Abstract: An active coating system capable of collecting, analyzing, managing and adapting to data and/or its environment in real time. An exemplary embodiment of our inventive active coating system is corrosion resistant and includes a flexible sensor layer, a switch layer and a visual display layer. Operationally, the flexible sensor layer senses particular environmental conditions and the visual display layer provides visual indication of the condition(s) sensed.

Abstract: A portable, handheld, automatic protection level interpreting cathodic protection meter for testing the level of protection being afforded to metallic structures protected by either sacrificial anode or impressed current cathodic protection systems, or both. The meter is suitable over a variety of environments including salt water, freshwater, and soil. The operator can select both the type of metal to be tested as well as the type of reference electrode that is being used. The meter automatically calibrates data interpretation of the level of protection based on the operator's selections and eliminates any voltage drop error existing between a reference electrode and the structure being protected.

Abstract: The present invention relates to monitoring the corrosive damage caused to items in a corrosive environment by using multiple monitored coupons 30 of varying thickness that, when corroded, transmit information to a monitor 40 allowing a user to estimate the corrosive damage valuable industrial components 20. The corrosion rate of the coupons 30 can be used to optimize the environmental conditions, so that items in the environment corrode at desired rates.

Abstract: A method for analyzing cavitation in a component includes establishing an energy level associated with a system condition associated with the component and analyzing cavitation in response to said energy level.

Abstract: In one embodiment, a sampling device has first and second detachable body parts defining a fluid flow path. The first body part defines a fluid inlet of the fluid flow path and the second body part defines a fluid outlet of the fluid flow path. A diameter of a portion of the fluid flow path is enlarged to receive and retain a tubular sampling coupon that further defines the fluid flow path. The tubular sampling coupon may be of a type having first and second coupon body parts mated along a long axis. The tubular sampling coupon is of a size and shape to be received and retained within a fluid flow path of a sampling device, wherein the tubular sampling coupon further defines the fluid flow path. Systems and methods using the sampling device and sampling coupon are also disclosed.

Abstract: The present invention is an apparatus for simulating corrosion activity in liquid and vapor/condensate corrosion environments. The apparatus includes a container, including a lower region containing the liquid and an upper region, including a condenser, a heater for providing heat to the lower region such that the liquid is maintained at a given temperature, a vacuum pump for providing a partial vacuum at a given pressure in the upper region of the container, one corrosion probe removably positioned in the liquid, and a second corrosion probe removably positioned above the liquid.

Abstract: A corrosion coupon rack includes one or more coupon mounting devices constructed of a coupon holder receiver including a handle recess of a given diameter and an end wall, a connection conduit in communication with the handle recess through an opening in the end wall and axially aligned therewith, and locking means having open and closed positions, the locking means including a cam surface extending into the handle recess when the locking means is in the closed position; and a coupon holder including a handle insertable into the handle recess, the handle having inner and outer ends, a locking recess, and a shaft axially aligned with the handle, the shaft having a proximal end attached to the handle inner end, and a distal end adapted to releasibly attach a corrosion coupon, the shaft extending through the T-connection and into the pipe.

Abstract: The wear resistance of impellers used in multi-stage turbine pumps is tested by using a multi-stage turbine pump having impellers with different physical properties to pump a fluid containing small amounts of an abrasive material. After the fluid has been pumped for a time period sufficient to provide measurable wear to the impellers, the impellers are inspected to determine their relative resistance to wear.

Abstract: A method involving the use and creation of pre-aged witness coupons which characterizes and monitors the rate and extent of chemical and physical aging of the polymer in the structure during use in the field is described.

Abstract: Disclosed is a runoff rain gauge 100 which includes a collector tube 104, soil infiltration resistance medium 108, a runoff resistance flow element 113, a standard rain gauge 102, and runoff collection tube 114. Precipitation enters the collector tube 104 and is divided to flow into the infiltration medium 108 and runoff collection tube 114 via flow element 113. Total precipitation is read in standard rain gauge 102, runoff in tube 114, and soil infiltration in medium 108 is calculated by the difference between total precipitation and the runoff.

Abstract: A system 10 for detecting sliding of a wheel 12 on a rail 14 includes a roller 16 disposed adjacent the rail 14 so that a wheel 12 travelling along the rail 14 can engage the roller 16, and a tachometer 18 coupled with the roller 16 for providing a rotation signal representative of the degree of rotation of the roller. The system 10 includes a computer 20 which receives the rotation signal from the tachometer 18 and by using an appropriate rotation algorithm calculates the degree of rotation of the roller 16. The computer 20 then compares the degree of rotation with a predetermined range of roller rotations and, if the calculated degree of rotation of the roller is less than predicted by analysis, the apparatus 10 provides a signal indicative of the wheel 12 sliding.

Abstract: A furnace probe measuring system and method used to measure conditions, such as wear, within an electric furnace. A position assembly is configured to attach to a portion of an electric furnace. A probe assembly is moveably coupled to the position assembly and includes a location sensing portion configured to adjust to a location. A measurement device is coupled to the location sensing portion and indicates the location of the location sensing portion to determine wear.

Abstract: An apparatus and process are described to test the effect of anti-foulant additives on scale information in industrial fluid streams. An apparatus of at least two cells plumbed in parallel is used in which at least one cell is a reference cell. The apparatus and process allow the simultaneous measurement of different conditions of anti-foulant additives, including anti-foulant concentration, fluid stream temperature, fluid stream flow rate, and heat transfer surface temperature.

Abstract: Apparatus and methods for measuring characteristics of a metallic target as well as other interior surfaces of a sputtering chamber. The apparatus includes a sensor configured to emit an energy beam toward a surface of interest and to detect an energy beam therefrom, the detected energy beam being indicative of parameters of a characteristic of interest of the surface of interest. Quantitative and qualitative characteristics of interest may be determined. A sputtering system including the apparatus and operable according to the methods of the invention is also disclosed.

Abstract: Wear-detection sensor has a body of electrically insulating material with an opening through which a flowable substance can pass, and one or more electrical conductors surrounding the opening and adapted to undergo a discernable change in conductivity as the insulating material is worn away by the flowable substance.

Abstract: An apparatus for indicating when a predetermined portion of a sacrificial anode has been corroded comprises a detector embedded within the interior of the sacrificial anode initially at a predetermined distance from an exposed exterior surface of the sacrificial anode. The detector detects the absence of sacrificial anode material when the predetermined portion has corroded and generates a detection signal. A monitoring system communicates with the detector for receiving detection signals and generates an indicator signal when a detection signal is received. An indicator in communication with the monitoring system receives indicator signals and generates an alarm when an indicator signal is received.

Abstract: A system and method for characterizing and measuring hydrodynamic grooves made by ECM processes is disclosed. The method includes a procedure for alignment of the work piece to the measurement apparatus as well as a technique for accurately reliably measuring the erosion pattern quickly. Additionally, the invention provides a system for characterizing and measuring the erosion of these grooves.

Abstract: An apparatus and method for measuring the erosion profile of a metallic target in a sputtering device are provided by inserting a thin sensor into a gap between the target and a substrate pedestal. The sensor is configured to emit an energy beam toward the surface of the target and detect a reflection of the energy beam. The sensor may comprise a source element configured to emit a collimated light beam and a plurality of detectors arranged in a linear array. The sensor may also comprise optical fibers configured to reduce the size of the sensor. The detectors are positioned relative to the source element so that one of the detectors in the array will be illuminated by a reflection of the collimated light beam. The distance from the sensor to the target may be derived from the position of the detector illuminated by the reflected beam.

Abstract: A method for predicting scale deposition in a general environment has been discovered which involves providing a localized environment where scale would preferentially form, where the localized environment is adjacent the general environment. Monitoring the deposition of scale in the localized environment is performed for the purpose of taking preemptive action to prevent scale deposition in the general environment once scale begins to form, or a certain threshold is reached. Scale is removed from the localized environment so that monitoring can be performed by the probe again. Preemptive action will often be the introduction of a scale inhibiting agent into the general environment. An apparatus for practicing the method of predicting and preventing scale deposition in a general environment is also described.

Abstract: A coupon for monitoring cathodic protection includes a metallic coupon structure on the outer surface of which at least one type of coating disbondment geometry anticipated on a pipeline is fabricated.

Abstract: A comprehensive system for the cleaning, inspection, and testing of tubulars, particularly riser pipes, is provided. In a first aspect, a method of inspecting a tubular comprises cleaning, visually inspecting, corrosion mapping, and TOM testing the tubular. In another aspect, a specially designed or adapted tool is provided for each of the steps of the method.

Abstract: The present invention is an apparatus for simulating corrosion activity in liquid and vapor/condensate corrosion environments. The apparatus includes a container, including a lower region containing the liquid and an upper region, including a condenser, a heater for providing heat to the lower region such that the liquid is maintained at a given temperature, a vacuum pump for providing a partial vacuum at a given pressure in the upper region of the container, one corrosion probe removably positioned in the liquid, and a second corrosion probe removably positioned above the liquid.

Abstract: A system and method for characterizing and measuring hydrodynamic grooves made by ECM processes is disclosed. The method includes a procedure for alignment of the work piece to the measurement apparatus as well as a technique for accurately reliably measuring the erosion pattern quickly. Additionally, the invention provides a system for characterizing and measuring the erosion of these grooves.

Abstract: Detecting erosion of refractory thermal insulation or a ceramic shield over a wide area is achieved by monitoring an electrical property of at least one wide area, planar, electrically conductive grid through which a current flows. The grid is located in or under the insulation or shield, with the grid plane and parallel to its hot or impact face, preferably over at least two square feet. When erosion erodes part of the grid, the electrical property changes and indicates that erosion has reached the grid.

Abstract: Detecting erosion of refractory thermal insulation or a ceramic shield over a wide area is achieved by monitoring the gas pressure in at least one wide area planar grid, in or under the insulation or shield and parallel to its hot or impact face. The plane of the grid follows that of the hot or impact face of the shield. The grid is fabricated from one or more hollow conduits in fluid communication and a single fluid conduit connects it to a pressure detector. Using a plurality of grids at different distances from the hot or impact face enables monitoring erosion over time. This enables wide area coverage as much or more than eight square feet in, e.g., a coker, without unduly impairing the integrity of the vessel wall and eliminates the danger of sparks associated with electrical means.

Abstract: A method and apparatus for measuring erosion rates of sediments and at high shear stresses due to complex wave action with, or without, a superimposed unidirectional current. Water is forced in a channel past an exposed sediment core sample, which erodes sediments when a critical shear stress has been exceeded. The height of the core sample is adjusted during testing so that the sediment surface remains level with the bottom of the channel as the sediments erode. Complex wave action is simulated by driving tandom piston/cylinder mechanisms with computer-controlled stepper motors. Unidirectional flow, forced by a head difference between two open tanks attached to each end of the channel, may be superimposed on to the complex wave action. Sediment traps may be used to collect bedload sediments. The total erosion rate equals the change in height of the sediment core sample divided by a fixed period of time.

Abstract: A comparator for determining a degree of erosion on a metallic surface of a part including a panel having a plurality of cells arranged on a side of the panel, wherein each cell has a surface finish representative of a certain surface condition of the part, and each surface condition replicates a degree of erosion on the metallic surface of the part.

Abstract: A detection method of coating film thickness and an ion implantation equipment using the detection method. The detection method comprises providing on a surface of materials, such as disk (11) of a wafer support on which a coating film comprising a low conductive material, an electrical measurement sensor (18) having a coating film comprising the same material, and detecting thickness change of the coating film on the surface of the materials by irradiation with particle beams in the form of a signal from the sensor (18). The ion implantation equipment comprises an electrical measurement sensor provided on a disk and having a sample piece that forms a coating film of the same material as that of a surface coating of the disk, and means to monitor thickness change of the coating film by sensor signal from the measurement sensor.

Abstract: The invention relates to a device and a method for determining the quality of the corrosion on the inside of a wall manufactured from non-corrosion-resistant material of a space in which corrosive conditions prevail, wherein at least one part of the wall is removable from the wall without destructive operations and is available after removal for examination outside the space. This measure has the advantage that an element to be removed without destructive operations can be removed easily and can be replaced. Although in the first instance a screw is envisaged, other embodiments are in no way precluded, such as a pin or a prop onto which another fixation device is arranged, for instance a bayonet fitting.

Abstract: Corrosion sensors and methods of their use for monitoring corrosion of a material of interest. The corrosion sensors are adapted to be placed in the environment containing the material of interest during the period when corrosion is taking place. The corrosion sensors include a power source, a visual indicator and an electrode contained on a support. Changes in the electrical resistance of the electrode facilitate a display on the visual indicator including changes in color or brightness. Some corrosion sensors have power sources activated by directing a light source or other electromagnetic radiation source at the corrosion sensor. Some corrosion sensors have visual indicators containing thermochromic or electrochromic materials that are responsive to changes in voltage drop or current flow across the visual indicator. Some corrosion sensors have tracking devices to provide tracking information about the corrosion sensor.

Abstract: An apparatus to visually check coolant corrosiveness having first and second opposing ends in spaced apart relation to each other, and a sidewall extending substantially unbroken therebetween to define a hollow body; a non corrodible coolant barrier at said first end occluding said first end and forming a water tight seal over said first end; said non corrodible barrier having a transparency in at least a portion of said barrier; a corrodible coolant barrier at said second end occluding said second end and forming a water tight seal over said second end; whereby changes in coolant pH render the coolant corrosive, which corrodes the coolant corrodible barrier, thereby allowing coolant into said hollow body to be seen through said transparency in said first end.

Abstract: A coupon for measuring the corrosion rates of metals in a hostile environment, including two or more thin-film resistive conductors formed on a substrate and positioned in close physical proximity so that they are subjected to essentially the same physical environment. One or more of the thin-film resistive conductors is directly exposed to the potentially corrosive environment while at least one of the thin-film elements is protected from the corrosive nature of the environment. The element or elements that are protected from corrosion are either shielded from the corrosive effects of the environment by the presence of a thermally thin protective layer or by being isolated from the corrosive environment while being maintained at essentially the same temperature as the elements exposed to the corrosive environment. The invention is also directed to a system for measuring the corrosion rate by measuring the change in resistance of the exposed conductor in comparison to the protected chamber.

Abstract: The mill comprises a cylindrical shell ring (10) revolving about its longitudinal axis and containing a grinding charge comprising grinding bodies made of metal alloy. At least one grinding body (30) identical to those that make up the grinding charge is fixed to an elastomer or rubber pedestal (28), itself fixed to the interior surface of the shell ring. This grinding body (30) is exposed to the conditions inside the mill and is associated with a reference electrode (36) from which it is electrically insulated. This reference electrode (36) is protected from the impact knocks of the charge in the mill but is in electrical contact with the pulp in the mill, the said grinding body (30) and the said electrode (36) being electrically connected to measurement apparatus (18) fixed inside the shell ring of the mill.

Abstract: A coupon for monitoring cathodic protection includes a metallic coupon structure on the outer surface of which at least one type of coating disbondment geometry anticipated on a pipeline is fabricated.

Abstract: A method and apparatus for measuring the total erosion rate and downstream transport of suspended and bedload sediments using an adjustable shear stress erosion and transport (ASSET) flume with a variable-depth sediment core sample. Water is forced past a variable-depth sediment core sample in a closed channel, eroding sediments, and introducing suspended and bedload sediments into the flow stream. The core sample is continuously pushed into the flow stream, while keeping the surface level with the bottom of the channel. Eroded bedload sediments are transported downstream and then gravitationally separated from the flow stream into one or more quiescent traps. The captured bedload sediments (particles and aggregates) are weighed and compared to the total mass of sediment eroded, and also to the concentration of sediments suspended in the flow stream.

Abstract: A corrosion sensor and method for its use to detect and determine the, type, location, size and growth rate of corrosion of metals and the like in a corrosive environment. The corrosion sensor can distinguish between different types of corrosion such as uniform corrosion, pitting, crevice, and stress corrosion cracking. The sensor detects corrosion conditions of a corrodible metal article in a corrosive environment. It has a metal probe comprised of a metal which is substantially identical to that of the corrodible metal article and a transducer element attached to said probe, which is capable of projecting and receiving ultrasonic or radio frequency signals through the probe. The received signals indicate corrosion of the probe and hence the corrodible metal article.

Abstract: A corrosion sensor for sensing corrosion in a pipeline. The sensor includes a housing and a device for joining the housing to a wall of an enclosure that receives a fluid. The sensor also includes a rupture member which extends across a portion of the housing to define a sealed chamber in the housing. The rupture member, upon rupture, provides an opening to the sealed chamber. The rupture member is formed of a material and thickness such that the rupture member will fail from corrosion before the enclosure wall will fail from corrosion. The rupture member is arranged such that fluid received in the enclosure can contact the rupture member. The sensor also includes a sensory device which is connected to the housing at the sealed chamber to signal a rupture condition of the rupture member when the sealed chamber opens.

Abstract: Ultrasonic energy in the form of guided waves (plate waves or Lamb waves) is launched into the wall of a container. The guided wave propagates around the circumference of the container from a transmitting transducer to a receiving transducer. Analysis of the received waves determines the presence of corrosion pitting and MIC nodules on the container inner wall, as well as the existence of foreign objects in intimate contact with the container wall. The guided waves are created with wideband transducers excited at certain frequencies that depend on the material and geometry of the part being measured. The guided wave ultrasonic energy is maximized with a shaped tone burst pulse at the specified frequency rather than an electrical spike commonly used to excite transducers in standard ultrasonic search units.

Abstract: The method uses color to determine the wear of the screw and barrel of the molding machine. The method measures the color and/or color variation to determine the wear. A first material of a first color and a second material of a second color are fed into the machine to create a third material with a third color. The third material is either extruded to form a part or is injected into a mold to form a part. The color of the part is then measured with a measuring device, such as, spectrophotometer. The color will change as the screw and barrel wear. The color value would then be compared with previous color values to determine the amount of wear.

Abstract: A method and apparatus for anticipating the onset of or measurement of a deleterious condition in a bearing comprising monitoring the bearing for electrostatic activity indicative of the onset of the condition using one or more electrostatic sensors, processing signals derived from the sensors and employing same to activate alarm means, alter bearing loading to reduce or eliminate the source condition or shut down the equipment to prevent further bearing damage.

Abstract: The mill comprises a cylindrical shell ring (10) revolving about its longitudinal axis and containing a grinding charge comprising grinding bodies made of metal alloy. At least one grinding body (30) identical to those that make up the grinding charge is fixed to an elastomer or rubber pedestal (28), itself fixed to the interior surface of the shell ring. This grinding body (30) is exposed to the conditions inside the mill and is associated with a reference electrode (36) from which it is electrically insulated. This reference electrode (36) is protected from the impact knocks of the charge in the mill but is in electrical contact with the pulp in the mill, the said grinding body (30) and the said electrode (36) being electrically connected to measurement apparatus (18) fixed inside the shell ring of the mill.

Abstract: A corrosion sensor and method for its use to detect and determine the, type, location, size and growth rate of corrosion of metals and the like in a corrosive environment. The corrosion sensor can distinguish between different types of corrosion such as uniform corrosion, pitting, crevice, and stress corrosion cracking. The sensor detects corrosion conditions of a corrodible metal article in a corrosive environment. It has a metal probe comprised of a metal which is substantially identical to that of the corrodible metal article and a transducer element attached to said probe, which is capable of projecting and receiving ultrasonic or radio frequency signals through the probe. The received signals indicate corrosion of the probe and hence the corrodible metal article.

Abstract: A method and apparatus for anticipating the onset of or measurement of a deleterious condition in a bearing comprising monitoring the bearing for electrostatic activity indicative of the onset of the condition using one or more electrostatic sensors, processing signals derived from the sensors and employing same to activate alarm means, alter bearing loading to reduce or eliminate the source condition or shut down the equipment to prevent further bearing damage.

Abstract: A method for measuring the thickness of a layer of crud containing ferromagnetic material deposited on nuclear fuel rods using eddy current lift-off (coil-to-conductor spacing) measurement by exciting a probe coil at predetermined frequency which penetrates only into the layer of crud containing the ferromagnetic material.

Abstract: A corrosion sensor (20) for sensing corrosion includes a housing (28) and a device (36) for jointing the housing (28) to a wall of a pipeline (10) that receives a fluid (24). The sensor (20) also includes a rupture member (44) which extends across a portion of the housing (28) to define a seal chamber (48) in the housing (28). The rupture member (44), upon rupture, provides an opening to the sealed chamber (48). The rupture member (44) is formed of a material and thickness such that the rupture member (44) will fail from corrosion before the enclosure wall will fail from corrosion. The sensor also includes a sensory device (100) which is connected to the housing (28) at the sealed chamber (48) to signal a rupture condition.

Abstract: A parallel resistor array for progressively detecting brake lining wear. A plurality of conductors are embedded within a brake lining or otherwise disposed between the brake surface and an actuator. Each of the conductors is connected to a resistor that is in turn connected to an indicator circuit. The indicator circuit is also connected to the brake surface. The conductors have progressively increasing lengths extending from the brake surface to the actuator. When the brakes are applied, the brake surface may contact at least one of the conductors to close the indicator circuit. As the brake lining wears, each of the conductors progressively contact the brake surface when the brakes are applied thus progressively adding a resistor to the indicator circuit. The conductors and resistors are arranged in parallel and thus as the brake lining wears, the overall resistance in the indicator circuit progressively decreases.

Abstract: A corrosion sensor for sensing corrosion in a pipeline. The sensor includes a housing and a device for joining the housing to a wall of an enclosure that receives a fluid. The sensor also includes a rupture member which extends across a portion of the housing to define a sealed chamber in the housing. The rupture member, upon rupture, provides an opening to the sealed chamber. The rupture member is formed of a material and thickness such that the rupture member will fail from corrosion before the enclosure wall will fail from corrosion. The rupture member is arranged such that fluid received in the enclosure can contact the rupture member. The sensor also includes a sensory device which is connected to the housing at the sealed chamber to signal a rupture condition of the rupture member when the sealed chamber opens.

Abstract: A ceramic sensor is disclosed that includes a ceramic tube having a closed end and an open end, and a metal sleeve having open first and second ends. The ceramic tube is formed of stabilized zirconia. The metal sleeve extends about the open end of the ceramic tube and is sealingly joined thereto at a contact region by a brazeless bond resulting from hot isostatic pressing. A mixture of metal and metal oxide powders is provided within the ceramic tube adjacent the closed end, and a conducting wire extends from the mixture of metal and metal oxide powders to the second end of the metal sleeve.

Abstract: A system and method for detecting corrosion in elongate conductive members. The importance of the present invention is that it utilizes the full electromagnetic wave field equations that oppose the traditional approach to electromagnetics, they are quasi-static dealing with a diffusion field. The inclusion of this propagation term in the development of the present invention completely separates the present techniques from those of Spies and Lara, as well as others. Surface corrosion on pipe changes the electromagnetic physical properties of pipe where the corrosion exists. Electromagnetic waves propagating through a pipe will be affected by these localized changes in the electromagnetic physical properties of the pipe. Electromagnetic pulses are created that cause electromagnetic waves to propagate from a first location to a second location on the pipe.

Abstract: Methods are described for measurement and prediction of site specific scour around a structure obstructing a flow. Representative soil samples are collected from an area proximate the structure location and tests are conducted on the samples to determine the erosion rate and hydraulic shear stress imposed. The maximum shear stress and initial scour rates around the structure are also obtained. Next, the maximum depth of scour is calculated, and the depth of scour versus time curve for the structure is then predicted. In a preferred embodiment, the methods described are used to predict a scour depth versus time curve around a cylindrical bridge support standing in the way of a constant velocity flow and founded in a uniform cohesive soil. An erosion function apparatus is also described which can be used to test representative samples of soil in the area where a structure is located.