In line inspection method and apparatus for performing in line inspections

Abstract

An apparatus and method for performing inline inspections of pipelines of composite structure installed in a host pipeline or standing alone comprising a multiplicity of sensor/transducers located on or within the pipe structure to measure and record various pipeline properties, an activation/reading/storage device to activate read and collect measurement results from the sensor transducers, an automatic launch and recovery system for the activation/reading/storage device, and a database/storage/analytical device to receive, analyze and interpret results from collected data and transmit appropriate instructions to a pipeline operator or remotely activated system for action. The remote reading of sensor/transducers may be accomplished by a device running through the pipeline or passing over or near the pipeline, where ground-level handheld or wheeled vehicle mounted, fixed wing or rotary aircraft, hovercraft watercraft or satellite based instrumentation can record the location and condition of a pipeline.

Claims

1. An inline inspection system to assess the integrity of non-corrosive, non-metallic reinforced or partially metallic reinforced composite pipe-installed in a host pipeline or standing alone in lengths of up to ten miles comprising: a. a composite pipe structure having a pulling end further comprising: a round pressure barrier core pipe with a wall; reinforcement fabric layers helically wrapped externally around the core pipe, with axial pulling tapes of fibers having tensile strength above 400 ksi, fiber tows and protective covering with a multiplicity of sensor/transducers embedded in the reinforcement fabric layers, to measure and record data; a reduction in cross sectional shape of the composite pipe structure by a shape reduction machine with a series of rollers and mandrels and wrapping the composite pipe structure with reduced cross sectional shape with a protective covering having a multiplicity of sensor/transducers embedded under the protective covering; installation of the composite pipe structure by pulling a towline attached to the pulling tapes and fully expanding the composite pipe structure to a round cross section after installation; b. a reader/activator unit internal to the composite pipe structure to activate, read and collect data including the presence of hydrates or chemical build up on the composite walls, annular spaces and pipe pressure from the sensor/transducers embedded in the reinforcement fabric layers, the pulling tapes, the fiber tows or the protective covering of the composite pipe; c. an inline launch and recovery system in the composite pipe structure for launch and retrieval of the reader/activator unit internal to the composite pipe without having to open the composite pipe; and d. a database/storage/analytical computer based system to receive, store and process data including the presence of hydrates or chemical build up on the composite walls, annular spaces and pipe pressure read and collected from the sensor/transducers embedded in the reinforcement fabric layers, the pulling tapes, the fiber tows or the protective covering of the composite pipe structure by the reader/activator unit.

2. The system of claim 1 wherein the sensor/transducers comprise wired sensors, non-wired sensors, networked sensors, sensors without connectivity to a power source, sensors with connectivity to a power source, radio frequency operated sensors, nano-technology based sensors, wireless identification and sensing platform sensors, optical sensors, or graphene sensors.

3. The system of claim 1 wherein the data measured and recorded by the sensors/transducers comprises: acoustic, vibration, acceleration, strain or force, electrical current, electrical potential, magnetic, flow, fluid/gas velocity, density, ionizing radiation, subatomic particles, mechanical, chemical, optical, thermal, environmental, hydraulic, global positioning data (GPS), conductivity or inductivity.

4. The system of claim 1 wherein the sensors/transducers comprise; piezoelectric crystals, piezoelectric ceramics, analog or digital pressure, vibration monitoring sensors, fluid pulse transducers/sensors, temperature, and strain transducers/sensors, radio frequency sensors, geophone, hydrophone, soil moisture sensors, electrochemical sensors, graphene sensors, nano material sensing systems, optical sensors, Wireless Identification and Sensing Platform sensors, amplifiers and integrated circuit technologies and conductivity, or inductivity sensing systems.

5. The system of claim 1 installed in a host pipeline wherein connectivity is provided by metallic or non-metallic wires installed in the reinforcement fabric layers, the pulling tapes, the fiber tows or the protective covering of the composite pipe structure or are separately installed within the core pipe wall to provide connectivity.

6. The system of claim 1 wherein a power source is provided by proximity to a metallic host pipe having electrical properties resultant from an operating Cathodic Protection system for a metallic host pipe.

7. The system of claim 1 wherein sensor/transducers with modified frequency identifiers provide the identity and location of the sensor/transducer embedded in the reinforcement fabric layers, the pulling tapes, the fiber tows or the protective covering of the composite pipe structure and separate sensors/transducers measure and record data comprising pressure, humidity, temperature, strain (bi-axial), fluid or gas composition, temperature, dimension, circumferential measurement, ovality or flow rate.

8. The system of claim 1 wherein the sensor/transducers and reader/activator units are tuned to operate in equivalent operating frequency ranges.

9. The system of claim 1 wherein the reader/activator unit is configured to pass through the composite pipe structure, driven by flow in the composite pipe structure or pulled through the composite pipe structure by tether, and wherein the reader/activator unit further comprises a power source and a transceiver that activates and powers sensor/transducers and receives a resulting data transmission from a sensor/transducer storing the data received in a memory-storage area with the capability to wirelessly or cable transfer the stored data to a data storage and manipulation computer based system.

10. The reader/activator unit of claim 9 wherein the power source comprises a battery, battery pack, proximity to the host pipe with operating Cathodic Protection system, generator, invertor, or micro-nuclear power plant.

11. The reader/activator unit of claim 9 wherein the transceiver is an integrated circuit with an antenna tuned to a radio frequency identifier frequency in the same frequency range as the operating frequency of the sensor/transducers.

12. The system of claim 11 wherein the reader/activator unit is configured as a hand held or vehicle mounted to pass over a composite pipe structure, and wherein the reader/activator unit comprises a power source and a transceiver that activates and powers sensor/transducers and receives a resulting transmission from the sensor/transducers and storing the data received in a memory-storage area with the capability to wirelessly or cable transfer the data received in a memory-storage area to a data storage and manipulation computer based system.

13. The reader/activator unit of claim 12 wherein the vehicle is manually moved.

14. The reader/activator unit of claim 12 wherein power to pass the vehicle over a composite pipe structure is provided from a list comprising: a hovercraft, water craft, two or more wheeled vehicle, a tracked vehicle, a rotary aircraft or a fixed wing aircraft, or satellite.

15. The reader/activator unit of claim 12 wherein a database/storage/analytical computer based system is mounted on the vehicle and connected to the reader/activator unit.

16. The system of claim 1 wherein the database/storage/analytical computer based system comprises hardware and software that contains interpretation programs to compile, analyze and compare recorded data, furnish results to an operators and/or a pipeline supervisory control and data acquisition system, react upon results, inform from results, substitute and correlate results, offer readings for an operators action, and provide history of the pipeline over the life of the composite pipe structure.

17. The database/storage/analytical computer based system of claim 16 further comprising a wireless input/output port for communications with other systems.

18. The database/storage/analytical computer based system of claim 16 comprising analytical software for analysis of composite pipes including the use of a material properties database for strips, wires, fibers, fabrics and polymers.

19. The inline inspection system of claim 1 wherein the inline launch and recovery system further comprises a fill chamber, a launch chamber, a receiving chamber and a recovery chamber, all with valves for launch and recovery of the reader/activator unit.

20. The inline inspection system of claim 1 wherein the reader/activator unit is a data retrieval pod, a data retrieval ball or a self propelled reader.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is the cross sectional presentation of a composite pipeline within a host pipeline, shown with the sensors in different positions and under the variety of angles, within the composite pipeline; showing launching and receiving stations.

(2) FIG. 2 is a depiction of the recorded data in one form of the presentation by the ARS or DSA reading instrumentation.

(3) FIG. 3 depicts non-dimensional sketches of the ARS data retrieval pod and data retrieval ball and a self propelled reader, implying the variety of sizes and shapes that are possible.

(4) FIG. 4 is an isometric depiction of a composite pipe structure where the components of the pipe materials have built in sensor/transducers and the sensor/transducers are independently attached or those which can be applied and built within the material itself. There are also nano sensor/transducers, WISP Sensors and graphene sensors included as part of the materials of construction. The nano enhanced coating, adhesive and filler materials are also included. Such systems have a high strength and resilience that can sustain high pressures, temperatures and impacts.

(5) FIG. 4a shows a segment of a fully expanded cross section of the composite pipe with an inserted sensor/transducer.

(6) FIG. 5 is a reduced C shape alongside a fully expanded shape, among other shapes for the reduction of the composite pipe used as a structural form for easy insertion into an existing pipeline, showing the covers as a protection and also available as mentioned in FIG. 4.

(7) FIG. 6 shows the detail of the installed pulling tapes and the fabric composition with built in components for sensors and material built in sensors such as nano fibers and graphene materials.

(8) FIG. 7 is the detail of the machine showing the patented application by helical means of the tapes as overlays over a core pipe as a shape and size control member of the composite pipe.

(9) FIGS. 8, 9 and 10 are side views of the components of the composite pipe of FIG. 4.

(10) FIGS. 11, 11A, 11B, and 11C are isometric, plan, front and side views of a helical wrapping machine similar to that depicted in FIG. 7.

(11) FIG. 12 is a shape reduction machine for reducing the cross sectional shape of the composite pipe from round to a C shape.

(12) FIG. 12A is an end view of the shape reduction machine showing the composite pipe exiting the machine with a reduced cross sectional shape.

(13) FIG. 13 shows the tow head or pulling end of the composite pipe with a reduced cross sectional shape wrapped in a protective coating with high strength pulling tapes spliced into a tow line being pulled through a leader by a pulling winch.

(14) FIG. 14 shows a wrapping machine applying a continuous longitudinal wrap on the composite pipe.

DETAILED DESCRIPTION OF THE INVENTION

(15) FIG. 1 shows a cross sectional presentation of a typical pipeline with the inventive system and method for monitoring pipelines installed along with novel automatic launch and recovery system (ALRS) for an activation/reading/storage device (ARS). In FIG. 1, a host pipeline 6 is fitted with a launching fitting 1 having an ARS launcher 2, an adapter spool piece 5 with a protective enclosure 7, an ALRS receiver 11A, and a retractable gate 12A. Also shown are sensor/transducers 3 in various positions 13A. A wired sensor 4 is shown as well as a radio frequency identifier RFID 8.

(16) It is intended that the inventive system and method be applicable to a length of pipeline with an existing technology pig retrieval fitting adapted for use with composite piping and ARS unit at the opposite end of the pipeline.

(17) It is also intended that the inventive system and method be applicable on re-habilitation projects for a host metallic pipeline and for pipes, conduits, pipelines or systems that are non-corrosive, non-metallic reinforced or are partially metallic reinforced that are either inserted into a steel host pipe or deployed as a stand-alone composite pipe.

(18) The sensor/transducers 3 are positioned axially and circumferentially, or manufactured in-situ within the non-metallic or partially metallic reinforced thermoplastic composite pipe wall layers in strategic locations where: The sensor/transducers 3 are passivethere is no local power. The sensor/transducers 3 are semi-active modified radio frequency identifier devices that have limited local power such as a battery or power generator. The sensor/transducers 3 are powered or active-that is with full local power or hardwired into the system.

(19) FIG. 2 depicts a graphical reading 9 or electronic presentation from the ARS or DAS instrumentation.

(20) FIG. 3 shows two possible cross sections of ARS Units, including the data retrieval pod 10, the data retrieval ball ARS unit 10a and a self propelled reader 10b.

(21) In FIG. 4 an isometric representation of one type of high strength light weight composite pipe 17 in one form of manufacturing is depicted with a pressure barrier core pipe 11, reinforcement fabric strength layers 12 helical and circularly wound as per the design requirements for strength with sensor/transducers 3 embedded within the fabric as required, high strength axial pulling tapes 13 with imbedded sensors as required, and fiber tows 14 with embedded sensors. The fibers used in both the fabric strength layers 12 and the axial pulling tapes 13 are high strength liquid crystal polyester (VECTRAN) and aramid (TWARON and TECHNORA). These fibers have tensile strengths in excess of 400 ksi, and an elastic modulus about 40% of steel. These fibers have a density of about 1.4 times that of water compared to 7.85 times for steel.

(22) FIG. 5 shows a cross section formed in one possible shape for reduction of the pipe diameter with sensor/transducers 3 embedded under a protective covering 15 required for some installations in a host pipe. Alongside the formed shape is shown a fully expanded shape from which a section is marked and depicted in FIG. 4a to show the placement/insertion of a sensor/transducer 3 in the composite wall structure.

(23) FIG. 6 shows the detail of the high strength pulling tapes 13 and the reinforcing fabric 16 woven with nano fibers as sensors as a part of the fabric composition capable of functioning within the structural fabric. Other types of sensors can include; piezoelectric sensors, transducers, radio frequency sensors, graphene sensors, nano material sensing systems, WISP sensors, optical sensors and conductivity sensing.

(24) In FIG. 7 the machine used for one method of pipe construction is shown applying the reinforcement fabric layers 12 on the pressure barrier core pipe 11. In one embodiment the core pipe 11 is extruded HDPE in any suitable grade such as PE 4710 or PE100. In certain aspects, a fluid resistant thermoplastic material is used for the core pipe 11 that resists fluids being transported through a pipeline. Among the materials that may be used are NYLON 6, RILSON, or NYLON 11 or other suitable thermoplastic material. In certain embodiments, lengths of the core pipe 11 are welded together at a location at which the composite pipe 17 is to be installed.

(25) In FIGS. 8, 9 and 10 are side views of the components of a composite pipe structure 17 during manufacture.

(26) In FIG. 8, the first layer 16a of reinforcing fabric 16 is wrapped around the pressure barrier core pipe 11. Suitable materials for this fabric 16 include fabric with highly oriented high molecular weight polyethylene (HMPE); or ultra high molecular weight polyethylene (UHMPE); KEVLAR; ARAMID; VECTRAN; liquid crystal polymer (LCP); DYNEEMA; TWARON; TECHNORA; fiber-reinforcing material, e.g. carbon fibers, fiberglass fibers and/or hybrid fibers; fabric made from carbon fibers and/or glass fibers; and fabric made from carbon fibers and SPECTRA. The thickness of first layer 16a and 16b as shown in FIG. 9 ranges between 0.010 and 0.240 inches.

(27) The first layer 16a is wrapped around the pressure barrier core pipe 11 at a wrap angle between 45 degrees and 85 degrees. In FIG. 8, the wind angle is shown as 56 degrees with respect to the longitudinal axis A of the pressure barrier core pipe 11. Edges of each wrap are butted up against edges of adjacent wraps so no part of the first layer 16a overlaps itself. The butting is indicated by W. Alternatively, a minimal overlap is used or there is a gap G. Each wrap of first layer 16a has a width H. Optionally, one or more tapes 18, strips, or lines of adhesive or glue are applied on the pressure barrier core pipe 11.

(28) As shown in FIG. 9, a second layer 16b is wrapped over the first layer 16a and may be wrapped in any of the number of ways described for the first layer 16a and may be of the material described for the first layer 16a. Also shown are sensor/transducers 3.

(29) As shown in FIG. 10, up to forty or more fiber strands 19 or tows are wound on the second layer 16b, or on the first layer 16a, or on the tapes 18 to strengthen the composite pipe structure 17 and facilitate its integrity while it is being pulled through a pipeline. Strands 19a are at a positive wind angle to the longitudinal axis A and strands 19b are at a negative wind angle. Fiber optic cables 20 are also shown.

(30) This composite pipe structure 17 with a pressure barrier core pipe 11 with high strength, low weight helical reinforcement fabric layers 16a and 16b, and axial pull tapes 13 must be flexible and strong enough to allow reduction in cross section shape such as C-forming, pulling of the composite pipe structure 17 in extreme continuous lengths of as much as 10 miles, and then restoring the composite pipe structure 17 to a round shape installed in a host pipeline. These extreme specifications require the implementation of the present invention.

(31) FIGS. 11, 11A, 11B, and 11C, respectively show isometric, plan, front and side views of a helical wrapping machine similar to that depicted in FIG. 7 with a pressure barrier core pipe 11 being fed continuously through the wrapping machine.

(32) FIG. 12 shows a shape reduction machine for reducing the cross sectional shape of the composite pipe structure 17 from round to a C shape as traveling through a series of rollers and mandrels from left to right. As the composite pipe structure 17 is reduced in cross sectional shape from round to a C shape a protective coating 15 is installed to protect and hold the C shape. FIG. 12A shows the end view of the composite pipe structure 17 in reduced C cross sectional shape 21 with protective coating 15 exiting the shape reduction machine. A C shape is depicted but other shapes are possible.

(33) As noted above the composite pipe structure 17 is reduced in cross sectional shape from round to a C shape to facilitate installation in a host pipe by pulling the reduced composite pipe structure 21 through the host pipe.

(34) FIG. 13 shows the tow head or pulling end 23 of the composite pipe with a reduced cross sectional shape 21 wrapped in a protective coating 15 with high strength pulling tapes 13 spliced into a tow line 22 being pulled through a leader 24 by a pulling winch 25.

(35) FIG. 14 shows a wrapping machine 26 applying a continuous longitudinal wrap on the composite pipe structure 17 before reduction in cross sectional shape.