INTERNAL SURFACE PIPE ROUGHNESS CLASSIFICATION USING HIGH FREQUENCY ACOUSTIC EVALUATION AMAR REZA BIN MOHAMMAD FIRDAUS BACHELOR OF ENGINEERING UNIVERSITI MALAYSIA PAHANG 2010
AMAR REZA BACHELOR OF MECHANICAL ENGINEERING 2010 UMP
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 (870813146357) (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 68000 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).
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
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
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 :
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 :
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 1 1.2 Problem Statement 2 1.3 Objectives 3 1.4 Scope of the Project 3 1.5 Important of the Study 3 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction 4 2.2 Basic Component of Piping System 4 2.3 Flow Analysis in Pipe 5 2.4 Roughness of Pipe 7 2.5 Corrosion in Pipe 9 2.5.1 Uniform Corrosion 10 2.5.2 Galvanic Corrosion 11 2.5.3 Pitting Corrosion 11 2.5.4 Crevice Corrosion 12 2.5.5 Intergranular Corrosion 13
ix 2.6 Acoustic Emission (AE) Method 13 2.6.1. Type of Acoustic Emission 14 2.6.2. Sources of Acoustic Emission in Friction 16 2.6.3. Acoustic Emission Signal Features 17 2.6.4. Operation of Acoustic Emission System 19 2.6.5. Acoustic Emission in Pipe 21 2.6.6. Advantages of Acoustic Emission Technique 22 2.7 Nondestructive Techniques (NDT) 22 2.7.1. Eddy Current Testing 22 2.7.2. Radiography Testing 23 2.7.3. Ultrasonic Testing 24 2.7.4. Comparison of NDT Methods 25 2.8 Previous Research 26 CHAPTER 3 METHODOLOGY 3.1 Introduction 29 3.2 Project Flow Chart 30 3.3 Gantt Chart 32 3.4 Test Rig and Tools Preparation 34 3.5 Instrumentation of Acoustic Emission System 36 3.6 Experimental Procedures 39 3.6.1. Acoustic Emission Measurement 40 3.6.2. Flow Rate Measurement 42 3.6.3. Surface Roughness Measurement 42 CHAPTER 4 RESULTS AND DISCUSSION 4.1 Introduction 43 4.2 Test 43 4.3 Results 45 4.3.1. Fluid Flow Through Smooth Pipe with Four Different 45 Pressures 4.3.2. Fluid Flow Through Rough Pipe with Four Different 47 Pressures 4.3.3. Comparison between Smooth Pipe and Rough Pipe 48 4.3.4. Water Flow Rate and Reynolds Number in Several 50 Pressure Inlets 4.3.5. Surface Roughness 51
x 4.4 Discussion 53 4.4.1. Precaution Steps 53 4.4.2. Determine the Sources of Acoustic Emission Signal 54 4.4.3. Pipe Roughness Classification 55 4.4.4. Comparison between Bangi Number with Surface 60 Roughness CHAPTER 5 CONCLUSION 5.1 Conclusion 62 5.2 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
xi LIST OF TABLES Table No. Title Page 2.1 Basic component of piping system 5 2.2 Equivalent roughness values for new commercial pipes 8 2.3 Sources of AE signals at friction 16 2.4 The advantages and disadvantages of other selected NDT methods 25 4.1 Average RMS (V) values for internal smooth pipe surface 46 4.2 Average RMS (V) values for internal rough pipe surface 47 4.3 Water flow rate and Reynolds number in several pressure inlets 51 4.4 Surface roughness values for smooth pipe and rough pipe 52 4.5 Bangi Number for smooth pipe 56 4.6 Bangi Number for rough pipe 56 5.1 Bangi Number, AB indication for rough and smooth pipe 63
xii LIST OF FIGURES Figure No. Title Page 2.1 Laminar and turbulent flow 6 2.2 Uniform corrosion 11 2.3 Galvanic corrosion 11 2.4 Pitting corrosion 12 2.5 Crevice corrosion 12 2.6 Intergranular corrosion 13 2.7 Basic principles of acoustic emission technique 14 2.8 Continuous AE signal 15 2.9 Discrete AE signal 16 2.10 AE signal features 18 2.11 Schematic diagram available in organizing a basic acoustic emission 19 testing system 2.12 Transducer 20 2.13 Basic principles of eddy current inspection 23 2.14 Basic principles of radiography inspection 24 2.15 Basic principles of ultrasonic inspection 24 3.1 Project flow chart 30 3.2 Experimental architecture 34 3.3 Test rig setup 35 3.4 Smooth pipe and rough pipe 35 3.5 Pipe joint integrated with pressure indicator 36 3.6 Sensor attachment on pipe 36 3.7 AED-2000V virtual instrument 37
xiii 3.8 Integral preamp AE sensor 37 3.9 Grease 38 3.10 Computer with built-in ADC card and acoustic emission detector 38 software version 2.1.3 3.11 Acoustic emission detector software version 2.1.3 39 3.12 Valve controller 40 3.13 Channel setting 41 3.14 Sampling setup 41 3.15 Volume water indicator 42 3.16 Perthometer 42 4.1 RMS values for smooth pipe at each pressure inlet 44 4.2 RMS values for rough pipe at each pressure inlet 44 4.3 Fluid flow through smooth pipe with four different pressures 46 4.4 Fluid flow through rough pipe with four different pressures 47 4.5 Fluid pressure 1.8 bar flow through smooth pipe and rough pipe 48 4.6 Fluid pressure 1.6 bar flow through smooth pipe and rough pipe 49 4.7 Fluid pressure 1.4 bar flow through smooth pipe and rough pipe 49 4.8 Fluid pressure 1.2 bar flow through smooth pipe and rough pipe 50 4.9 Appearance of smooth inner surface pipe 51 4.10 Appearance of rough inner surface pipe 52 4.11 Comparison roughness average between smooth pipe and rough pipe 52 4.12 Comparison mean roughness depth between smooth pipe and rough 53 pipe 4.13 Bangi Number when pressure 1.8 bar over 1.6 bar 57 4.14 Bangi Number when pressure 1.8 bar over 1.4 bar 57 4.15 Bangi Number when pressure 1.8 bar over 1.2 bar 58
xiv 4.16 Bangi Number when pressure 1.6 bar over 1.4 bar 58 4.17 Bangi Number when pressure 1.6 bar over 1.2 bar 59 4.18 Bangi Number when pressure 1.4 bar over 1.2 bar 59 4.19 Comparison between Bangi Number and roughness average 61 4.20 Comparison between Bangi Number and mean roughness depth 61 5.1 New test rig proposed 64
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
xvi ρ P L o F Fluid density Pressure drop Degree Fahrenheit < Below than > Above than
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
xviii s V Second Volt µm Micrometers