Real-Time Integrity Monitoring During Pressurization
Acoustic Emission (AE) testing provides a powerful approach for evaluating the structural integrity of pressure vessels—including spheres, tanks, reactors, and pipelines—during hydrostatic or pneumatic pressure tests. Unlike conventional methods that inspect before or after testing, AE continuously monitors the vessel during stress application.
As internal pressure rises, defects such as cracks, corrosion zones, or weld flaws release transient elastic waves when stressed. Arrays of piezoelectric sensors detect these signals, allowing analysts to determine damage activity, intensity, and location in real time.
BQCIS AE systems deliver immediate insight into vessel performance under load, helping clients confirm design reliability, locate potential weaknesses, and avoid costly or hazardous failures.
Key AE Pressure Vessel Testing Activities
Key Benefits of AE for Pressure Vessels
Real-Time Integrity Assessment
Provides live data on vessel performance during loading, allowing early detection of abnormal stress responses or active defects.
Global Volumetric Assessment
Monitors the entire vessel shell and head areas simultaneously from minimal sensor coverage, offering a complete integrity profile.
Early Warning of Failure
Detects the onset of flaw propagation before rupture occurs, allowing safe termination of tests and corrective actions.
Locates Areas for Follow-Up NDT
Identifies high-activity zones to guide focused ultrasonic, magnetic particle, or radiographic examinations post-test.
Success Story
AE Monitoring Halts Hydrotest, Preventing Vessel Rupture
An aging reactor vessel required a hydrostatic recertification test amid concerns about hidden fatigue cracks in critical weld joints.
BQCIS installed a 12-channel AE sensor network, calibrated sensitivity zones, and monitored acoustic activity as pressure increased in controlled increments.
Significant AE bursts indicated active crack propagation at 75% of test pressure. The test was halted immediately per AE criteria. Follow-up UT confirmed a large weld defect—preventing a catastrophic failure and saving the client from major downtime and loss.