INSPECTION TOOL
20230160518 · 2023-05-25
Inventors
- Robert Victor DE LORENZO (Seatle, WA, US)
- Paul MANZAK (Kent, WA, US)
- Colum Mark HOLTAM (Stafford, TX, US)
- Charles Jess LEE (Kent, WA, US)
Cpc classification
F16L55/48
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L55/38
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L55/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L2101/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F16L55/48
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L55/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A system and method for inspecting offshore and onshore tubular or piping assets is described. The system and method utilizes an inspection tool comprising a communication system, a sensor, a long distance travel system, and a localized travel system, allowing fast long distance travel until the inspection tool approximates an area of interest, followed by actuating the localized travel system to accurately inspect the area of interest.
Claims
1. An inspection tool for inspecting a localized area of interest within a pipeline, the tool comprising: (a) a communication system providing communication between the inspection tool and a controller; (b) a sensor for detecting abnormality within the localized area of interest; (c) a long distance travel system; and (d) a localized travel system; wherein the communication system controls the travel system of the inspection tool.
2. The inspection tool of claim 1, wherein the communication system uses extremely low frequency (ELF), fiber optic, guided wave, or pulsed transducer for communication.
3. The inspection tool of claim 1, wherein the long distance travel system is a flow-driven navigation system.
4. The inspection tool of claim 3, wherein the inspection tool further comprises an adjustable seal to allow variation of fluid flow through the adjustable seal.
5. The inspection tool of claim 4, wherein the adjustable seal is an iris-type seal.
6. The inspection tool of claim 4, wherein the adjustable seal is a variable pitch seal.
7. The inspection tool of claim 1, wherein the localized travel system is a self-propelled drive system.
8. The inspection tool of claim 7, wherein the localized travel system is selected from clutch-controlled wheels, a tracked tank-drive system, or a roller-type drive.
9. The inspection tool of claim 1, wherein the sensor is configured between an extended position to contact surfaces near the area of interest and a retracted position without contacting the surfaces near the area of interest.
10. The inspection tool of claim 1, wherein the localized drive system is configured between an extended position to contact surfaces near the area of interest and a retracted position without contacting the surfaces near the area of interest.
11. The inspection tool of claim 1, wherein the sensor detects the abnormality through radiography, external or internal ultrasonic inspection, Magnetic Flux Leakage (MFL) or eddy current, acoustic emission, computed tomography, or combinations thereof.
12. A method for performing an inspection of an area of interest in a pipe, the method comprising the steps of: (a) conveying an inspection tool into the pipe, the inspection tool comprising a communication system, a sensor, a long distance travel system, and a localized travel system; (b) activating the long distance travel system until the inspection tool is proximate the area of interest; and (c) activating the localized travel system to perform the inspection of the area of interest.
13. The method of claim 12, wherein in step (b) the sensor and/or the localized travel system are configured in a retracted position without contacting external surfaces.
14. The method of claim 12, wherein in step (c) the sensor and/or the localized travel system are configured in an extended position to contact external surfaces near the area of interest.
15. The method of claim 12, wherein the communication system uses extremely low frequency (ELF), fiber optic, guided wave, or pulsed transducer for communication.
16. The method of claim 12, wherein the long distance travel system is a flow-driven navigation system.
17. The method of claim 12, wherein the inspection tool further comprises an adjustable seal to allow variation of fluid flow through the adjustable seal, wherein the adjustable seal is an iris-type seal or a variable-pitch seal.
18. The method of claim 12, wherein the localized travel system is a self-propelled drive system.
19. The method of claim 18, wherein the localized travel system is selected from clutch-controlled wheels, a tracked tank-drive system, or a roller-type drive.
20. The method of claim 12, wherein the sensor detects the abnormality through radiography, external or internal ultrasonic inspection, Magnetic Flux Leakage (MFL) or eddy current, acoustic emission, computed tomography, or combinations thereof.
21. The method of claim 12, wherein in step (c) further comprises: (c-1) stopping fluid flow within the pipe.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0014] Certain embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It is emphasized that, in accordance with standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of various features may be arbitrarily increased or reduced for clarity of discussion. It should be understood, however, that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein, and:
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DETAILED DESCRIPTION
[0029] In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments are possible. This description is not to be taken in a limiting sense, but rather made merely for the purpose of describing general principles of the implementations. The scope of the described implementations should be ascertained with reference to the issued claims.
[0030] As used herein, the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms “up” and “down”; “upper” and “lower”; “top” and “bottom”; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements.
[0031] The present disclosure describes embodiments of a system and methodology for facilitating structural integrity assessment, gain life extension or for prove-up on, but not limited to, offshore risers (production, export and drilling risers), offshore pipelines, flowlines, gathering lines and injection lines, flexible risers and pipelines, access restricted onshore pipelines, and other offshore and onshore tubular or piping assets. This is accomplished by examining areas of critical interest on the unit under inspection and recording measurements, either on the inside or outside of the system.
[0032] Embodiments of the method and system enable a tool to stop at an area or areas of interest to collect localized data. Since the inspection tool has zero or near-zero velocity while an active inspection occurs, data resolution is optimized and can provide a clearer picture of the area than existing inspection methods allow.
[0033] The present disclosure describes a system and methodology used to detect, dwell and perform detailed inspections on specific areas of critical interest within onshore and offshore pipelines, offshore risers (including but not limited to production, export and drilling risers), and other tubular or piping assets commonly used in the power and oil & gas industries in order to provide relevant data needed to assess structural integrity, gain life extension or for prove-up of said assets.
[0034] Areas of interest include, but are not exclusive to, girth welds at or close to the hang-off and touchdown regions of a riser (or other critical locations identified along the length of the riser), other girth welds along a pipeline's length (for example at free spans or buckle locations), areas of corrosion, areas of high stress or fatigue sensitive locations, areas with wall thickness reduction or deformities, any leak point, or any other area as prescribed by customers. These areas may be determined by other sources or inspections prior to employing embodiments of the present disclosure, or may be found as part of the system and method of the present disclosure.
[0035] Central to the present disclosure is an inspection tool which is capable of navigating to these hard to access areas. Example areas for offshore assets may include any point of the system from topside to the seabed and downhole. Onshore areas would focus on points where excavation is not practical, such as beneath roads, buildings, railways and other critical infrastructure. An embodiment of the inspection tool of the present disclosure is shown schematically in
[0036] Verification and analysis of the data collected by this system and method produces a usable report. Each report shows an overview of the asset inspected and highlights the areas of interest which were found and analyzed. A detailed analysis for each area of interest is provided, which will identify features of note and the presence of any anomalies detected. An estimate on remaining life of the system may additionally be provided.
[0037] Embodiments of the inspection tool utilized to perform this localized type of inspection consist of several subsystems which work cognitively to provide high intensity scans of previously identified areas of interest (AOI) from other inspection methods. The main subsystems in this case are: two-way communication, localized travel for areas of interest, long distance travel between areas of interest and sensor deployment and scanning.
[0038] One embodiment of the inspection tool of the present disclosure is a hybrid design between a flow-driven navigation system and a self-propelled drive system, as shown in FIGS. 4 and 5. In particular,
[0039] Referring to
[0040] The communication module 401 can use different communication technologies, such as tethering, pressure transducer or extremely low frequency (ELF). The communication module 401 in
[0041] The sensor module 405 can be any known non-destructive testing sensor modules or combinations thereof, depending on the intended conditions. As known in the art, sensors using eddy current, ultrasonic, visual, MFL, or magnetic readings can be used. As seen in
[0042] In the present disclosure, there are numerous drive mechanisms that can be utilized to drive the tool once it has reached an area of interest which include, but are not limited to, clutch-controlled wheels, a tracked tank-drive system, or roller-type drive. They are generally referred to as the drive module in the inspection tool, and will be explained in more details with reference to
[0043] The drive module 407 allows the inspection tool to engage with the inner wall of the pipeline 420, to allow either parking or moving toward either direction through a motor. As further illustrated with regard to
[0044] Referring also to
[0045] In operation, when the inspection tool is being driven by the fluid inside the pipeline during long distance travel, the clutch is disengaged, and the drive wheels 1201 can spin freely. However, when the inspection tool moves close to an area of interest, the controller/power module 403 actuate the motor 1205 and the clutch 1203, which engages the drive wheels 1201 through the drive belt 1209 to slow down the inspection tool. According to the operation condition, the motor 1207 can then drive the inspection tool at a controlled rate allowing the tool to move at a precise rate (both forwards and backwards) over the area of interest. This allows the inspection tool to perform multiple scans if necessary.
[0046] Referring now to
[0047] In
[0048] The diameter of the body 1309 of the track drive system is smaller than the inner diameter of the pipeline 1320 for easier maneuver therein, and centralizing material 1319 are added annularly to keep the drive system in the center of the pipeline.
[0049] To retract the drive module from the extended position, as shown in
[0050] Comparing to the wheels in
[0051] The flow-driven navigation system is used for high speed, long distance travel between areas of interest. The self-propelled drive system is used to drive the inspection tool only in areas of interest and provide very precise speed control and direction within the area(s) of interest.
[0052] When utilizing a hybrid drive system described above, communication with the pipeline's pump operator is essential. The flow driven system is partially reliant on the operator shutting down flow when the tool approach(s) an area of interest. There are several methods of communication, but not limited to, Extremely Low Frequency (ELF) communication, Fiber Optic Tether, Guided Wave, and pulsed transducer messaging. This communication is bi-directional and used to issue and receive commands from the inspection tool.
[0053] Additionally, in the case of communication loss the tool will default to high speed travel mode so the tool can be easily retrieved.
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[0057] As discussed above, the tether can be deployed from the base station 719, the spool 723 within the tool 700, or both. In certain embodiments, the capability to deploy the tether from both the base station 719 and the spool 723 may be necessary if the reverse deployment of the tool is necessary to remove the tool from the pipeline. Using a prespooled fiber optic cable allows the user to easily determine the location of the tool in case where the need for trouble shooting arises.
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[0059] Referring to
[0060] In this embodiment, the tool has an onboard capability to slow itself in the line to compensate for the time lag it may take between sending a shutdown command to the pipeline operator and actual shutdown of flow in the line. This involves but is not limited to utilizing an iris type seal (illustrated in
[0061] The iris-type seal illustrated in
[0062] The variable-pitch type seal illustrated in
[0063] With the inspection tool of this disclosure, it is possible to quickly send the inspection tool over a long distance using fluid-driven travel system, and when the inspection tool approaches the area of interest, activating the localized travel system to allow the inspection tool to accurately detect any defect in the pipes.
[0064] Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. The scope of the invention should be determined only by the language of the claims that follow. The term “comprising” within the claims is intended to mean “including at least” such that the recited listing of elements in a claim are an open group. The terms “a,” “an” and other singular terms are intended to include the plural forms thereof unless specifically excluded. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words “means for” together with an associated function.