Guided Wave Pipe Inspection

and Monitoring System

TAKASHI KUROISHI*1 AKIRA SHIIBASHI*1

NOBUHIKO NISHIMURA*2 FUMITOSHI SAKATA*2
HIROTOSHI MATSUMOTO*2 KIYOTAKA AOKI*2

In recent years a very large number of UT inspections have been performed to detect wall thickness reduction of
feed water pipe, etc. These inspections are accompanied by heat insulation removal and restoration work through-
out the inspection range. In order to enable efficient execution of such a great number of tests, a new method of pipe
damage detection and monitoring has been developed which makes it possible to inspect a long range of pipe with
one sensor, using the ultrasonic characteristics of so-called "guided wave." This new technique has drastically re-
duces the work of heat insulation removal, scaffolding and restoration. This method has also made it possible to
reduce inspection work itself. This report introduces the results of some pipe damage detection tests performed
using the method described above and shows an outline of the application of the system to a thermal power plant.

1. Introduction 2. Role sharing between G-Monitor and UT inspection

In the maintenance of thermal power plant piping sys-
tems dealing with wall thickness reduction of feed water
pipe, etc., a very large number of UT inspections have
been performed in recent years by removing the heat in-
sulation work over the entire testing area and spending
much time and labor. In the meantime, the applicabil-
ity of a long-range testing method using guided wave
has been confirmed in the petrochemical industry in the
United States and this method has already been used
for pipeline, etc.(1) As this technique enables reduction
of the testing cost and provides sophisticated mainte-
nance techniques by structural health monitoring, it
would be used widely for application to piping in ther-
mal power plants, etc. in the future. This report deals
with the guided wave pipe inspection and structural
health monitoring system (G-Monitor) built up through
various verification tests of piping in thermal power
plants. Fig.1 shows the system of the G-Monitor.
The role sharing between G-Monitor and UT inspec-
tion can be better understood by the image of an iceberg
shown in Fig. 2 2. By using conventional UT method, we
can only see part of the iceberg and it is difficult to
image the whole of it. So in a manner of speaking, the
role of the G-Monitor is to figure out the whole picture
of the iceberg, and the role of the UT inspection is to
test in detail the part of the iceberg that is visible above
the water.
Specifically, in the inspection of piping in a thermal
power plant, the G-Monitor is used for detecting dam-
age existing within a pipe length of 5 to 15 meters as a
screening tests and immediately determines the degrees
and positions of such damege. The UT inspection then
performs its main role of carefully investigating each
defect found by the G-Monitor.

(Flat plate inspection case) (Pipe inspection case)

Quantitative
Sensor strip Ultrasonic measurement
Ultrasonic
reflection wave by UT inspection
transmission wave Sensor strip
Defect Defect
Whole picture
screening by
Ultrasonic G-Monitor
Ultrasonic transmission wave
transmission wave

Transducer system
PC

Fig. 1 System of guided wave pipe inspection and monitoring Fig. 2 Image of iceberg whole picture
This system is composed of a sensor comprising pieces of magnetstrictive screening by G-Monitor
strip of Ni, etc. and coils, a transducer system and a PC for controls.

*1 Power Systems Headquarters Mitsubishi Heavy Industries, Ltd.

*2 Nagasaki Research & Development Center, Technical Headquarters Technical Review Vol. 42 No. 3 (Oct. 2005)
1

3. Outline of G-Monitor system
So-called guided wave means the ultrasonic wave
propagated in the axial (longitudinal) direction in the test
specimen. To understand such characteristics, the surge
of a tsunami may be imaged. When the tsunami encoun-
ters a small obstacle, its level rises only a little to override
the obstacle.
On the other hand, its level rises greatly to override a
large obstacle encountered. Such an obstacle may be lik-
ened to a defect and the tsunami water level to the echo
oscillation amplitude. Fig. 1 shows the system of the G-
Monitor, which transmits the guided wave (having such
characteristics) to the pipe. Pieces of strip of a metal such
as Ni are bonded to the outer surface of the pipe using an
adhesive and lead wires are wound on their outer sur-
faces like coils to form a sensor. The guided wave
transmitted from the sensor propagate in the axial direc-
tion of the pipe, and when there is a section area loss in
the pipe due to the existence of a flaw or a wall reduction,
a transmitted wave is reflected from that position. The
distance from the sensor to the damage portion can be
estimated in terms of the round traveling time from sen-
sor through the damaged portionThe size of the area
reduction can be estimated by the echo amplitude of the
reflected wave.
4. Advantages of inspection by using G-Monitor
Fig. 3 shows the advantages of this monitor system.
The sensor to be used consists of pieces of approximately
0.2 mm thick magnetostrictive strip material , an adhe-
sive andcoils. Since total sensor thickness including such
. Inspection can be implemented over a long range
Inspection of a 5 - 15m range is possible.
Sensor installed in a position with scaffolding is
capable of covering positions without scaffolding.
Use for primary damage screening
. Detailed inspection to be performed by UT inspection.
Sensor can be set up easily
. One sensor can be installed in 90minutes.
Environmental protection taken into consideration
One sensor is capable of covering a wide range,
reducing work of heat insulation and waste materials.
MHI is now applying for a patent for this system.
Pipe wound with
pieces of strip of
Fe-Co, etc.
Fig. 3 Advantages of guided wave pipe inspection and
monitoring system
as strips and coils is only approximately 4 mm thick, the
heat insulation can be re-installed easily with the sensor
in place. Therefore, even in locations where scaffolding
for heat removal and restration is required, long time
measurement can be done just installing longer lead
wires. (Measurement is possible without repeating scaf-
fold placement, heat insulation removal and restoration).
Further, since a low frequency guided wave , which
shows low attenuation, is used and the wave is propa-
gated in the axial direction of the pipe for long distance,
damage such as a flaw or corrosion detection within a
5-15 m range from the sensor is possible. Accordingly, it
is not necessary to remove the heat insulation over the
entire range to be tested as in the case of UT inspection.
In other words, inspection can be done just removing the
heat insulation around the sensor installation position,
and spending time for the heat insulation covering and
materials wastage can thus be reduced drastically.
5. Principle of flaw detection by guided wave
Fig. 4 shows the principle of guide wave reflection at
the point where pipe wall thickness loss has been occurred.
The transmitted wave is reflected at the point of acoustic
impedance change that indicates the resistance change in
ultrasonic wave propagation. The acoustic impedance is
expressed by the section area, density and sound velocity
in the material so that when the material and tempera-
ture are the same, the acoustic impedance depends solely
on the section area. Therefore, a reflection wave is gen-
erated where the section area changes. For this reason,
it is also understandable that wall thickness reduction
occurred at both inner and outer surface can be detected
In case of stepped section change
Transmission
Generated
wave wave 1 Acoustic impedance Z
(ultrasonic wave propagation resistance)
= A (section area) (density)
(sound velocity)
A2 2 Ultrasonic wave reflection ratio: R
Reflection A 1 Z 2
wave Z1
R=
Reflection wave
=
Z 1-Z 2
Generated wave Z 1+Z 2
A: Medium section area
Z: Acoustic impedance
In case of gradual change The reflection ratio of guided wave
Generated Transmission changes in response to change in
wave wave the section area.
When wall thickness is reduced, the
reflection ratio takes a positive value.
When it is increased, the ratio takes
a negative value.
Reflection Reflection wave shifts 180 deg.
A1 A2
Z1 wave upon Z2 to reverse the amplitude.
defect detection
Fig. 4 Principle of guided wave reflection at point where wall thickness
is reduced
Reflection wave is generated at a point where wall thickness is reduced as
the acoustic impedance that expresses the ultrasonic wave propagation
resistance changes at such point.
Mitsubishi Heavy Industries, Ltd.
Technical Review Vol. 42 No. 3 (Oct. 2005)
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6. Positions where G-Monitor is capable of performing
measurement
Various verification tests were performed with a view to
applying the G-Monitor to piping at thermal power plants.
Results confirmed that this system is capable of detecting
gradual pipe wall thickness loss as well as flaws in straight
pipe, pipe elbow and pipe diameter reducer. Fig. 5 shows
an example of where in the thermal power plant piping sys-
tem the G-Monitors may be installed. The results of the
various verification tests performed are described below:
6.1 Detection of gradual reduction of pipe wall
thickness
Wall thickness reduction of pipe in service is usually
prone to be in the axial direction. Reduction area detec-
tion tests were performed on pipes artificially simulating
three types of defects: a gradual axial direction wall re-
duction 3 mm in depth and 400 mm in length; 3 mm in
depth and 200 mm in length, and a 3 mm depth notch
like defect. Here, the artificial defects section loss ratio
was 10% in all three specimens. Fig. 6 shows the re-
sults of the measurement tests. Although the echo
amplitude values of the two artificial gradual thinning
areas were approximately half of the value at the the
notch like defect, amplitude due to the reflection from
those two gradual thinning showed twice as high as the
noise. This test results indicates that gradual thinning
can be detected by guided wave inspection

Sensor installation Steam Low-pressure turbine

positions (proposed)
Steam
Boiler Medium-
5 6 High-pressure
Superheater turbine pressure
Water turbine
Reheater 7
Steam Water Condenser
Furnace From feed separator
water pump
Steam mid-step Steam separator drain valve Condensate
Water pump
Economizer Deaerator Water Condensed
Water supply 2 Water water
flow meter heat-exchanger
Water Low-pressure Gland steam
Drain level water heater condenser
regulating valve Condensed
No. 3A No. 8 water
Sensor installation positions 4 No. 3B desalinator
No. 7 Condensed
1 Downstream side of condensed
No. 2B No. 2A Water water booster
water flow meter No. 1B No. 1A No. 6 Condensed pump
2 Downstream side of drain level High-pressure No. 5 water
water heater flow meter
regulating valve x 2
3 Downstream side of water supply 3
Water supply booster pump Water
flow control valve Water supply 1
Water supply pump
4 Downstream side of water supply control valve
flow meter
5 Downstream side of RH spray 6 Downstream side of RH spray flow meter
control valve 7 Downstream side of steam separator drain valve x 3

Fig. 5 Example of G-Monitor installation at thermal power plant

Notch like defect (depth 3.0mm x 3 positions; section loss ratio 10.8%) Measurement result
Reflection from sensor
Gradual thickness reduction 2 Sensor A B-side end surface Notch
(length 200mm x 3 points) like
0.08 defect
Pipe dimension: 114.3 x t 6 Gradual thickness
Amplitude (V)

0.04 reduction 1

-0.04 Gradual thickness

reduction 2
-0.08
Sensor A -0.1
0 0.5 1 1.5
Distance (m)
Sensor B Appearance of gradual thickness loss 1
(length 400 mm, depth 3.0 mm x 6 points; 400 mm 200 mm
Pipe size: 114.3 x t 6
Gradual thickness reduction 1 thickness reduction ratio 10.8%)
(length 400 mm x 3 points) 3 mm
3 mm 3 mm
Fig. 6 Results of defct detection test on pipe with gradual wall thickness Sensor A
reduction in axial direction
Artificial flaws simulating gradual thickness reduction of 400 mm in axial direction Thickness loss more gradual than at point of
length and 3 mm in depth that may be caused to pipe in service can be detected. leakage of pipe in service can be detected.

Mitsubishi Heavy Industries, Ltd.

Technical Review Vol. 42 No. 3 (Oct. 2005)
3
 6.2 Results of checking of defect detection limits
Notch-like artificial flaws were introduced to a
straight pipe, elbow and reducer, and their detectability
limits were verified.
Fig. 7 shows the measurement result of a cut with a
section loss of 1.6% introduced to a straight pipe. The
echo amplitude at the cut point is twice the value of the
noise level of the range subject to measurement. Flaws
of section loss ratios up to 1.6% can thus be detected.
An elbow and reducer with a cut were then subjected
to measurement, and it was confirmed that flaws in the
elbow with section loss of up to 4.2% and flaws in the
reducer with section loss of up to 5.2% could be detected.
6.3 Influences of guided wave attenuation factors
At first it was feared that measurement would hardly
be conducted , because of its high attenuation at the ge-
ometry changing portion like pipe supporting point or
where the pipe configuration changes. Accordingly, vari-
ous measurement tests were performed to make sure the
influences of various attenuation factors.
Fig. 8 shows the result of measurement at the elbow
section. A change was seen in the echo amplitude be-
tween the circumferential weld 1 and the circumferential
weld 2 before and after the elbow section. Approximately
15% attenuation was found, revealing that guided wave
is attenuated in the elbow section.
It was also confirmed as a result of measurement at
the reducer section and the U-rod section that the guided
wave attenuating at the reducer section and the U-rod
section could be ignored.
Fig. 9 shows the positions on the pipe where mea-
surement is possible based on the influences of
attenuation factors found as a result of the measure-
ments performed so far.

The echo amplitude of the cut point is 0.05 V, The amplitude will be attenuated 15% by elbow transmission
which is twice the noise level. (circumferential weld 1 circumferential weld 2).

Circumferential Circumferential
In the case of straight pipe, a cut of 1.6% weld 2 weld 1
in section loss ratio can be detected. Sensor
Sensor 0.5
0.4
Initial noise
Amplitude (V)

Measurement range 0.3

0.2
Cut
introduction 0.1
0.2
point 0
Amplitude (V)

0.1 Noise level 0.025 V -0.1

-0.2
0
-0.3
-0.1 -0.4 Elbow 1
-0.5
-0.2
0 0.2 0.4 0.6 0.8 1 1.2 Upstream -4 -2 0 Downstream
Distance (m) Distance (m)

Fig. 7 Defect detection limit in straight pipe Fig. 8 Elbow section attenuation measurement result
Notch-like cut flaw of 1.6% in section loss ratio can be detected. Guided wave is attenuated 15% by elbow transmission.

[Positions where measurement is possible]

Not measurable
(Dead zone: 1m)
Not measurable Not measurable
(From orifice onwards) (Echo noise)
Measurable Measurable Measurable

Note 1
Note 1 Note 1
Flow Guided wave Guided wave

Detectability is reduced
Orifice Sensor Reducer due to attenuation caused
by elbow transmission.
U-rod (Support) (Note 2) Elbow

(Note 1) Weld sections cannot be measured due to echo noise.

(Note 2) Elbow back surface can be measured. Inner surface is subject to investigation in the future.

Fig. 9 Positions measurable by system available at present

When guided wave passes the elbow, it is attenuated so that positions after elbow transmission are subject to reduced detectability.

Mitsubishi Heavy Industries, Ltd.

Technical Review Vol. 42 No. 3 (Oct. 2005)
4
 6.4 Temperature conditions to enable measurement
The temperature of piping at thermal power plants
rises during operation, and depending on the tem-
perature, monitoring during operation may be
difficult. On the other hand, for practical purposes,
inspection when the plant is on shutdown may be
sufficient, because pipe wall thinning generally pro-
ceeds very slowly.
Therefore, in order to clarify the temperature con-
ditions at which measurement is possible, a high
temperature measurement test using metal strip sen-
sors for high temperature was performed in an
electric furnace. Results confirmed that the sensors
could work efficientlyas long as the pipe temperature
is up to 370 o C.
At present, a long-term durability verification test
is in progress with a view to monitoring while piping
is in operation.
Takashi Kuroishi Akira Shiibashi Nobuhiko Nishimura
5
7. Conclusion and future prospects
We have already reported on a guided wave pipe
inspection and monitoring system intended for appli-
cation to thermal power plants.
This technique drastically reduces the work of heat
insulation removal and restoration which has hitherto
been required for pipe maintenance andmanagement,
and that it is usable as a system that enables pipe
damage detection by monitoring at any time.
We will be very pleased if this report contributes
to maintenance and management of thermal power
plant facilities.
Reference
(1) Takahiro Hayashi, Circumferential Guided Wave Inspec-
tion for a Defect at Inner Surface of a Pipe, ASME-
PVP2004 (2004)
Fumitoshi Sakata Hirotoshi Matsumoto Kiyotaka Aoki
Mitsubishi Heavy Industries, Ltd.
Technical Review Vol. 42 No. 3 (Oct. 2005)