30.12.2021, 18:50 MachMan2011005Grazion fm | Enhanced Reader 191 10526185, our of Machinery Mangacr and Realy, 200, Vo. 4, Ne 1 pp 871-97. Alert Prey ne, 220 aston Tet © fhe tah), 208 pub Prolony MathinattocivaAvomadeaa, 2020, Noh pp I-28 EXPERIMENTAL MECHANICS. DIAGNOSTICS, AND TESTING Experimental Estimation of the Waveguide Effect on the Acoustic Emission Signal Parameters in Monitoring Facilities with a Long Surface Radius of Curvature S. V. Grazion’, M. V. Mukomela’, M. N. Erofeev*, V. V. Spiryagin’, and S. S. Amelin® AO MIT Corporation, Moscow, 127410 Russia * Peter the Great Military Academy of Sirategie Rocket Forces, Ministry of Defense of the Russian Federation, Balashikha, Moscow oblast, 143900 Russia © Blagonravov Institute of Mechanical Engineering, Moscow, 119334 Russia e-mail: erofeevmn®imash.ra Received May 14, 2020; accepted August 14, 2020 Abstract—The experimentally estimated effect ofa waveguide on the acoustic emission signal par eters in the monitoring of high-curvature facilities has been studied. The frequency characteristics of the acoustic emission signals when passing from the pipeline to the waveguide remain almost unchanged, and the attenuation of the acoustic emission signals is no more than 2~3 dB. Keywords: acoustic waveguide, technical diagnostics, acoustic emission, DOK: 10,3103/S1052618820110059 INTRODUCTION ‘The problem of ensuring the safe operation and efficient functioning of complex technical systems and. equipment at hazardous production facilities is of particular importance today. Major deterioration of the basic industrial equipment during the crisis; technical, financial and economic problems related to the replacement of obsolete facilities; and a number of other factors suggest the search for new approaches to solving nondestructive testing and technical diagnostics (NDT & TD) problems. It is necessary to improve the traditional NDT & TD and to create and develop new methods. Not all potential capabilities, of the scientifically developed NDT & TD methods are implemented in reliable, effective, and highly informative control tools, Acoustic emission (AE) is one of the most promising and relatively new NDT & TD methods. It is based on the recording of sound signals emitted during plastic deformation of solid bodies, defect devel- ‘opment, and friction and during passage of liquid and gas through narrow holes called “through defects, ‘This method has a number of advantages that expand the capabilities of TD & NDT. AE isa range of sci- entific models, special technical means, industrial methods, technologies, and approaches that help to prevent the catastrophic destruction of a facility [1] The choice of NDT & TD methods and means for technical diagnostics of specific monitored facilities is based on their defectoscopic processability, the nature of the alleged defects, the method resolution, monitoring efficiency, defect detectability, and reduced costs. The solutions for optimizing the choice of the best option from a variety of alternative nondestructive testing methods in relation to the defect and wear processes of metal structures such as cracks and frac- turing are considered in [2—4]. In terms of the “specific effect,” the acoustic emission is the best, whereas, the capillary method and some special tests are the worst. AE is characterized by the lowest values in terms, of the “specific costs” criterion. The main advantages of AE relative to other NDT & TD methods are as follows: (1) the detectabili of developing defects in the facilities to classify them in terms of their danger degree; (2) the high sensi to growing defects; (3) the remotability which makes it possible to monitor the facilites at a significant om _chrome-extensionsidagemkpagihakldhnbomgmdpkchitienhanced:-reader himIopenApp&pat-hlins%43A%2F%42Flink springer.com¥s2Fcontent.. 1/1030.12.2021, 18:50 MachMan2011005Grazion fm | Enhanced Reader on GRAZION et al. distance from the operator: in contrast to other methods, the AE system is able to cover fully long strue~ tures, main pipelines, hard-to-reach facilities, ete Each AE system consists of AE transducers; preamplifiers and main amplifiers; signal identification and processing tools, including threshold devices, devices to measure AE signal parameters, recording and reporting equipment; and controllers. The set of components, such as the AE transducer (AET) as a cable connecting AET with the pream- plifier; the cable connecting the preamplifier to the main unit, and the main amplifier—AE signal process ing units, form the AE channel, Despite constant improvements in the acoustic emission equipment, the AE piezoelectric transducer is still a major acoustic wave detector [5]. The main purpose of AET is to receive an AE acoustic signal and to convert it into an electrical signal the parameters of which are used to assess the technical status. The AET specifications and parameters have a fundamental effect on the parameters of the AE electrical signals. When monitoring industrial facilities, AETs transform signal parameters and thereby significantly affect the reliability of AE monitoring and interpretation results. The AET requirements are established depending on the monitoring objectives and conditions. The correct use of AETs plays an important role in solution of the issues related to practical use of AE in monitoring the production facility. The experience of using AE in production and the estimated effect of the contact layer on the AE mon- itoring results [6] are indicative of the fact that when installing AET and providing the acoustic contact, the following is necessary: (1) to choose the type of acoustic contact based on the following conditions: temperature, accessibility, surface radius of curvature, chemical compatibility with a facility, stability over time, radiation load, and acoustic matching; (2) to prepare the AET installation site so as to avoid breaking the acoustic contact; it is necessary to ensure a surface roughness of not lower than Rz40 taking into account its curvature; (3) fo choose a contact medium that ean provide minimum losses in the wave trans- mission from a facility to AET. Great difficulties with providing the acoustic contact arise when installing AET at various facilities [7], in particular, at those with a long radius of curvature (pipelines of refrigeration and compressor units, air~ craft, ete.). In the 26—20 mm pipelines, even when installing a GT200 AET (outer 16 mm), the contact surface is almost a line. The danger of absence or loss of the AET acoustic contact with the monitored facility (MF) surface in the course of the AE monitoring makes the operator periodically monitor the AE channel operability during the testing. As a result, it becomes impossible to carry out the AE control, or Work deadlines are delayed, or the additional AE control becomes occasionally needed. One of the basic ways to solve this problem is to use the acoustic waveguides which make it possible to expand significantly the AE area of application when monitoring facilities with a long radius of curvature. Ina broad sense, the wavewuide is understood as an artificial or natural channel capable of supporting the propagating waves the fields of which are concentrated within the channel or in the area adjacent to it. ‘The underground pipes that distribute AE stress waves from the AE generation source to the control point can serve as the simplest example of the waveguide [8]. The waveguide can be estimated by the analysis of ‘waveguide delay lines used in radar and sonar technology. DEVELOPMENT OF THE EXPERIMENTAL SETUP TO ASSESS THE WAVEGUIDE EFFECT ON THE AE SIGNAL PARAMETERS The operating element of the waveguide for the monitored facility with a high surface curvature (a vari- ant of the operating element of the waveguide is shown in Fig. 1) should have the following parameters: ‘ris equal to the inspected pipeline radius; ¢ is not less than r; a is based on the size of the installed AETs, their number, and the attachment method (magnetic, mechanical, etc.); 6 defines the contact zone of the ‘waveguide with the pipeline, and it should reach at least an acoustic wave length that is based on the mon- itoring frequency range and the propagation velocity of ultrasonic vibrations in the pipeline; A is no less than the wall thickness of the controlled pipeline, A possible type of the clamping element of the waveguide for MF with a high surface curvature isshown in Fig. 2. The size of this clamping element is based on the way it is attached to the main element of the ‘waveguide. It can be attached using bolted connections, clamps, ete Figure 3 shows the waveguide without a clamping element and with two operating elements, made in the form of a “clothespin.” The waveguides should be made ofa material that is similar to that of the MF ora material that is sim- ilar in its acoustic properties to that of the MF. JOURNAL OF MACHINERY MANUFACTURE AND RELIABILITY Vol. 49 No. 11 _chrome-extensionsidagemkpagihakldhnbomgmdpkcitienhanced:-reader himI?openApp&patshlins%43A%2F%42Flink springer. com¥2Fcontent... 2/1030.12.2021, 18:50 MachMan2011005Grazion fm | Enhanced Reader EXPERIMENTAL ESTIMATION OF THE WAVEGUIDE EFFECT 973 Fig 1. A variant ofthe operating element of the waveguide, Fig. 2. The clamping clement ofthe waveguide. Spring ru ye Fig. 3. The waveguide without a clamping element. ‘A waveguide that can be used when inspecting the pipelines with an outer diameter of 6 and 8 mm was made to estimate experimentally the waveguide effect on the AE signal parameters in the facility monitor- ing. The basic parameters of the waveguide were selected on the basis of the following conditions: (1) mon- itoring frequency range of 10-300 kHz; (2) use of DRIST and DR61 AETs; (3) the average velocity of the waves recorded by AET is about 3000 m/s; (4) the MF is a pipeline made of 12X18HI0T in accordance with GOST 9941 [9]. Based on these conditions, the wavelength will be in the range of 1.6 em. The AET specifications are given in Table 1. Magnetic clamps are used to fasten AET. The clamp spec- ations are given in Table 2. MF isa pipeline 6 1.5, I2XISHI0T, GOST 9941-81. The waveguide parameters were determined on the basis of the data reported: r= 6, 8 mm; 70 mm; 6 = 60 mm; and f= 4 mm. The waveguide made is shown in Fig. 4. The experimental waveguide effect on the AE signal parame- ters was studied by changing the estimated parameters (amplitude—frequency of the waveguide, attentia- tion, etc.) of the acoustic pulses that passed through the waveguide, which were set by the Su-Nelson acoustic pulse simulator. The waveguide is installed on the pipeline 6 * 1.5, I2XISHIOT, GOST 9941-81, through an acousti- cally transparent lubricant (Fig. 5). 6mm; JOURNAL OF MACHINERY MANUFACTURE AND RELIABILITY Vol.49 No.1 2020, _chrome-extensionsidagemkpagihakldhnbomgmdpkcitienhanced:-reader himI7openApp&patshlins%43A%2F%42Flink springer. com¥2Fcontent... 3I1030.12.2021, 18:50 MachMan2011005Grazion fm | Enhanced Reader om GRAZION et al. Specification Value Designation MG-144 Type Magnetic Dimensions, mm 35% 70 Weight, ¢ 200 Clamping force, N 20 Table 2. Clamp specifications for DR AETs Sensor type DROIAT DRISIAT. Specifications Resonant frequency number, KHz 60 150 Operating frequency range, kHz 30-120 75-300 ILA amp. coef., dB 34 4 Power voltage, V 5 15 Dimensions without cable (diameter/height), mm 28x 38 28x 32 Weight, ¢ 100 90 Material ofthe protector Ceramics Design Sealed Table 3. Frequency range of signals exceeding 80 dB when simulating AE signals in the waveguide and the pipeline Ar sunal simu Signal frequency range >80 dB, KHz AE signal simulating point : ae DRISI DR6L Wavewuide, point 0 0-280 20-170 Pipeline, point / 43260 20-176 EXPERIMENTAL ESTIMATES OF THE WAVEGUIDE EFFECT ON THE AE SIGNAL PARAMETERS FOR MF WITH A HIGH CURVATURE AND DISCUSSION The AE signals were simulated in the waveguide (noint 0) and the pipeline at the point located at a dis- tance of 100 mm from the waveguide (point 7), Eight simulations were carried out at each point, DRISIAT and DROIAT AETs with an AC-14A acoustic emission system were used at the following basic setup parameters: frequency range 10-300 kHz, amplification 34 dB, and threshold 40 dB. Figures 6-9 show the amplitude, pulse duration, number of oscillations, and energy parameter [10] (SL, area under the signal, 1V us) of the recorded AE signals during the simulation in the waveguide (0-60 s) and the pipeline (125—185 5) for (a) DRISIAT and (b) DR6IAT AETS, Fig. 4. The waveguide design: (1) operating element; (2) clamping element; (3) attaching node. JOURNAL OF MACHINERY MANUFACTURE AND RELIABILITY Vol. #9. No 112020 _chrome-extensionsidagemkpagihakldhnbomgmdpkchitienhanced:-reader himIopenApp&pathlins%43A%2F%42Flink springer.com¥2Fcontent.. 4/1030.12.2021, 18:50 MachMan2011005Grazion fm | Enhanced Reader EXPERIMENTAL ESTIMATION OF THE WAVEGUIDE EFFECT 975 cH Signals 100 90 80 70 60 50 40 30 2 10 10 O) 20 30 40.5060 70 80 90 100 110 120 130 140 150 160 170 180 190 200, A,B ys Ts cH 0 1 20-30 40-30-60 70 80 90 100 TIO 120 130 140 150 160 170 10 190-200 Fig. 6. The amplitude of the recorded AE signals when simulated inthe waveguide (060) and the pipeline (12 () DRISIAT AET; (b) DROIAT AET. A,dBvs T,s 185): Figure 10 shows variations in (a) the average amplitude, (b) pulse duration, (c) number of pulses, and (a) energy parameter based on the results of processing eight simulations. When the AE signals pass from the pipeline to the waveguide (Fig. 10) the signal parameters change as follows: the amplitude decreases slightly by 1.01 times for DRISIAT and by 1.003 times for DROIAT; the pulse duration inereases by 4.6 times for DRISIAT and by 3.5 times for DROIAT: the number of pulses increases by 4.2 times for DRISIAT and by 4.7 times for DROIAT: and the puise force increases by 2.4 times for DRISIAT and by 2.7 times for DROLAT. The higher number and duration of pulses are likely due to a repeated signal re-reflection from the end surfaces of the waveguide and an occasional signal overlapping. The pulse force (J1V is) increases because itis directly proportional to otherabove-mentioned param- ters; only the amplitude decreases slightly, whereas other parameters increase considerably. JOURNAL OF MACHINERY MANUFACTURE AND RELIABILITY Vol. 49 No. 11 amo _chrome-extensionsidagemkpagihakldhnbomgmdpkcitienhanced:-reader himIopenApp&patshlins%43A%2F%42Flink springer. com¥2Fcontent... Si1030.12.2021, 18:50 976 Signals 45000} 40000] 35000 30000 25000 20000] 15000| 10000 | or | Lata MachMan2011005Grazion fm | Enhanced Reader GRAZION et al. @ CHL Signals 45000; 40000] 35000 30000 25000 20000 15000| 0000 | 00 F | ) 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190200 DyysvsT.s cH 1 0 1020 Fig. 7. The duration ofthe recorded AE signals when simulated in the waveguide (060s) and the pipeline (125-185 () DRISIAT AET; (b) DROIAT AET. Signals 3200 2800 2400 2000 1600 1200 800 mH Lala 10 40-30 60 70 80 90 100110120 130140150160170 180190200 @ Diss Tes 0 10 20 30 40 50 60 70 80 90 100110 1201 Signals 3200 2800 2400 2000 1600 1200 800 400 «) 30 140 150 160 170 180 190 200 cH Cus Ts 0 10-20-30 4030 60 70 80 90 100 110 120 130 140 150 160 170 180190200 Cvs Ts Fig. 8. The number of pulses ofthe recorded AE signals when simulating nthe waveguide (0-60) and the pipeline (125 188): (a) DRISIAT AET: (0) DRGIAT AET. JOURNAL OF MACHINERY MANUFACTURE AND RELIABILITY Vol. 49 No.1 2020 _chrome-extensionsidagemkpagihakldhnbomgmdpkcitienhanced:-reader himIopenApp&patshlins%3A%2F%42Flink springer. com¥2Fcontent.. 8/1030.12.2021, 18:50 MachMan2011005Grazion fm | Enhanced Reader EXPERIMENTAL ESTIMATION OF THE WAVEGUIDE EFFECT om Signals oh ® $321 cut Boer 18 oer 382 Bost 38e7 det ise Sieo | 0 10 20 30 40 50 60 70 BO 90 100 110 120 130 140 130 160 170 180 190.200 EVs Ts Signals i 7067 ©) ae 10 20-30 40 50 GO 70 80 90 100 110 120 130 140 150 160 170 180 190 200 E,W sys Ts Fig. 9. The energy parameter ofthe recorded AE signals when simulated inthe waveguide (060) and the pipeline (125 188): (a) DRISIAT ABT: (b) DRGIAT AET. Pulse duration, ps Amplitude, &B @ oe DRISIAT 94. v fo 1 Points Points Energy parameter, nV ps W-e7 Number of pues, nes 6 0p PE " @ SuT37s 2000 ; 1500 + 3.65625 1000 3g a 1 ° 1 Poims Points Fig. 10. Variations inthe parameters of the recorded AE signals when simulated inthe waveguide (060 s) and the pipe Tine (125185 5): (@) DRISIAT ABT: (b) DR6IAT AET. (a) Amplitude; (b) pulse duration; (e) number of pulses, (G) energy parameter, (rhom) DRISIAT ABT; (square) DR6IAT AET, JOURNAL OF MACHINERY MANUFACTURE AND RELIABILITY Vol. 49 No. 112020 _chrome-extensionsidagemkpagihakldhnbomgmdpkcitienhanced:-reader himIopenApp&pathlins%43A%2F%42Flink springer. com¥2Fcontent.. 7/1030.12.2021, 18:50 MachMan2011005Grazion fm | Enhanced Reader o78 GRAZION et al. 4B Channel| 100 A Sol amar ape i. Ayano TW cern ene Oy 40 80 120 160-200-240 280320 360 400 440480 ae kHz BCom y we My wy pane op! My MIN unndran nd 0 0 40-80-1060 200240 «280 «320 360M) KHz Fig. 11. Signal spectra recorded with a DRISI AET during the simulation: (a) inthe waveguide; (b) inthe pipetine. a ‘Channel 2 of WW. Wye a wy Pal Ia col a OT kHz B Channel ! a eh op 40 0 pron ND agate 4 80-20 160 200 240 «28 320-300 «40040. AND kHz, Fig. 12, Signal spectra recorded with a DR6I AET during the simulation: () in the waveguide: (b) in te pipeline. The signal spectra were also recorded when simulating the AE signals at points /and 2. Figures |aand 1b show the signal spectra recorded by DRISI AET during simulation in the waveguide and the pipeline. Figures 12a and 12b show analogous graphs for DR6I AET. According to the spectra analysis results, the signal frequency range exceeding 80 dB remains almost unchanged (Table 1). The signal range above 80 dB was selected based on the recommendations ofthe PB. (03-593-03 safety rules [11] CONCLUSIONS The AE signal frequency remains almost unchanged when passing from the pipeline to the waveguide. ‘The AE signal attenuation is no more than 2—3 dB when passing from the pipeline to the waveguide. The pulse duration, number of pulses, and pulse force increase when using the waveguide with a given des The waveguides make it possible to carry out the AE monitoring of MF with a high surface curvature. ‘When selecting the signal parameters used to assess the hazard level of AE sourees, il is necessary (0 esti- mate the waveguide effect on the signal parameters. CONFLICT OF INTEREST ‘The authors declare that there is no conflict of interest JOURNAL OF MACHINERY MANUFACTURE AND RELIABILITY Vol. #9. No 112020 _chrome-extensionsidagemkpagihakldhnbomgmdpkchitienhanced:-reader himIopenApp&pat-hlins%43A%2F%42Flink springer.com¥2Fcontent... 8/1030.12.2021, 18:50 MachMan2011005Grazion fm | Enhanced Reader EXPERIMENTAL ESTIMATION OF THE WAVEGUIDE EFFECT 979 REFERENCES 1. Ivanov, VL and Viasov, LE., Aeoustc Emission Method, vol. 7 of Non-Destructive Testing: Handbook, Kiyuev, WV. Ed., Moscow: Mashinostroenie, 2005, 2. Gnevko, A.L., Assessment of technical objects operating under pressure without their dismantling, Teklmadzor, 2016, no. 2, p. 100, 3. Kabanov, B.S., Sokolov, V.L., Gomera, \VP., and Fedorov, V.P., Experience of using the acoustic emission method for monitoring pressure vessels, Kir. Tekh, 2011, no. 4, p. 12. 4, Chmykhalo, A.I., Medelyacv, ILA., Erofeey, M.N., and Pankin, D.A., Technical and economic assessment of the technique of technical diagnostics of metal structures of a heat exchanger using the acoustic emission method, Sb. nauch. trudov XXXVI Vserossivskoy NTK «Problemy effektivnost | bezopasnost funkisionirovaniva sloghnykh tekhnicheskikh 1 informaisionnykh sisiem» (Proc. XXXVIL All-Russian Scientifié and Technical Conference “Problems ofthe Erficieney and Safety of Functioning of Complex Technical and Information Systems”), Ser- pukhov, 2018, part 5, Beattie, A.G., Acoustic Emission Non-Destructive Testing of Structures Using Source Location Techniques. Report, Albuquerque, NM, 2013. 6. Ryaboy, A.N., Ivanov, ViI., Kuranov, VL, and Tsarev, K.K., Distribution of acoustic emission signals by load during the development of a fatigue crack, Defekroskopiv, 1983, no. 4, p. 93. 7. Jiangong Li, Research on the application of acoustic emission intelligent monitoring and early warning technol- ‘ogy for the éoal-rock dynamic disasters in underground mining faces, JOP Conf. Ser: Earth Environ. Sci., 2020, vol. 526. 8. Smith, A., Neil, D.,and Gary, F., Monitoring buried pipe deformation using acoustic emission: Quantification ofattenuation, Tat. J. Geotech. Eng., 2017, vol. II, no. 4, p. IB, 9. GOST (State Standard) 9941-81: Seamless Cold- and Heat-Deformed Pipes Made of Corrosion Resistant Steel Technical Conditions. 10. AC-14A Operation Manual AM109.0104,00.006RE. IL, RD 03-593-03 Rules for the Organization and Conduct of Acoustic Emission Control of Vessels, Apparatus, Boilers, and Process Pipelines. Translated by E. Maslennikova JOURNAL OF MACHINERY MANUFACTURE AND RELIABILITY Vol.49 No.1 2020, _chrome-extensionsidagemkpagihakldhnbomgmdpkckitienhanced:-reader himI7openApp&pathlins%43A%2F%42Flink springer. com¥2Fcontent... 9i1030.12.2021, 18:50 MachMan2011005Grazion fm | Enhanced Reader chrome-extension:idagem&pagithakfdhnbomgmidpkckifenhanced-readerhtmi?openAppSpdf=htos%3A%2F%2Flink springer.com%2Fconten.... 10/10