empirical mode decomposition (EMD) processing has been adopted and has been found to significantly improve the signal-to-noise (SNR) ratio. Furthermore, the effect of the circumferential extent of defects on the signal amplitude is analyzed through experimental and finite-element-model–based studies. The linear resolution of the designed radial coil detector and its repeatability behavior are also scrutinized. Studies demonstrate that the developed radial field detector is a promising configuration in remote field eddy current technique for enhanced defect detection and also in designing an array probe.

Accurate Identification for 3-D Position of Hybrid Defects in Ferromagnetic Pipe Using External Remote Field Eddy Current Testing

Remote field eddy current (RFEC) testing is extensively used for the defect evaluation of ferromagnetic pipes, which depends on accurate measurement and complete information. In practice, the misalignment between the probe and defect can affect the accuracy of response signals. In addition to defect size, the 3-D position of a defect is critical information for pipe defect evaluation as well. However, existing RFEC methods find it difficult to identify the radial position of defects, especially the hybrid defect. In this article, an external RFEC (ERFEC) method under sine and pulse excitation is proposed to address these issues. By studying the influences of the axial offset distances and circumferential deflection angles between the probe and defect against RFEC signals, the strategy for position correction of the probe placement is provided to reduce signal error. A pulse signal with optimal excitation parameters is utilized to drive the probe. The time-domain characteristics of the pulsed RFEC signal in shape and magnitude are used for the radial position identification of pipe defects. The results indicate that the probe misalignment effects can be removed using RFEC signal features. Besides, the axial and circumferential positions of hybrid defects can be identified using the probe scanning method, while the radial position identification of the hybrid defect needs to use the valley feature of pulsed RFEC signals combined with the RFEC signal phase. In general, this work makes it possible for depth quantification and accurate profile inversion of the hybrid defect.

Detection of localised flaws in small-diameter carbon steel tubes using multi-NDE techniques

This paper proposes multi-NDE techniques for enhanced and reliable detection of localised defects or flaws in small-diameter (19.05 mm outer diameter (OD) and 2.77 mm wall thickness (WT)) low-carbon steel tubes. Multi-NDE techniques comprising magnetic flux leakage (MFL), remote field eddy current (RFEC) and the ultrasonic internal rotary inspection system (IRIS) are used to investigate the detectability and spatial resolution for the detection of localised flaws of different types and sizes, which simulate flaws generally formed in carbon steel tubes. The studies reveal that the MFL and IRIS techniques detect 0.55 mm-deep holes and notches while the RFEC technique detects 1.11 mm-deep holes and 0.55 mm-deep notches. The IRIS technique is capable of resolving axial and circumferential holes (1 mm diameter and 1.39 mm depth) of 2 mm hole-to-hole separation, while the MFL technique can resolve axial holes of 2 mm hole-to-hole separation but not circumferential holes. The RFEC technique can detect axial holes as a single hole but is unable to detect circumferential holes, resulting in no spatial resolution for the axial and circumferential holes. Compared to the MFL and RFEC signals, IRIS readily discerns the spatial extent of the flaws with the possibility of sizing from the images. The study also reveals that the resolution capability of the IRIS technique is influenced by the speed of the turbine rotation inside the tube.

Defect Detection and Segmentation Framework for Remote Field Eddy Current Sensor Data.

Remote-Field Eddy-Current (RFEC) technology is often used as a Non-Destructive Evaluation (NDE) method to prevent water pipe failures. By analyzing the RFEC data, it is possible to quantify the corrosion present in pipes. Quantifying the corrosion involves detecting defects and extracting their depth and shape. For large sections of pipelines, this can be extremely time-consuming if performed manually. Automated approaches are therefore well motivated. In this article, we propose an automated framework to locate and segment defects in individual pipe segments, starting from raw RFEC measurements taken over large pipelines. The framework relies on a novel feature to robustly detect these defects and a segmentation algorithm applied to the deconvolved RFEC signal. The framework is evaluated using both simulated and real datasets, demonstrating its ability to efficiently segment the shape of corrosion defects.

Method for Removing Secondary Peaks in Remote Field Eddy Current Testing of Pipes

In the remote field eddy current (RFEC) testing of pipes, because the remote eddy current penetrates the pipe’s wall twice, the testing results exhibit two peaks (primary peak and secondary peak) that originate from both the transmitter and receiver passing by the same place in the pipe. The secondary peaks have the same features as the primary peaks that are used to assess defects, and if there is no separation between primary peaks and secondary peaks, incorrect evaluations of defects will be obtained. Considering the benefits of removing secondary peaks in RFEC testing, dual receivers are taken into account. Dual receivers are set in remote fields and are set coaxially to the transmitter to obtain differential signals at the same time. In the proposed method, position dependent response of the differential signals from the dual receivers is calibrated, a Wiener deconvolution filter is used to identify secondary peaks and filter testing noise, and the factors that affect results of removing secondary peaks are also analyzed. To validate the feasibility of the proposed method of RFEC testing, ANSYS is made use of when setting up the analysis model, and an experimental pipe is designed to be identical to ANSYS model. The results of the analysis of ANSYS and experiments both validate the practicality of the proposed method and show the benefits of simplifying the analysis of RFEC signals.

Methodology for non‐destructive assessment of integrity of steam generator shell welds

PurposeDevelopment of non‐destructive methodology for detection of arc strike, spatter and fusion type of welding defects which may form on steam generator (SG) tubes that are in close proximity to the circumferential shell welds. Such defects, especially fusion‐type defects, are detrimental to the structural integrity of the SG. This paper aims to focus on this problem.Design/methodology/approachThis paper presents a new methodology for non‐destructive detection of arc strike, spatter and fusion type of welding defects. This methodology uses remote field eddy current (RFEC) ultrasonic non‐destructive techniques and K‐means clustering.FindingsDistinctly different RFEC signals have been observed for the three types of defects and this information has been effectively utilized for automated identification of weld fusion which produces two back‐wall echoes in ultrasonic A‐scan signals. The methodology can readily distinguish fusion‐type defect from arc strike and spatter type of defects.Originality/valueThe methodology is unique as there is no standard guideline for non‐destructive evaluation of peripheral tubes after shell welding to detect arc strike, spatter and fusion type of welding defects.

Techniques for processing remote field eddy current signals from bend regions of steam generator tubes of prototype fast breeder reactor

Steam generator (SG) is one of the most critical components of sodium cooled fast breeder reactor. Remote field eddy current (RFEC) technique has been chosen for in-service inspection (ISI) of these ferromagnetic SG tubes made of modified 9Cr–1Mo steel (Grade 91). Expansion bends are provided in the SGs to accommodate differential thermal expansion. During ISI using RFEC technique, in expansion bend regions, exciter–receiver coil misalignment, bending stresses, probe wobble and magnetic permeability variations produce disturbing noise hindering detection of defects. Fourier filtering, cross-correlation and wavelet transform techniques have been studied for noise reduction as well as enhancement of RFEC signals of defects in bend regions, having machined grooves and localized defects. Performance of these three techniques has been compared using signal-to-noise ratio (SNR). Fourier filtering technique has shown better performance for noise reduction while cross-correlation technique has resulted in significant enhancement of signals. Wavelet transform technique has shown the combined capability of noise reduction and signal enhancement and resulted in unambiguous detection of 10% of wall loss grooves and localized defects in the bend regions with SNR better than 7 dB.

Three-Dimensional Finite Element Modeling of Remote Field Eddy Current Technique for Detection of Localized Defects

Three-dimensional finite element (FE) modeling of remote field eddy current (RFEC) technique has been performed to detect localized defects in ferromagnetic steam generator tubes. The excitation frequency, intercoil spacing, and the design of localized receiver coil have been optimized using this model. Amplitude and phase of RFEC signals of radial and axial receiver coils have been predicted for a through hole and two flat bottom holes (FBH). The detection sensitivity of the receiver coils has been compared, and the model has been validated for a few cases.

Influence of sodium deposits in steam generator tubes on remote field eddy current signals

The presence of sodium deposits in defective regions of steam generator (SG) tubes of fast-breeder reactors is expected to influence the remote field eddy current (RFEC) signals. By exposing five SG tubes having uniform wall loss grooves to a sodium environment in a specially designed test vessel, changes in the shape of RFEC signals were observed and it was possible to approximate the volume of sodium deposited in defects. An invariant signal parameter was determined for quantitative characterization of defects despite the presence of sodium in the defects.

Design of encircling remote field eddy-current probe

This paper explains the progress in designing a shielded encircling remote-field eddy-current (RFEC) probe to inspect nuclear fuel rods and investigates resulting signal characteristics. To force electromagnetic energy from the encircling exciter coil to penetrate into the rod, the exciter coil is shielded outside. The effects of the shielding and operating frequency are studied by finite-element analysis and the location for the sensor coil is decided. The sensor coil is also shielded to prevent direct influence from exciter fields. The totally shielded probe dramatically improves signal characteristics. Numerical modeling with the designed probe shows that the phase signal is almost equally sensitive to inner- and outer-diameter defects and there is a linear relationship between phase signal strength and defect depth, which are typical characteristics of RFEC signal.

Remote-field eddy current signal representation : Atherton, D.L.; Mackintosh, D.D.; Sullivan, S.P.; Dubois, J.M.S.; Schmidt, T.R. Materials Evaluation, Vol. 51, No. 7, pp. 782–789 (Jul. 1993)

While conventional reflected impedance eddy current testing (ET) techniques are limited by skin depth considerations to near surface defects, the RFEC (remote field eddy current) technique exploits skin effects. The RFEC method is a through-wall inspection technique. Only the field which has made a double transit of the pipe wall is detected. The skin depth equation can be used to predict the approximate effect of metal loss on the RFEC signal. Metal loss effectively reduces the shielding so that the attenuation and phase lag of the field is less. A method of analyzing RFEC defect signals is therefore to compare the signals with the phase and amplitude in uncorroded pipe. RFEC probes are used for inspecting ferromagnetic and nonferromagnetic tubulars for corrosion and, since eddy current detectors are generally well suited to crack detection, there is considerable interest in their potential to detect stress corrosion cracking in pipelines. Here the authors first of all summarize the impedance plane representation and scope monitor displays customarily used for conventional exploring coil ET probes in tubes. They then present the normalized voltage plane and monitor displays that are most appropriate for RFEC probes. They discuss the similarities and differences between the preferred monitormore » displays.« less

Finite element modelling and physics of remote field eddy current responses for axially aligned cracks

A simplified physical model for two-dimensional (2-D) finite element analysis of axially aligned crack responses for the remote field eddy current (RFEC) technique is proposed. Two formulations are applied to model the problems. Reasonable agreement between calculated results and some preliminary experimental results is achieved. A hypothesis, based on the physical model, is presented. It explains the RFEC signals from axially aligned cracks and makes some predictions of possible features for future verification.< <ETX xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">&gt;</ETX>