16th FPSO Forum

The Welding Institute - 25th October 2005

Crack Detection in Hull Structures by

Acoustic Emission Monitoring

Len Rogers and Jack Still

Benefits of an in-service Acoustic Emission

based inspection strategy

Enhance safety and operational reliability by providing

100% volumetric inspection of the critical structural
elements predicted by the statutory Fatigue Design
Assessment (FDA)
Detect crack initiation and rate of growth while the
vessel is in service
Intervene only when significant acoustic emission hot
spots are detected.
Schedule remedial work to minimise service disruption

There now exists:

Fundamental understanding of the mechanics
of crack growth on a micro-scale, as the basis
for the interpretation of AE results.
Industry standard intrinsically safe equipment
and distributed processing for cost effective
installation
AE detection algorithms with a proven record
of reliability on offshore installations.
Standards for the measurement and
interpretation of results and the qualification
of personnel

Comparison of Magnitude 4 events on the

Richter and AE Event Magnitude Scales.
Parameter

Seismic
event

Acoustic
event

fracture event area

100m x 100m 100m x 100m

fracture velocity

500m/s

250m/s

characteristic time

0.2sec

0.4s

characteristic freq.

2.5Hz

1.25MHz

wavelength (press.)

2km

4mm

Microstructure of a fatigue crack in a

medium strength steel

Threshold stress intensity factor for

crack growth Kth

If the initial defect can create a stress intensity at the crack tip
such that = y (the yield strength) at r = l (the threshold plastic
zone size for local fracture instability), then the crack will
propagate in steps l given by

Kth y( l ) E( d1).

Calculated alternating stress intensity factor K as a

function of cycles to failure for a ferrite-pearlite steel

Mechanics of fracture on a micro-scale

Under cyclic stress clusters of atomic imperfections occur at
intervals given by:
typically 10m
x 4m2cl2d13/3h3
The strain hardened zone grows by this plastic deformation
process to its threshold size given by:
typically 100m
l d1E2 / y2
At this point the crack advances suddenly through the
embrittled zone with velocity:
typically 250m/s
vf (u/)
Each crack jump is accompanied by acoustic emission with
characteristic frequency given by:
typically 1.25MHz
c = vf /2l
and stress-wave amplitude given by:
ui(r)|max = (3/64) / rciE

Longitudinal (pressure) and transverse (shear)

wave lobes from a micro-fracture event
Scruby and Wadley have produced the
following analytical solutions for the
displacement amplitudes of the transverse
and longitudinal stress-waves in a half
space at distance r from a micro-fracture
event of area a :

ui(r)|max = (3/64) / r ci E
where P = y a vf is the Acoustic
Power of the explosive micro-fracture
event (watts).

Relationship between acoustic emission activity and

change in crack area for medium strength steel.
V (e) (Volts)
1.E+06

1.E+05

j= n

V (e)
j =1

= 0.25 a

where a is in mm 2

1.E+04

1.E+03

1.E+02

1.E+01

1.E+00

Minimum Detectable
Fatigue Crack is typically
10mm 1mm using a
detectability '' of 30dB

1.E-01

1.E-02
1.E-01

1.E+00

1.E+01

1.E+02

1.E+03

1.E+04

1.E+05

1.E+06
2
a (mm )

Determination of crack status from the change

in crack area estimated from the AE power.

AE data base on fatigue in full scale node

joints simulating North Sea wave loading

Typical acoustic emission signals at different

distances from the source event in a tubular
steel node joint

2nd HIT SENSOR

3rd HIT SENSOR

4th HIT SENSOR

1st HIT SENSOR

AE amplitude distributions at
different stages of crack growth

Grading the sources of AE

according to signal amplitude.

Industry standard black box AE and Strain

data acquisition unit.

Illustration of the use of coarse and fine resolution delta-T

space filters to resolve crack growth and fluid noise

Location of AE sources from a fatigue crack in an

access window measured at different times (a) in
plan and (b) projected onto the weld line

Why use Acoustic Emission Monitoring

on Offshore Structures?

Case Study 1 - fatigue crack detection in jack-up

and floating production platforms
Global surveillance of
critical load path areas
e.g. complete leg segments,
leg-hull locking supports
and leg-spud can
connections
Monitoring during jacking,
towing and operation
An in-service measure of
physical damage in terms of
increase in crack growth
area.

Close-up of sub-sea AE sensor

AE Installation on a Steel Tower Structure

AE sensors attached to a node joint

The installation of AE and strain sensors on the inside of a

subsea tubular brace of a floating production unit

Typical tanker hull with acoustic emission

sensors installed at fatigue sensitive areas.
Data acquisition unit
located in wheel house
or control room

Potential sites for

fatigue cracks
Signals related
to monitoring
station

Satellite dish
to relay data for
further evaluation

Location of acoustic
emissions sensors

Tanker hull structure

Bulkhead

Moonpool

Mooring system

FPSO turret

Case study 2: Sensor positions A, B, C and D

on a crane slewring bearing

AE generated from damaged inner raceway as it passed

through the load zone at low speed (clock pos. 5 to 6)

LR Innovative Technology

In Conclusion: Acoustic
Emission Monitoring Offers
Remote
non-invasive
Enables
you to:

inspection

Continuous global surveillance

Hear cracks propagating anywhere in the structure.
Response to fatigue and SCC cracks
Determine
their
structural
significance
using real time information
Location
and
severity
of cracks
supplied by the structure.
A means of reducing uncertainty in
Benefit
years of experience in acoustic engineering
crackfrom
life20prediction
applications.
Ability to determine when to intervene
to minimise maintenance costs