Acoustic Emission Monitoring for Pressure Vessels and Storage Tanks

Pressure vessels and storage tanks are both important industrial assets, but their acoustic emission monitoring purposes are different.

For pressure vessels, AE testing is mainly used to detect active cracks, leakage, weld activity, fatigue damage and abnormal acoustic sources under pressure or loading conditions.

For aboveground storage tanks, AE monitoring is mainly used to evaluate tank bottom plate corrosion, leakage and active corrosion sources, especially when the tank cannot be opened, cleaned or taken out of service.

For Pressure Vessels, Boilers, Reactors and Pressure Equipment

Pressure vessels are commonly exposed to internal pressure, temperature variation, corrosion, fatigue, vibration and cyclic loading. Active defects may occur in welds, nozzles, heads, shells or other high-stress areas.

Acoustic emission testing can monitor the whole pressure vessel during pressure loading or operation. When an active crack grows, leakage occurs, or a defect releases stress energy, elastic waves are generated and transmitted through the vessel wall. AE sensors detect these signals and help locate the active source area.

Typical Applications

Typical AE Detection Targets

Main Advantages

• Global monitoring of the pressure vessel during one loading process
• Real-time detection during hydrostatic or pneumatic pressure testing
• Source location capability with multiple AE sensors
• Reduced inspection blindness compared with purely local inspection
• Useful guidance for follow-up UT, PAUT, MT, PT or visual inspection
• Suitable for both short-term testing and long-term online monitoring

Recommended System

A pressure vessel AE testing system usually includes AE sensors, preamplifiers, low-noise signal cables, multi-channel AE acquisition system, pressure input, analysis software and source location function.

The system can record AE parameters such as amplitude, energy, counts, duration, rise time, ASL, RMS, waveform and pressure history. With proper sensor layout and calibration, the software can provide AE source location maps and activity trends.

Pressure Vessel AE Testing System

For Atmospheric Storage Tanks and AST Bottom Plate Evaluation

Aboveground storage tanks may suffer from bottom plate corrosion, leakage and corrosion-related damage after long-term service. Traditional internal inspection usually requires emptying, cleaning and opening the tank, which can be costly and time-consuming.

Acoustic emission testing provides a non-intrusive method to evaluate active corrosion and leakage-related acoustic sources from the tank bottom. AE sensors are typically installed around the lower shell of the tank. The system collects signals generated by active corrosion, leakage or other acoustic sources and helps evaluate the tank bottom condition.

Typical Applications

Typical AE Detection Targets

• Active tank bottom corrosion
• Leakage-related acoustic sources
• Corrosion activity distribution
• Abnormal acoustic activity from tank bottom area
• Long-term tank condition trend

Main Advantages

• No need to open the tank for preliminary screening
• No need to empty or clean the tank for AE monitoring
• Suitable for large storage tanks
• Helps evaluate active corrosion risk
• Supports maintenance planning and inspection prioritization
• Suitable for periodic testing or online monitoring

Recommended System

A storage tank AE monitoring solution usually includes AE sensors installed around the tank lower shell, preamplifiers, signal cables, AE acquisition system and analysis software.

For online monitoring, remote data access, alarm output, trend analysis and cloud-based monitoring can be configured according to the project requirements.

Storage Tank Corrosion Monitoring

The basic AE monitoring process is similar for both pressure vessels and storage tanks.

AE technology is especially useful for detecting active sources. A completely inactive defect may not generate detectable AE signals. Therefore, the testing condition, loading process, background noise and sensor layout are important for reliable AE evaluation.

QAWRUMS can provide complete acoustic emission testing and monitoring configurations for different industrial applications.

AE Acquisition Systems

Multi-channel AE acquisition systems can be used for pressure vessel testing, tank bottom corrosion detection, source location and long-term monitoring. For critical assets, online AE monitoring systems can provide continuous signal acquisition, remote access, alarm output and long-term trend analysis.

SAEU3H Multi-Channel AE System	RAEM1-6 Multi-Channel Monitoring System
Recommended for pressure testing, proof testing and projects requiring high-performance synchronized multi-channel acquisition and source location. Modular 4-, 20- or 48-channel system configurations Multiple chassis can be cascaded for larger channel counts AE feature parameters and waveform acquisition External pressure or process-signal synchronization Compatible with SWAE acquisition and analysis software	RAEM1-6 can be used when the application requires distributed acquisition, standalone operation or remote data transmission. Two to six AE channels per unit Multiple units can be cascaded for larger systems Ethernet, Wi-Fi or 4G communication options Four external input channels Local software, private server or cloud connection options Suitable for unattended or longer-term monitoring configurations

AE Sensors

Different AE sensors can be selected according to tank/vessel material, frequency range, sensitivity, surface temperature, installation environment and expected signal characteristics.

GI150 Sensor	GI40 Sensor
GI150 sensor is recommended for metal pressure vessel testing.	GI40 sensor is recommended for storage tank bottom corrosion monitoring.

The above sensors are integral sensors that include preamplifier inside. Contact us to help you select or evaluate the suitable sensors for your own project.

Preamplifiers and Cables

Preamplifiers amplify weak AE signals from sensors, while low-noise cables ensure reliable signal transmission in industrial environments. The preamplifier can be built-in the sensor (integral sensors like GI150 or GI40 above) or be external independent component after the general sensor.

View Preamplifiers

Both schedule testing projects and long-term monitoring projects workflow is like below.

1. Application Review

We review the equipment type, size, material, operating pressure, temperature, medium, inspection purpose and expected damage mechanism.

2. Solution Design

Based on the equipment condition and monitoring target, we recommend the AE system, sensor type, channel number, sensor layout and data analysis method.

3. System Installation

AE sensors are installed on suitable positions with proper coupling and fixation. Preamplifiers, cables, acquisition units and pressure or process inputs are connected according to the testing plan.

4. System Verification

Before formal testing, channel sensitivity, background noise, coupling quality and source location performance are checked.

5. Data Acquisition

The AE system collects signals during pressure loading, operation or long-term monitoring. Data can be analyzed in real time and stored for further evaluation.

6. Analysis and Report

The software provides AE parameter analysis, trend curves, source location maps, alarm records and recommended follow-up inspection areas.

Note: Step 3-6 are handled by the customers. We can provide online and remote supports.

Q1: Is this page for pressure vessels or storage tanks?

This page is an overview of QAWRUMS acoustic emission solutions for both pressure vessels and storage tanks. If your application is a pressure vessel, boiler, reactor or tower, please visit the Pressure Vessel AE Testing System page. If your application is an aboveground storage tank or AST bottom corrosion monitoring, please visit the Storage Tank Corrosion Monitoring page.

Q1: What is the main difference between pressure vessel AE testing and tank AE monitoring?

Pressure vessel AE testing focuses on active cracks, weld activity, leakage and fatigue damage under pressure or loading conditions. Storage tank AE monitoring focuses mainly on bottom plate corrosion, leakage and active corrosion sources in atmospheric storage tanks.

Q3: Can AE testing locate defects?

Yes. With multiple AE sensors and proper calibration, the system can estimate the source location of acoustic emission activity. The result helps identify suspicious areas for follow-up inspection.

Q4: Can AE detect inactive defects?

AE testing is mainly sensitive to active defects. A completely inactive defect may not generate detectable acoustic emission signals. Therefore, AE is best used when the equipment is under pressure, load, thermal stress, corrosion activity or operating conditions.

Q5: Does AE replace ultrasonic testing or other NDT methods?

Usually no. AE is a global monitoring and screening method. It helps identify active source areas. Follow-up methods such as ultrasonic testing, phased array UT, magnetic particle testing, penetrant testing or visual inspection may be used to confirm and size the defect.

Q6: Can AE be used for online monitoring?

Yes. AE systems can be configured for short-term testing, periodic inspection or long-term online monitoring. Online monitoring can provide continuous data acquisition, alarm output, trend analysis and remote access.

Not sure whether your application belongs to pressure vessel testing or storage tank corrosion monitoring?

Contact us and share your equipment information. Our team will recommend a suitable AE testing or monitoring configuration based on your equipment type, material, pressure, temperature, inspection target and site conditions.

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