Detection system and method of detecting corrosion under an outer protective layer

• US 9,874,516 B2
• Filed: 08/08/2017
• Issued: 01/23/2018
• Est. Priority Date: 02/25/2013
• Status: Active Grant

• Current Assignee: Subterandt Limited
• Original Assignee: Subterandt Limited
• Inventors: Mann, Christopher Mark, Dunne, Joseph Peter
• Primary Examiner(s): Porta, David
• Assistant Examiner(s): GUTIERREZ, GISSELLE M
• Application Number:
  US15/671,869
• Publication Number:
  US 20170336323A1
• Time in Patent Office: 168 Days
• Field of Search: 25033905
• CPC Class Codes: G01N 17/006 of metals
• CPC Class Codes: G01N 17/04 Corrosion probes
• CPC Class Codes: G01N 2021/4764 Special kinds of physical applications
• CPC Class Codes: G01N 2021/8427 Coatings
• CPC Class Codes: G01N 2021/8812 Diffuse illumination, e.g. "sky"
• CPC Class Codes: G01N 21/3563 for analysing solids; Preparation of samples therefor
• CPC Class Codes: G01N 21/3581 using far infrared light; using Terahertz radiation
• CPC Class Codes: G01N 21/4738 Diffuse reflection precedence is given to G01N21/55 - G01N21/57 if specular component is taken into consideration, e.g. also for testing fluids, fibrous materials
• CPC Class Codes: G01N 21/55 Specular reflectivity
• CPC Class Codes: G01N 21/952 Inspecting the exterior surface of cylindrical bodies or wires G01N21/956 takes precedence
• CPC Class Codes: G01N 22/02 Investigating the presence of flaws
• CPC Class Codes: G01N 22/04 Investigating moisture content

Abstract

Wide-angled incoherent millimeter or sub-millimeter electromagnetic waves from an extended active source are used to probe substrates and their protective coatings or outer layers, such as paint or thermal insulation. The incoherent waves provide dispersion and angular variation with respect to angular incidence to the substrate. Illumination of the substrate permits differentiation between un-corroded and corroded sections of the sample because reflectivity, emissivity and/or transmissivity from the substrate or protective coating various according to its homogeneousness. A detector/camera is arranged to identify and resolve differences in detected power within an observed frequency range of the area under test, with this contrast in power being relative to either adjacent areas or anticipated reference levels. The power differences therefore signify the presence or lack of corrosion or, indeed, the presence of anomalies within or on the substrate or in or under the protective coating or layer applied to the substrate.

Claims

1. A method of detecting the presence of anomalies in or on a substrate covered by a protective coating or layer or detecting the presence of anomalies in or on the protective coating or layer applied to the substrate, the substrate in an in-situ environment, the method comprising:

observing, in an observed frequency range, at least one of reflectivity, transmissivity and/or emissivity from an area of interest under investigation on or in the substrate or on or in or under the protective coating or layer, said reflectivity, transmissivity and emissivity being in a frequency range corresponding to incident electromagnetic waves having millimeter or sub-millimeter wavelengths, said reflectivity, transmissivity and emissivity arising from incident electromagnetic waves falling incident on the area of interest and wherein the incident electromagnetic waves are produced from an extended source that is wider in dimensions than a dimension of a width of the area of interest under investigation and which extended source illuminates the area of interest from a wide angle with a first incoherent active source arranged to produce an illumination of the area under investigation in the observed frequency range, said illumination producing a contrast in detected power arising from reflectivity, transmissivity and/or emissivity in the presence of anomalies in or on the substrate or in or on or under the protective coating or layer, which contrast in the observed frequency range is different to one of (a) a detected power arising from naturally-occurring passive illumination of the substrate, protective coating or layer in the in situ environment in which the substrate or protective coating or layer is sited; and

(b) a detected power emanating from the substrate or protective coating or layer in the in situ environment in which the substrate or protective coating or layer is sited;

identifying the presence of anomalies in the substrate by at least one of;

contrasting at least one of observed reflectivity, transmissivity and/or emissivity in adjacent areas of the substrate or the protective coating or layer applied to the substrate; and

contrasting at least one of observed reflectivity, transmissivity and/or emissivity of an area of the substrate or protecting layer or coating under investigation respectively against a reference reflectivity value, reference transmissivity value or reference emissivity anticipated for the area of the substrate under investigation.

2. The method of claim 1, further comprising:

determining emissivity from the substrate at two different temperatures to assess whether a change in emissivity has occurred between the two different temperatures; and

generating an output in the event that the change in emissivity exceeds a predetermined threshold, the output indicating the presence of at an anomaly in or on the substrate.

3. The method of claim 1, wherein the observed detected power is within at least one of frequency band in which atmospheric water and atmospheric oxygen are transparent to electromagnetic waves.

4. A detection system for identifying corrosion or anomalies in a substrate or in or under a protective layer or coating on the substrate, the detection system having:

an extended source arranged to generate incident electromagnetic waves;

an imaging system including a detector configured to receive and detect, in use, power emanating from an area of interest under investigation on or in the substrate or on or in or under the protective layer or coating;

a processor-based evaluation system responsive to the imaging system, the processor based evaluation system configured to present an indication of a difference in detected power;

wherein the detection system is configured to;

a) observe, in an observed frequency range, at least one of reflectivity, transmissivity and/or emissivity from the area of interest, said reflectivity, transmissivity and emissivity being in a frequency range corresponding to incident electromagnetic waves having millimeter or sub-millimeter wavelengths, said reflectivity, transmissivity and emissivity arising from incident electromagnetic waves falling incident on the area of interest;

and wherein the extended source is wider in dimensions than a dimension of a width of the area of interest under investigation and which extended source is arranged to illuminate the area of interest from a wide angle with a first incoherent active source configured to produce an illumination of the area under investigation in the observed frequency range, said illumination producing a contrast in detected power arising from reflectivity, transmissivity and/or emissivity in the presence of anomalies in or on or under the substrate or in or on the protective coating or layer, which contrast in the observed frequency range is different to one of (i) a detected power arising from naturally-occurring passive illumination of the substrate, protective coating or layer in the in situ environment in which the substrate or protective coating or layer is sited; and

(ii) a detected power emanating from the substrate or protective coating or layer in the in situ environment in which the substrate or protective coating or layer is sited;

b) identify the presence of anomalies in or on the substrate or in, on or under the protective coating or layer by at least one of;

i) contrasting at least one of observed reflectivity, transmissivity and/or emissivity in adjacent areas of the substrate or the protective coating or layer applied to the substrate; and

ii) contrasting at least one of observed reflectivity, transmissivity and/or emissivity of an area of the substrate or protecting layer or coating under investigation respectively against a reference reflectivity value, reference transmissivity value or reference emissivity anticipated for the area of the substrate under investigation.

5. The detection system of claim 4, wherein the observed detected power is within at least one of frequency band in which atmospheric water and atmospheric oxygen are transparent to electromagnetic waves.

6. The detection system according to claim 4, wherein the processor-based evaluation system is further configured to provide an indication of confidence in structural integrity of the substrate under the layer applied over, or coating covering, the area under investigation on the substrate under investigation, the indication based on evaluating transmissivity through or emissivity of or the reflectivity from the layer or coating, the evaluation contrasting differences in the spectral profiles observed using the passive source and the active source.

7. The detection system according to claim 6, wherein the processor-based evaluation system is further configured to:

determine emissivity from the substrate at two different temperatures to assess whether a change in emissivity has occurred between the two different temperatures; and

generate an output in the event that the change in emissivity exceeds a predetermined threshold, the output indicating the presence of an anomaly in, on or under the layer applied to the substrate.