This invention helps monitor the health of metal parts used to protect steel structures like bridges, pipelines, and storage tanks from rust. A small sensor is attached to the protective metal (called a sacrificial anode). This sensor checks for changes inside the metal as it corrodes. It does this without stopping or disturbing the system. The collected data helps owners know when to replace the part before it fails. This method is cost-effective, easy to install, and works even in harsh environments like underwater or underground.
Figure (1) Sacrificial anode with PZT sensor; (2) Corrosion test setup with EMI measurement
Steel structures like pipelines, bridges, and water tanks often face rusting due to exposure to moisture and chemicals. To prevent this, a method called cathodic protection is used, where a sacrificial anode (usually made of zinc) is attached to the structure. This anode corrodes instead of the main structure. However, the challenge is knowing when the anode is used up and needs replacement. Current methods to check this are either costly, time-consuming, or require stopping the system, which is not ideal. A smarter and non-intrusive solution is needed.
- Easy-to-Attach Sensor: A compact sensor is placed directly on the anode without changing the setup.
- Real-Time Detection: The sensor continuously monitors how much the anode has corroded by checking internal property changes.
- Works in Any Environment: Waterproof and durable design is suitable for underwater, underground, or harsh weather.
- No Extra Hardware Required: It uses common measuring devices like impedance meters; no bulky equipment needed.
- Non-Intrusive Monitoring: It works silently in the background without disturbing the ongoing protection system.
- High Accuracy and Early Alerts: It captures even small changes early, reducing the risk of failure and avoiding guesswork.
A prototype was built using a zinc sacrificial anode with a PZT sensor patch placed at its center. The sensor was sealed with a waterproof epoxy coating. The setup was tested in a saltwater solution to imitate real corrosion. As corrosion occurred, the sensor accurately detected internal changes and sent data to a measuring device. The setup successfully worked without interrupting the system.
The technology has passed lab testing and simulated trials. The working prototype showed promising results in controlled experiments. Impedance signatures were successfully recorded and analyzed. The technology is ready for industry-scale trials and adoption.
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This technology makes it easier and cheaper to maintain critical steel infrastructure. By giving early warnings of damage, it can prevent costly failures and improve safety. It reduces the need for frequent manual inspections and increases the lifespan of expensive assets. This makes it highly beneficial for sectors like oil & gas, marine, and public infrastructure.
- Civil engineering: RCC bridges, buildings
- Oil and gas pipelines: Underground or submerged
- Marine structures: Ships, offshore platforms, docks
- Storage tanks: Fuel, chemical, water
- Power generation: Cooling systems, transmission towers
- Railways: Embedded metal structures
- Infrastructure asset management and preventive maintenance services
Geography of IP
Type of IP
202021041671
557521