Non-Invasive Measurement for Crack Detection and Thickness Measurement of Carbon Steel Pipe

Crack detection and pipe wall thickness measurement are critical parameters continuously monitored in pipelines used in the oil and gas industry. Even minor deviations in these measurements can compromise pipeline integrity, potentially leading to hazardous spills. Pipelines are constructed from cylindrical metal sections, with wall thickness tailored to expected operating pressures. Defects, such as metal loss or corrosion, represent deviations from the pipeline's original structure. Common non-destructive testing (NDT) methods, such as X-ray tomography (XT) and Gamma-ray tomography (GRT), are widely used for pipe inspection due to their ability to penetrate various materials. However, these radiographic methods pose safety risks due to radiation exposure, leading to high operational costs to meet safety standards. To address these concerns, this study proposes an alternative non-ionizing method using ultrasonic testing (UT) in reflection mode for pipe inspection. The approach utilizes acoustic waves that propagate through different media, reflecting at boundaries with acoustic impedance mismatches. An ultrasonic transducer is mounted on the pipe surface to capture reflected signals, enabling accurate detection of cracks and measurement of pipe wall thickness. The system achieved an accuracy of 99.68%, with deviations below 0.32%, confirming the effectiveness of ultrasonic testing as a safe, costeffective, and reliable method for industrial pipeline inspection.