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Development of Permanently Installed Magnetic Eddy Current Sensor for Corrosion Monitoring of Ferromagnetic Pipelines

Permanently installed sensors are a cost-effective solution for corrosion monitoring due to their advantages, such as less human interference and continuous data acquisition. Some of the most widely used permanently installed corrosion sensors are ultrasonic thickness (UT) gauges. However, UT sensors are limited by the need for coupling agents between pipe surfaces and sensors. The magnetic eddy current (MEC) method, on the other hand, does not require couplant and can be used over insulations. With the development of powerful rare earth magnets, MEC sensors with low power consumption are possible, and there is the prospect of using them as permanently installed sensors. A novel wireless magnetic eddy current sensor has been designed and optimized using finite element simulation. Sensitivity studies of the sensors reveal that the excitation frequency is a critical parameter for the detection of corrosion defects. An in-depth explanation of the relationship between the sensitivity of the sensor and the excitation frequency is presented in this paper. The results of an accelerated corrosion test, conducted to simulate the service environment of the sensor, are also discussed. It was observed that the sensor signals are very sensitive to corrosion defects and show no subtle differences due to temperature and humidity changes.