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© 2019 The Authors. Fouling build-up is a well-known industrial problem and its accumulation is dependent on the conditions surrounding the structure. Conventional fouling removal methods are costly and also require an operational halt to carry out the procedure. The use of Ultrasonics has gained popularity in recent years as a non-invasive means of fouling removal but further research and development are required to improve and optimize the technology. Currently in industry, Ultrasonic horns are designed and optimized to generate high amplitude vibrations for various applications including welding, cutting and sonochemistry. Some research has been done to design horns for the generation of cavitation, but none specifically for fouling removal applications. This work investigates the addition of half-wavelength transducer horns of varying shapes (cylindrical, conical, exponential and stepped) to an existing 40 kHz cleaning transducer. Numerical modelling is carried out to optimize the length of the horn before manufacturing final geometries. Experiments were conducted to attach an ultrasonic horn to the transducer and to a carbon steel plate (300 mm x 300 mm x 2 mm), and to measure wave propagation across the structure using a PSV-400 3D Laser Scanning Vibrometer. This has shown that the addition of an ultrasonic horn improves the out-of-plane displacement across the structure, which correlates to an improvement in fouling removal for steel tube ultrasonic cleaning. 10.13039/501100000266-Engineering and Physical Sciences Research Council

The structural integrity assessment of thermoplastic pipes has become an interesting area of research due to its elevated usage in the liquid/gas transportation industry. Ultrasonic guided wave testing has gained higher attention from industry for the inspection of elongated structures due to the reduced inspection time and cost associated with conventional non-destructive testing techniques, e.g., ultrasonic testing, radiography, and visual inspection. Current research addresses the inspection of thermoplastic pipes using ultrasonic guided waves as a low cost and permanently installed structural health-monitoring tool. Laboratory and numerical investigations were conducted to study the potential of using ultrasonic guided waves to assess the structural health of thermoplastic pipe structures in order to define optimum frequency range for inspection, array design, and length of inspection. In order to achieve a better surface contact, flexible Macro-Fiber Composite transducers were used in this investigation, and the Teletest&reg, Focus+ system was used as the pulser/receiver. Optimum frequency range of inspection was at 15&minus, 25 kHz due to the level of attenuation at higher frequencies and the larger dead zone at lower frequencies due to the pulse length. A minimum of 14 transducers around the circumference of a 3 inch pipe were required to suppress higher order flexural modes at 16 kHz. According to the studied condition, 1.84 m of inspection coverage could be achieved at a single direction for pulse-echo, which could be improved by using a higher number of transducers for excitation and using pitch-catch configuration.

Fouling build-up in engineering assets is a known problem and, as a solution, the application of power ultrasonic for in-situ fouling removal has gained much attention from the industry. Current state-of-the-art fouling removal includes the use of hydraulic, chemical and manual techniques. Much research has been conducted to advance the knowledge on the potential uses of ultrasonics across different fouling applications, primarily in reverse osmosis membranes and heat exchangers. However, the optimization of in-situ ultrasonic fouling removal has not yet been investigated and is still in its infancy. The present study uses a previously experimentally-validated numerical model to conduct a parametric study in order to optimize the technique. Focus was given to the adoption of ultrasonics for large diameter pipes. Therefore, this investigation was conducted on a 6 in. schedule 40-carbon steel pipe. Parameters investigated include: optimum number of transducers to remove fouling in long pipes from a single transducer location; performance at elevated temperature; different fluid domains; optimum voltage; variety of input signals and incremental thickness of fouling. Depending on the particular studied conditions, the possible fouling removal of up to +/−3 m from a single transducer location is demonstrated in a 6 in. schedule 40 carbon steel pipe.

The accumulation of fouling within a structure is a well-known and costly problem across many industries. The build-up is dependent on the environmental conditions surrounding the fouled structure. Many attempts have been made to detect fouling accumulation in critical engineering structures and to optimize the application of power ultrasonic fouling removal procedures, i.e., flow monitoring, ultrasonic guided waves and thermal imaging. In recent years, the use of ultrasonic guided waves has been identified as a promising technology to detect fouling deposition/growth. This technology also has the capability to assess structural health, an added value to the industry. The use of ultrasonic guided waves for structural health monitoring is established but fouling detection using ultrasonic guided waves is still in its infancy. The present study focuses on the characterization of fouling detection using ultrasonic guided waves. A 6.2-m long 6-inch schedule 40 carbon steel pipe has been used to study the effect of (Calcite) fouling on ultrasonic guided wave propagation within the structure. Parameters considered include frequency selection, number of cycles and dispersion at incremental fouling thickness. According to the studied conditions, a 0.5 dB/m drop in signal amplitude occurs for a fouling deposition of 1 mm. The findings demonstrate the potential to detect fouling build-up in lengthy pipes and to quantify its thickness by the reduction in amplitude found from further numerical investigation. This variable can be exploited to optimize the power ultrasonic fouling removal procedure.

Fouling formation on high value assets i.e. ships, offshore platforms, pipelines in the processing industry is a significant problem causing destruction to the environment and operations of the structure. Common fouling mechanisms in industry are deposit of scales, settlement and growth of marine organisms. It is an important factor, in order to assess the service lifetime and safety of these assets. Large sums of money are spent for removal and preventative methods to maintain efficient operation of the asset. Most of these methods are toxic and the environmental concerns associated with these techniques has led to studies on alternative methods to remove fouling. This paper proposes a non-invasive method of removing fouling using high power ultrasound. The acoustic cavitation phenomenon is related with the out-of-the-plane displacement occurring in structures for the fouling removal process. This is a cost and time effective method and more importantly, an environmentally sustainable method of fouling removal. Furthermore, this paper presents the research carried out at the Brunel Innovation Centre in this field. Through collaborative research projects, this technology has been developed for different fouling types specific to various industrial applications. A methodology has been established for the selection of the transducers and the hardware. The techniques effectiveness has been proven through experimental and simulation results.

Fouling build up is a well-known problem in the offshore industry. Accumulation of fouling occurs in different structures, e.g. offshore pipes, ship hulls, floating production platforms. The type of fouling that accumulates is dependent on environmental conditions surrounding the structure itself. Current methods deployed for fouling removal span across hydraulic, chemical and manual, all sharing the common disadvantage of necessitating halting production for the cleaning process to commence. Conventionally, ultrasound is used in ultrasonic baths to clean a submerged component by the generation and implosion of cavitation bubbles on the fouled surface; this method is particularly used in Reverse Osmosis applications. However, this requires the submersion of the fouled structure and thus may require a halt to production. Large fouled structures such as pipelines may not be accommodated. The application of high power ultrasonics is proposed in this work as a means to remove fouling on a structure whilst in operation. The work presented in this paper consists of the development of a finite element analysis model based on successful cleaning results from a pipe fouled with calcite on the inner pipe wall. A Polytec 3D Laser Doppler Vibrometer was used in this investigation to study the fouling removal process. Results show the potential of high power ultrasonics for fouling removal in pipe structures from the wave propagation across the structure under excitation, and are used to validate a COMSOL model to determine cleaning patterns based on pressure and displacement distributions for future transducer array design and optimization.

Fouling build up is a known problem in the industry. Accumulation of fouling can occur in different structures e.g. offshore pipes, ship hulls, floating production platforms. The type of fouling that is being accumulated is dependent on environmental conditions surrounding the structure itself. Current methods that are deployed for fouling removal spans over hydraulic, chemical and manual means. Current technologies such as DynaJet (cavitating water jets) and Hydrex's underwater ship hull cleaner have both advantages and disadvantages, where one common disadvantage is to put the operation of the structure to a halt in order to commence the fouling removal process. Currently, ultrasonic baths are used for cleaning by generating cavitation bubbles which implode on the surface of fouling, particularly in Reverse Osmosis applications. Conventionally, components that have accumulated fouling are placed into an ultrasonic bath which yet again, requires to stop the operation of the structure for fouling removal process to commence. Application of high power ultrasonic transducers are proposed in this work as a means to remove fouling on a structure whilst in operation. The work presented in this paper consists of the designing of bespoke high power transducers, transducer array design and development of bespoke power amplifiers to drive the high power transducers. The Polytec 3D Laser Doppler Vibrometer has been incorporated into this investigation to study the fouling removal process. Results shows the potential of using high power ultrasonic transducers for fouling removal in marine structures due to the wave propagation across the structure that is under excitation.