Magnetic Flux Leakage techniques for detecting corrosion of pipes

Abstract

Oil and gas pipelines are subjected to corrosion due to harsh environmental conditions as in refinery and thermal power plants. Interesting problems such as internal and external corrosion, emerging from the increasing demand for pipeline protection have prompted this study. Thus, early detection of faults in pipes is essential to avoid disastrous outcomes. The research work presented in this thesis comprises investigations into the use of magnetic flux leakage (MFL) testing for pipe in extreme (underwater and high temperature) conditions. The design of a coil sensor (ferrite core with coil) with a magnetic circuit is carried out for high temperature conditions. The sensor thus developed lays the ground for non-destructive evaluation (NDE) of flaws in pipes through the MFL technique. The research focusses on the detection and characterization of MFL distribution caused by the loss of metal in ferromagnetic steel pipes. Experimental verifications are initially conducted with deeply rusted pipe samples of varying thicknesses in air. AlNiCo magnets are used along with Giant Magneto Resistance (GMR) sensor (AA002-02). The experiment is further repeated for saltwater conditions in relation to varying electrical conductivity with radio frequency identification (RFID) technique. A further study carried out in the research is the correlation between magnetic and underwater data communication. The study has resulted in the development and experimental evaluation of a coil sensor with its magnetic response at room and high temperatures. This makes the system effective under high temperature conditions where corrosion metal loss needs to be determined