Damage monitoring in pressure vessels and pipelines based on wireless sensor networks

Due to their high lightweight potential, fibre reinforced plastics have found a broad application in chemical apparatus and plantconstruction. Because of improved standards for safety, reliability and cost effectiveness of such composite components, numerous technical challenges arise for the producers of pressure vessels, tanks, reactors and pipe element systems. In this context, a multitude of problems appear during recurring acceptance inspections and equipment condition monitoring using non-destructive test methods. Promising advantages arise from novel monitoring concepts based on semi-active or even absolutely autarkic wireless sensor networks with so-called “sleeping sensors” as key function units with remote enquiry. These autonomoussensor-based monitoring modules are directly integrated into the composite and start recording signals not before a defined threshold is increased. This article discusses the scientific-technical issues that arise during the development of such intelligent damage monitoring systems. This includes the sensor network design, the sensor integration during manufacturing and the correlation between the relevant damage mechanisms and the sensor signals. Exemplary, sensor networks are integrated in GFPR composites. These composites have been tested in order to demonstrate the modes of operation of the sensor techniques and theircapability to detect the relevant damage mechanisms.