Enhancement of Defect Characterization With AC Magnetic Flux Leakage: Far-Side Defect Shape Estimation and Sensor Lift-Off Compensation

One of the most common methods for performing non-destructive testing (NDT) of the steel tank floors in aboveground storage tanks is dc magnetic flux leakage (MFL). This test method gives an estimate of the defect depth and width based on the MFL signal strength and its peak location, respectively. A key limitation is that the signal strength depends on not only the defect depth and width but also various other factors including a defect’s wall profile and sensor lift-off. Moreover, in a practical MFL test, the sensor lift-off changes due to surface roughness and uneven steel plate surface in tank floors. We present an ac MFL system to increase the accuracy of defect characterization by: 1) distinguishing between two common defect shapes located on the far side of the steel plate used in a typical above storage tank (AST) floor: lake-shaped and rectangular defects and 2) developing a sensor lift-off compensation scheme based on ac signal phase. Simulation results show that skewness of the ac MFL can be used to distinguish between far-side lake-shaped and rectangular defects. AC MFL signal phase is shown to be a suitable compensator for the dependence of signal strength on unintended variations in sensor lift-off. The simulation results have been validated through experiments.