INTERNAL SURFACE PIPE ROUGHNESS CLASSIFICATION USING HIGH FREQUENCY ACOUSTIC EVALUATION

Transcription

1 INTERNAL SURFACE PIPE ROUGHNESS CLASSIFICATION USING HIGH FREQUENCY ACOUSTIC EVALUATION AMAR REZA BIN MOHAMMAD FIRDAUS BACHELOR OF ENGINEERING UNIVERSITI MALAYSIA PAHANG 2010

2 AMAR REZA BACHELOR OF MECHANICAL ENGINEERING 2010 UMP

3 UNIVERSITI MALAYSIA PAHANG BORANG PENGESAHAN STATUS TESIS JUDUL: Saya INTERNAL SURFACE PIPE ROUGHNESS CLASSIFICATION USING HIGH FREQUENCY ACOUSTIC EVALUATION SESI PENGAJIAN: 2010/2011 AMAR REZA BIN MOHAMMAD FIRDAUS ( ) (HURUF BESAR) mengaku membenarkan tesis (Sarjana Muda/Sarjana /Doktor Falsafah)* ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut: 1. Tesis adalah hakmilik Universiti Malaysia Pahang (UMP). 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) TIDAK TERHAD Disahkan oleh: (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA) Alamat Tetap: NO 41 JALAN 24 MOHD HAFIZI BIN ZOHARI TAMAN SERAYA AMPANG ( Nama Penyelia ) SELANGOR Tarikh: Tarikh: CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali tempoh tesis ini perlu dikelaskan sebagai atau TERHAD. Tesis dimaksudkan sebagai tesis bagi Ijazah doktor Falsafah dan Sarjana secara Penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM).

4 UNIVERSITI MALAYSIA PAHANG FACULTY OF MECHANICAL ENGINEERING We certify that the project entitled Internal Surface Pipe Roughness Classification Using High Frequency Acoustic Evaluation is written by Amar Reza Bin Mohammad Firdaus. We have examined the final copy of this project and in our opinion; it is fully adequate in terms of scope and quality for the award of the degree of Bachelor of Engineering. We herewith recommend that it be accepted in partial fulfillment of the requirements for the degree of Bachelor of Mechanical Engineering. CHE KU EDDY NIZWAN CHE KU HUSIN Name of Examiner Signature

5 i INTERNAL SURFACE PIPE ROUGHNESS CLASSIFICATION USING HIGH FREQUENCY ACOUSTIC EVALUATION AMAR REZA BIN MOHAMMAD FIRDAUS Report submitted in partial fulfillment of the requirements for the award of the degree of Bachelor of Mechanical Engineering Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG DECEMBER 2010

6 ii SUPERVISOR S DECLARATION I hereby declare that I have checked this project and in my opinion, this project is adequate in terms of scope and quality for the award of the degree of Bachelor of Mechanical Engineering. Signature : Name of Supervisor : MOHD HAFIZI BIN ZOHARI Position : LECTURER Date :

7 iii STUDENT S DECLARATION I hereby declare that the work in this project is my own except for quotations and summaries which have been duly acknowledged. The project has not been accepted for any degree and is not concurrently submitted for award of other degree. Signature : Name : AMAR REZA BIN MOHAMMAD FIRDAUS ID Number : MA08003 Date :

8 viii TABLE OF CONTENTS SUPERVISOR S DECLARATION STUDENT S DECLARATION ACKNOWLEDGEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF SYMBOLS LIST OF ABBREVIATIONS Page ii iii v vi vii viii xi xii xv xvii CHAPTER 1 INTRODUCTION 1.1 Introduction Problem Statement Objectives Scope of the Project Important of the Study 3 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction Basic Component of Piping System Flow Analysis in Pipe Roughness of Pipe Corrosion in Pipe Uniform Corrosion Galvanic Corrosion Pitting Corrosion Crevice Corrosion Intergranular Corrosion 13

9 ix 2.6 Acoustic Emission (AE) Method Type of Acoustic Emission Sources of Acoustic Emission in Friction Acoustic Emission Signal Features Operation of Acoustic Emission System Acoustic Emission in Pipe Advantages of Acoustic Emission Technique Nondestructive Techniques (NDT) Eddy Current Testing Radiography Testing Ultrasonic Testing Comparison of NDT Methods Previous Research 26 CHAPTER 3 METHODOLOGY 3.1 Introduction Project Flow Chart Gantt Chart Test Rig and Tools Preparation Instrumentation of Acoustic Emission System Experimental Procedures Acoustic Emission Measurement Flow Rate Measurement Surface Roughness Measurement 42 CHAPTER 4 RESULTS AND DISCUSSION 4.1 Introduction Test Results Fluid Flow Through Smooth Pipe with Four Different 45 Pressures Fluid Flow Through Rough Pipe with Four Different 47 Pressures Comparison between Smooth Pipe and Rough Pipe Water Flow Rate and Reynolds Number in Several 50 Pressure Inlets Surface Roughness 51

10 x 4.4 Discussion Precaution Steps Determine the Sources of Acoustic Emission Signal Pipe Roughness Classification Comparison between Bangi Number with Surface 60 Roughness CHAPTER 5 CONCLUSION 5.1 Conclusion Recommendations 63 REFERENCES 65 APPENDICES 68 A1 Data RMS Values for Smooth Pipe at Pressure 1.8 bar 68 A2 Data RMS Values for Smooth Pipe at Pressure 1.6 bar 69 A3 Data RMS Values for Smooth Pipe at Pressure 1.4 bar 70 A4 Data RMS Values for Smooth Pipe at Pressure 1.2 bar 71 A5 Data RMS Values for Rough Pipe at Pressure 1.8 bar 72 A6 Data RMS Values for Rough Pipe at Pressure 1.6 bar 73 A7 Data RMS Values for Rough Pipe at Pressure 1.4 bar 74 A8 Data RMS Values for Rough Pipe at Pressure 1.2 bar 75 B Hydraulic Bench 76

11 xi LIST OF TABLES Table No. Title Page 2.1 Basic component of piping system Equivalent roughness values for new commercial pipes Sources of AE signals at friction The advantages and disadvantages of other selected NDT methods Average RMS (V) values for internal smooth pipe surface Average RMS (V) values for internal rough pipe surface Water flow rate and Reynolds number in several pressure inlets Surface roughness values for smooth pipe and rough pipe Bangi Number for smooth pipe Bangi Number for rough pipe Bangi Number, AB indication for rough and smooth pipe 63

12 xii LIST OF FIGURES Figure No. Title Page 2.1 Laminar and turbulent flow Uniform corrosion Galvanic corrosion Pitting corrosion Crevice corrosion Intergranular corrosion Basic principles of acoustic emission technique Continuous AE signal Discrete AE signal AE signal features Schematic diagram available in organizing a basic acoustic emission 19 testing system 2.12 Transducer Basic principles of eddy current inspection Basic principles of radiography inspection Basic principles of ultrasonic inspection Project flow chart Experimental architecture Test rig setup Smooth pipe and rough pipe Pipe joint integrated with pressure indicator Sensor attachment on pipe AED-2000V virtual instrument 37

13 xiii 3.8 Integral preamp AE sensor Grease Computer with built-in ADC card and acoustic emission detector 38 software version Acoustic emission detector software version Valve controller Channel setting Sampling setup Volume water indicator Perthometer RMS values for smooth pipe at each pressure inlet RMS values for rough pipe at each pressure inlet Fluid flow through smooth pipe with four different pressures Fluid flow through rough pipe with four different pressures Fluid pressure 1.8 bar flow through smooth pipe and rough pipe Fluid pressure 1.6 bar flow through smooth pipe and rough pipe Fluid pressure 1.4 bar flow through smooth pipe and rough pipe Fluid pressure 1.2 bar flow through smooth pipe and rough pipe Appearance of smooth inner surface pipe Appearance of rough inner surface pipe Comparison roughness average between smooth pipe and rough pipe Comparison mean roughness depth between smooth pipe and rough 53 pipe 4.13 Bangi Number when pressure 1.8 bar over 1.6 bar Bangi Number when pressure 1.8 bar over 1.4 bar Bangi Number when pressure 1.8 bar over 1.2 bar 58

14 xiv 4.16 Bangi Number when pressure 1.6 bar over 1.4 bar Bangi Number when pressure 1.6 bar over 1.2 bar Bangi Number when pressure 1.4 bar over 1.2 bar Comparison between Bangi Number and roughness average Comparison between Bangi Number and mean roughness depth New test rig proposed 64

15 xv LIST OF SYMBOLS A AB A high A low D f g h L L l R a Re R z R zi T V V avg V RMS V(t) Q Z(x) ε Cross sectional area Bangi number RMS value at the high flow rate (low pressure) RMS value at the low flow rate (high pressure) Diameter Friction factor Gravity acceleration Head loss Length Evaluation length Roughness average Reynolds number Mean roughness depth Single roughness depths Duration Flow velocity Average velocity RMS value Voltage Volume flow rate Profile ordinates of the roughness profile Roughness µ Dynamic viscosity

16 xvi ρ P L o F Fluid density Pressure drop Degree Fahrenheit < Below than > Above than

17 xvii LIST OF ABBREVIATIONS ac ADC AE AED Avg cm db eg Eq etc FYP HF Hz k kg LF M m mm N NDT PC RMS Alternating current Analog to digital converter Acoustic emission Acoustic emission detector Average Centimeters Decibels Example Equation Etcetera Final year project High frequency Hertz Kilo Kilogram Low frequency Mega Meters Millimeters Newton Nondestructive techniques Personal computer Root mean square

18 xviii s V Second Volt µm Micrometers