DRY-COUPLED PERMANENTLY INSTALLED ULTRASONIC SENSOR LINEAR ARRAY

• US 20100236330A1
• Filed: 03/18/2009
• Published: 09/23/2010
• Est. Priority Date: 03/18/2009
• Status: Active Grant

• Current Assignee: BP Corporation North America Incorporated (BP PLC)
• Original Assignee: BP Corporation North America Incorporated (BP PLC)
• Inventors: Nyholt, John, Langlois, Gary N.
• Granted Patent: US 8,408,065 B2
• Time in Patent Office: Days
• US Class Current: 73/644
• CPC Class Codes: G01N 2291/106 one or more transducer arrays
• CPC Class Codes: G01N 29/223 Supports, positioning or alignment in fixed situation mounting transducers per se G10K11/004
• CPC Class Codes: G01N 29/2487 Directing probes, e.g. angle probes directing arrangements G01N29/221
• CPC Class Codes: G01N 29/28 providing acoustic coupling , e.g. water impedance matching G10K11/02
• CPC Class Codes: G10K 11/02 Mechanical acoustic impedances; Impedance matching, e.g. by horns; Acoustic resonators

Abstract

This invention relates to permanent, ultrasonic, flexible, dry-coupled, linear arrays for the inspection of pipelines, process equipment, and the like. The permanent, ultrasonic, flexible, dry-coupled, linear arrays detect and/or measure corrosion wall loss, stress corrosion cracking, and/or internal initiated pipeline cracking. The apparatus for ultrasonically testing materials includes a linear array of ultrasonic sensors, and a flexible, acoustically transmissive, dry-coupling surrounding at least a portion of each of the ultrasonic sensors.

Claims

1. An apparatus for ultrasonically testing materials, the apparatus comprising:

a linear array of ultrasonic sensors; and

a flexible, acoustically, transmissive, dry-coupling surrounding at least a portion of each of the ultrasonic sensors.

2. The apparatus of claim 1, wherein each ultrasonic sensor mounts at an angle of incidence relative to a test material surface of about −

90 degrees to about +90 degrees.

3. The apparatus of claim 1, wherein each ultrasonic sensor mounts at an angle of incidence relative to a test material surface at one of the group consisting of 0 degrees, 45 degrees and combinations thereof.

4. The apparatus of claim 1, wherein the linear array comprises at least 2 ultrasonic sensors.

5. The apparatus of claim 1, further comprising a second linear array.

6. The apparatus of claim 5, wherein the each linear array at least generally parallels one another.

7. The apparatus of claim 5, wherein the second linear array comprises a single elongated sensor or transmitter.

8. The apparatus of claim 1, wherein the dry-coupling comprises a semi-solid polymeric material.

9. The apparatus of claim 8, wherein the polymeric material comprises a polysilicone.

10. The apparatus of claim 8, wherein the polymeric material comprises a polyimide.

11. The apparatus of claim 1, wherein the dry-coupling excludes magnets, vacuum, adhesives, and liquid coupling agents.

12. The apparatus of claim 1, wherein the ultrasonic sensors comprise a zero-degree thickness configuration, an angle beam configuration, or a time-of-flight diffraction configuration.

13. The apparatus of claim 1, further comprising a rigid material between at least one ultrasonic sensor and a contact surface of the dry-coupling.

14. The apparatus of claim 13, wherein the rigid material comprises a wedge.

15. The apparatus of claim 13, wherein the rigid material comprises poly(methyl methacrylate).

16. A method of testing materials, the method comprising:

conforming a dry-coupling to a test material;

securing the dry-coupling to the test material;

disposing a linear array of ultrasonic sensors with respect to the dry-coupling; and

measuring or detecting at least one property of the test material with the linear array through the acoustically transmissive dry-coupling.

17. The method of claim 16, wherein the securing the linear array comprises ultrasonically coupling the linear array with the test material without magnets, vacuum, adhesives, or liquid coupling agents.

18. The method of claim 16, wherein the securing the dry-coupling to the test material comprises permanently affixing the linear array to the test material.

19. The method of claim 16, further comprising preparing a surface of the test material with an acoustically transmissive treatment.

20. The method of claim 19, wherein the acoustically transmissive treatment comprises a paint or a tape.

21. The method of claim 16, wherein the measuring comprises one of the group consisting of detecting wall loss and detecting cracking.

22. The method of claim 16, wherein the measuring comprises one of the group consisting of a zero-degree thickness operation, an angle beam operation, and a time-of-flight diffraction operation.

23. The method of claim 16, wherein the measuring comprises transmitting a signal to the linear array from a second generally parallel linear array.

24. The method of claim 23, wherein the transmitting from the second generally parallel linear array sends a signal corresponding to each of the ultrasonic transducers from a single elongated transmitting sensor.

25. The method of claim 23, wherein the securing the dry-coupling lasts for at least 6 months without requiring resecuring or repositioning.

26. The method of claim 23, wherein the securing the dry-coupling lasts for at least 3 years without requiring resecuring or repositioning.

27. The method of claim 23, wherein the conforming comprises imparting shape retaining properties to the dry-coupling.