MAGNETO-MECHANICAL IMPEDANCE METHODS AND APPARATUS FOR CRACK DETECTION AND CHARACTERIZATION OF CONDUITS AND OTHER STRUCTURES

Abstract

A crack detecting system operable to detect cracks along a conduit or structure includes a tool movable along a conduit or structure and having at least one sensing device for sensing cracks in a wall of the conduit or structure, and a processor operable to process an output of the at least one sensing device. Responsive to processing of the output by the processor, the processor is operable to determine cracks at the wall of the conduit or structure. The at least one sensing device employs excitation in the form of a high current continuous or pulse wave that is applied to a magneto-mechanical impedance transducer/sensor coil to generate a mechanical wave in the conduit or structure.

Claims

1. A crack detecting system operable to detect cracks along a conduit or structure, said crack detecting system comprising: a tool movable along a conduit or structure and having at least one sensing device for sensing cracks in a wall of the conduit or structure; a processor operable to process an output of said at least one sensing device; wherein, responsive to processing of the output by said processor, said processor is operable to determine presence of a crack at the wall of the conduit or structure; and wherein said at least one sensing device employs excitation in the form of a high current continuous or pulse wave that is applied to a magneto-mechanical impedance transducer/sensor coil to generate a mechanical wave in the conduit or structure.

2. The crack detecting system of claim 1, wherein said at least one sensing device comprises a magnetic yoke and a magneto sensor coil.

3. The crack detecting system of claim 1, wherein said at least one sensing device comprises an electro-mechanical impedance device.

4. The crack detecting system of claim 3, wherein said electro-mechanical impedance device utilizes vibroacoustic modulation.

5. The crack detecting system of claim 1, wherein said tool comprises at least one module with each module having at least one sensing device.

6. The crack detecting system of claim 1, wherein said tool comprises at least two modules with each module having a respective sensing device.

7. The crack detecting system of claim 1, wherein said at least one sensing device comprises at least two sensing devices using different sensing technologies.

8. The crack detecting system of claim 1, wherein said processor determines cracks at an interior surface of the conduit or structure.

9. The crack detecting system of claim 1, wherein said processor determines the cracks at an exterior surface of the conduit or structure.

10. The crack detecting system of claim 1, further comprising a caliper module operable to determine a geometry or flaw of the conduit or structure.

11. The crack detecting system of claim 1, further comprising storing data output from the at least one sensor in a data storage device of the tool.

12. The crack detecting system of claim 1, wherein the processor is located at a remote location from the tool.

13. The crack detecting system of claim 12, wherein the tool is operable to wirelessly transmit the output of said at least one sensing device to the processor.

14. A method for detecting cracks along a conduit or structure, the method comprising: providing a tool comprising at least one sensing device for sensing cracks in a wall of the conduit or structure, wherein the at least one sensing device employs excitation in the form of a high current continuous or pulse wave that is applied to a magneto-mechanical impedance transducer/sensor coil to generate a mechanical wave in the conduit or structure; moving the tool along the conduit or structure and collecting data output from the at least one sensor; processing the data output of the at least one sensing device; and determining, based at least in part on the processing of the output, presence of a crack at the wall of the conduit or structure.

15. The method of claim 14, wherein the at least one sensing device comprises an electro-mechanical impedance device.

16. The method of claim 15, wherein the electro-mechanical impedance device utilizes vibroacoustic modulation.

17. The method of claim 14, wherein the tool comprises at least one position determining device, and wherein the method comprises determining the position of the tool as the tool moves along the conduit or structure via processing data output of the position determining device.

18. The method of claim 14, wherein the processing occurs at a location remote from the tool.

19. The method of claim 18, further comprising transmitting the data output wirelessly from the tool to the remote processor.

20. The method of claim 18, further comprising storing the data output from the at least one sensor in a data storage device of the tool.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIGS. 1A-1B show a cross section of a structure with a tool of the present invention disposed thereat, shown with a magneto impedance sensor;

[0007] FIG. 2 shows a horizontal cross section of a pipe or tubular with another tool of the present invention disposed therein;

[0008] FIG. 3 shows a horizontal cross section of a pipe or tubular with another tool of the present invention disposed therein;

[0009] FIG. 4 shows a horizontal cross section of a pipe or tubular with another tool of the present invention disposed therein;

[0010] FIG. 5 is a block diagram showing post-run data processing stages of the system of the present invention; and

[0011] FIG. 6 is another block diagram showing real-time data processing in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The present invention provides a system and method and apparatus for determining cracks in pipelines or well casings, and other tubulars or conduits. The tool (see, for example, FIGS. 1-4) can be operated in pipelines (such as, for example, for inline inspection), downhole applications (drill strings, well casing and tubing), and other tubulars for the purpose of stress determination in the conduit walls (such as steel or type/grade of steel or the like), or the tool may be moved along any accessible surface of a conduit or tubular or plate or beam or other structure (such as, for example, an interior surface of a conduit or tubular or an exterior surface of a conduit or tubular or plate or beam).

[0013] An example of a tool suitable for such crack detection is shown in FIG. 2. The tool comprises a plurality of modules 1, 2, 3 coupled together by respective universal joints 4, with each module having a drive cup and/or cleaning ring 5. The tool is moved along the tubular 6, whereby sensing devices of the modules operate to sense the presence of cracks at the tubular, as discussed below. Optionally, and such as shown in FIG. 3, the modules 1, 2, 3 of a tool may have a tracked drive 7 that operates to move the tool and modules along the tubular 6. Optionally, and such as shown in FIG. 4, the forwardmost module 3 of the tool may include a pull loop 8 that attaches to a pull cable 9, and/or the rearwardmost module 1 of the tool may have a coiled tube or pushing device 10, that function to move the tool and modules along the tubular 6.

[0014] When an exciter is applied/coupled to a physical specimen or structure, there is an interaction between said exciter and physical specimen. This causes the exciter to move in a different manner than if it were in free space. As a result, differences can be observed in the drive circuitry attached to the transmitter and can be interpreted as a change in the material (such as, for example, cracks, defects, and/or the like in the material). There are two main methodology branches of the impedance method: electro-mechanical impedance method and magneto-mechanical impedance method. The electro-mechanical impedance method is a Vibroacoustic Modulation (VAM) method and apparatus used for crack detection and characterization (see, for example, the systems and methods and apparatuses described in U.S. patent application Ser. No. 15/825,312, filed Nov. 29, 2017, which is hereby incorporated herein by reference in its entirety).

[0015] The magneto-mechanical impedance methods, as well as the combined magneto-mechanical and electro-mechanical impedance methods, are outlined below.

Magneto-Mechanical Impedance Method

[0016] The magneto-mechanical impedance method (see FIGS. 1A-1B) of the present invention utilizes an electrical coil with or without a permanent magnet, in the most common implementations. Highly sensitive magneto-mechanical methods employ devices such as Giant Magneto Impedance (GMI) and/or Giant Magneto-Resistive (GMR) sensors (as examples). Some forms of magneto-mechanical methods employ excitation in the form of a high current continuous or pulse wave that is applied to a magneto-mechanical impedance transducer/sensor coil, which results in a mechanical wave in the structure under test.

[0017] As shown in FIGS. 1A and 1B, an apparatus for detecting cracks comprises a GMI sensor 13 at a magnetic yoke 17. The GMI sensor has an amorphous wire 14 and is placed near or in contact with material under test 11, which includes a crack 12. Signals carried on the wire 14 are passed through a filter 15 and an amplifier 16 and processed to determine the presence of a crack 12 at the structure or material under test.

[0018] Responses to such a magnetically induced mechanical wave reveals information regarding its health or damage state within the signal's analyzed frequency spectra. Other forms of magneto-mechanical impedance methods are implemented as devices that are classified as passive in the sense that a significant impinging energy is not produced to perturbate the material under test, but rather listen passively for variations that are being produced by way of ambient magnetic field and/or incidental mechanical variations (as examples).

[0019] Magneto-mechanical impedance methods are usually implemented as non-contact and tend to be used for the detection of near side defects including cracks, however, in combination with various external perturbation methods can produce results deeper into the material under test. The magneto-mechanical impedance method can be enhanced through the use of mechanical, acoustic, and other independent perturbation methods such that the said external force causes magneto-mechanical methods to more effectively derive the enhanced signals produced when various defects are present in the material under test.

[0020] Magnetic spectral noise density (a power spectral density (PSD) parameter) is a method to find unique patterns of defects and material properties via the magneto-mechanical impedance method with either passive listening or active perturbation.

[0021] The system may utilize a differential method in amplitude and phase change of parameters based on two or more sensors used in the magneto-mechanical impedance method with either passive listening or active perturbation. Common mode or ambient noise can be ignored or rejected to aid in discovering the signal of interest.

[0022] A magneto-optical impedance sensing device can be used for the magneto-mechanical impedance detection method. For example, optical characteristics change as a consequence of the impinging magnetic field. Thus, optical transmission characteristics change as a result of the change in magnetic material properties.

Combined Electro-Mechanical and Magneto-Mechanical Impedance Method

[0023] An electro-mechanical and magneto-mechanical impedance method or device comprises a device that responds to both acoustic energy and magnetic energy. Such devices may comprise (but are not limited to), for example, amorphous wire/microwire schemes based on GMI sensors, Galfenol cilia-like rods, and/or the like. Electro-Mechanical Impedance Methods may utilize aspects of the VAM methods and apparatus described in U.S. patent application Ser. No. 15/825,312, filed Nov. 29, 2017, which is hereby incorporated herein by reference in its entirety.

Advantages:

[0024] The system or method or apparatus of the present invention does not require elaborate receivers and provides simplicity in device design. Broad spectral frequency response enhancements are possible by way of simple enhancements in excitation frequency and pulse waveform tailoring. The methods provide ability to assess or characterize damage (such as cracks).

[0025] Magneto-mechanical methods are greatly enhanced through frequency and/or time domain analyses leveraging the simplicity of device design and associated electronics. Magneto-impedance methods are more conducive to simplified modelling in virtual analysis environments of a greatly simplified nature (such SPICE and SPICE-like electrical modeling environments). Therefore, magneto-mechanical methods make it possible to create a diversity of virtual defects that can more easily be simulated and tested in a virtual manner.

[0026] The data is collected and processed via a data processor, which may be part of the tool or may be remote from the tool (and may process data transmitted from the tool or collected by the tool and processed after the tool has completed its data collection). The processing steps are shown, for example, in FIGS. 5 and 6.

[0027] Thus, the present invention provides a tool that can be operated in pipelines (such as for inline inspection, for example), downhole applications, other tubulars and structures of various geometry, for the purpose of crack detection. The tool utilizes means for positional and/or spatial relationship via items such as a caliper, encoder, gyroscopic devices, inertial measurement unit (IMU), and the like. Optionally, the tool may also utilize a caliper module for determination of geometry flaws, dents, and the like.

[0028] The tool utilizes at least one impedance method, or any combination of impedance methods, such as magneto-mechanical, electro-mechanical, or a combination of both. The tool may utilize any impedance method or a combination of both mentioned herein, along with any individual or combination of VAM methods or systems or configurations or techniques.

[0029] The tool may utilize individual sensor(s) or array(s) unlimitedly disposed in uniform or non-uniform arrangements/patterns for the sensing technologies and/or methods. The tool may utilize an electro-magnetic acoustic transducer to impart acoustic energy into the material under test if combined with the electro-mechanical impedance method as outlined above.

[0030] The tool may store data on-board, or may transmit collected data to a remote location for storage (and/or processing), or may do a combination of both. The tool may employ advanced data processing techniques to isolate and extract useful data as required. The tool may employ advanced data processing techniques that use a single sensing technology and/or method, or any combination of sensing technologies (together or individually) and/or methods. The data processing may be conducted in real-time during tool operation, off-loaded externally to be conducted after completion of a tool operation, or a combination of both.

[0031] The tool may comprise at least one module, which may contain at least one, or any combination of impedance methods such as magneto-mechanical, electro-mechanical, or a combination of both. The module may contain multiple impedance methods, such as magneto-mechanical, electro-mechanical, or a combination of both that may or may not interact with each other, and/or utilize shared componentry. The tool with multiple modules may contain multiple impedance methods, such as magneto-mechanical, electro-mechanical, or a combination of both that interact with each other, and/or utilize shared componentry.

[0032] A tool with multiple modules may contain a single impedance method, or combinations of methods, that interacts between the multiple modules. The tool with multiple modules may contain multiple impedance methods, or combinations of methods, that interact between the multiple modules.

[0033] The module may contain multiple impedance methods, such as magneto-mechanical, electro-mechanical, or a combination of both, and may also include VAM methods or systems or configurations or techniques, that may or may not interact with each other, and/or utilize shared componentry. A tool with multiple modules may contain multiple impedance methods, such as magneto-mechanical, electro-mechanical, or a combination of both, and may also include VAM methods or systems or configurations or techniques that interact with each other, and/or utilize shared componentry.

[0034] A tool with multiple modules may contain a single impedance method, or combinations of, that may also include VAM methods or systems or configurations or techniques, that interact between said multiple modules. A tool with multiple modules may contain multiple impedance methods, or combinations of, that may also include VAM methods or systems or configurations or techniques that interact between the multiple modules.

[0035] The tool may be self-propelled (such as, but not limited to a robotic crawler such as shown in FIG. 3), or may propelled by a gaseous or liquid medium pressure differential, or is propelled via a cable in tension (pulled such as shown in FIG. 4), or is propelled via a coiled tube in compression (pushed such as shown in FIG. 4), or a combination of the aforementioned propulsion means.

[0036] The tool may be powered on-board, remotely, or a combination of both. The tool may have a system and method to clean surfaces for better sensing abilities, and that system may be incorporated with at least one module if utilized in the tool.

[0037] The tool may be operated in tubulars with a wide variety of diameters or cross-sectional areas. Optionally, the tool may be attached to other tools (such as, for example, material identification, magnetic flux leakage, calipers, etc.). The tool may simultaneously use the aforementioned sensing technologies with existing tools' sensing capabilities and/or system(s)(such as, for example, crack detection system(s) utilize other tool capabilities simultaneously through shared componentry, magnetic fields, perturbation energy, waves, etc.).

[0038] The tool may include the means to determine position/location/distance such as, but not limited to, global positioning system(s), gyroscopic systems, encoders or odometers, etc. The tool may include the means to determine position, location or distance that stores this data on-board or transmits it to a remote location, or a combination of both. The tool may combine the position, location or distance data simultaneously with sensing data collection at any discrete location within the tubular, or on a structure's surface.

[0039] An additional version of a tool may be configured to be mounted externally to a tubular via fixture, frame, cabling, etc. to detect cracks on the exterior surface(s). This version of the tool may have a sensing suite that is moved manually, is powered, or is pre-programmed to operate in a pattern.

[0040] The tool may utilize a transduction method such as time reversal techniques (via processing code) applied to one or more impedance methods included herein as an enhancement. The tool may utilize virtual phased arrays in the form of one or more virtual emitters and one or more virtual receivers.

[0041] The tool may be configured to be conveyed within a borehole to evaluate a tubular within the borehole. The tool may further include a conveyance device configured to convey the tool into the borehole. The tool may be configured to be conveyed into and within the borehole via wireline, tubing (tubing conveyed), crawlers, robotic apparatuses, and/or other means.

[0042] Therefore, the present invention provides a tool or device that utilizes a sensing system or device or means to sense and collect data pertaining to cracks in the pipe or conduit or other structures in or on which the tool is disposed. The collected data is processed and analyzed to determine the cracks in the pipe or structure at various locations along the conduit or pipeline or structure.

[0043] Changes and modifications to the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law including the doctrine of equivalents.