Automated ultrasonic safety inspection of food silos and road tankers

- AFM 151

Sponsor: DEFRA

Partners: University of Bath, Monitor NDT, Express Dairies, i2R, UK Robotics,

PERA Technology Centre.

Total Project Cost: £765,200

Start date/End date: 01/09/2000 – 31/08/2002

Project Co-ordinator: Dr Richard Shaw, Pera Technology, Technology Centre,

Melton Mowbray, Leicestershire LE13 0PB Tel: 01664 501501 Fax: 01644 501589
E-mail: richard.shaw@pera.com

Abstract

Milk silos can hold in excess of 100,000 litres - enough to make 40 million cups of
tea! As a result, the stresses on these structures, as they are emptied and filled daily,
are immense. Manually checking them for cracks and corrosion is a monumental task.

The overall aim of the project called ‘Ultrasub’ was to investigate, develop and trial
an automated ultrasonic based technology which will enable the examination of the
walls of stainless steel food tanks and silos (under operating conditions) for cracks
and incipient flaws.

Several of the original objectives for this project have turned out to be impracticable.
The prototype module is not self contained requiring an umbilical connection to
external batteries and a control module. Similarly the initial desire for a non-contact
propulsion system was abandoned as results showed that none of the proposed
systems would be sufficiently stable. Location/positioning systems based on external
beacons proved impossible to implement in a dairy environment. However the
externally powered and controlled , wheel driven module positioning itself by dead
reckoning meets the specification for accuracy, speed of operation and sensitivity in
detecting flaws. None of the enforced changes have compromised the capability of the
‘Ultrasub’ such that it would not be commercially useful. It is seen as a valuable
addition to the existing non-destructive testing methods.