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Circumferential Crack Detection in Ultra-High-Pressure Tubular Reactors with Pulsed Eddy Current Testing
Yaxing Wang1, Jie Sun2, Huasheng Hu2
1Key Laboratory of Nondestructive Testing, Ministry of Education, Nanchang Hangkong University, Nanchang 330063, China.
Sensors (Basel, Switzerland)
|October 26, 2024
Summary
This study developed a pulsed eddy current differential probe to detect circumferential cracks in ultra-high-pressure tubular reactors. The probe effectively identified cracks even with a protective layer, enhancing safety in polyethylene production.
Area of Science:
- Materials Science
- Non-destructive Testing
- Chemical Engineering
Background:
- Ultra-high-pressure tubular reactors are vital for polyethylene production but susceptible to circumferential cracks under harsh operating conditions.
- Detecting these cracks is difficult, especially when obscured by protective layers, posing significant safety risks.
- Existing detection methods may lack the sensitivity or specificity required for these challenging environments.
Purpose of the Study:
- To design and validate a pulsed eddy current differential probe for detecting circumferential cracks in ultra-high-pressure tubular reactors.
- To investigate the probe's performance under varying lift-off distances, simulating protective layers.
- To compare the effectiveness of semi-circular versus traditional cylindrical excitation probes in crack detection.
Main Methods:
- Finite element simulations were used to model detection probes and analyze eddy current field distribution.
- Experimental validation was performed under various lift-off conditions to verify simulation accuracy.
- The designed pulsed eddy current differential probe was tested for its ability to detect cracks of specific dimensions.
Main Results:
- The semi-circular excitation differential probe showed greater sensitivity to crack-induced disturbances compared to the cylindrical probe.
- The developed probe successfully detected 20 mm-long circumferential cracks at a lift-off distance of 60 mm.
- Detection coverage in the axial direction was found to be dependent on the lift-off height.
Conclusions:
- The designed pulsed eddy current differential probe is effective for detecting circumferential cracks in ultra-high-pressure tubular reactors, even with protective layers.
- The study validates the use of finite element modeling for probe design and performance prediction.
- Findings offer a valuable advancement for ensuring the safety and integrity of critical industrial equipment.
