COMPUTER-IMPLEMENTED METHOD TO SCREEN FOR LONGITUDINAL-SEAM ANOMALIES

• US 20110068782A1
• Filed: 11/24/2010
• Published: 03/24/2011
• Est. Priority Date: 12/21/2007
• Status: Active Grant

• Current Assignee: Kinder Morgan Incorporated (Knight Holdco LLC)
• Original Assignee: Kinder Morgan Incorporated (Knight Holdco LLC), Knight LLC
• Inventors: Duckworth, Noel, Sherstan, Ron
• Granted Patent: US 9,243,972 B2
• Time in Patent Office: Days
• US Class Current: 324/220
• CPC Class Codes: G01M 5/0025 of elongated objects, e.g. pipes, masts, towers or railways G01M5/0058 takes precedence
• CPC Class Codes: G01M 5/0033 by determining damage, crack or wear
• CPC Class Codes: G01M 5/0091 by using electromagnetic excitation or detection

Abstract

Embodiments of the present invention provide computer-implemented methods to detect crack-like features in pipeline welds using magnetic flux leakage data and pattern recognition. A screening process, for example, does not affect or change how survey data is recorded in survey tools; only how it is analyzed after the survey data is completed. Embodiments of the present invention can be used to screen for very narrow axial anomalies in the pipeline welds, and may also be used to predict the length of such anomalies. Embodiments of the present invention also produce a listing of the anomalies based on their relative signal characteristics.

Claims

1. A computer-implemented method to detect longitudinal-seam anomalies in a pipeline weld of a pipeline, the computer-implemented method comprising:

(a) receiving magnetic flux leakage data by a computer, the magnetic flux leakage data being representative of potential crack-like defects in a longitudinal pipeline weld;

(b) displaying the magnetic flux leakage data on a display associated with the computer;

(c) analyzing the magnetic flux leakage data by use of the computer associated with the display responsive to signal characteristics and critical flaw dimensions of the magnetic flux leakage data that may be indicators of the potential crack-like defects, the critical flaw dimensions including at least a maximum length of the potential crack-like defects; and

(d) determining potential crack-like defects by use of the computer and associated display responsive to the analyzing of the magnetic flux leakage data.

2. A computer-implemented method as defined in claim 1, wherein the step of analyzing comprises determining optimal display settings on the display, the display comprising a display screen and the optimal display settings being responsive to different magnetic flux leakage characteristics, the determining of the optimal display settings on the display screen including changing a gain and offset of the display screen in order to achieve a high contrast display so that the presence of the potential crack-like defects readily may be perceived on the display screen.

3. A computer-implemented method as defined in claim 1, wherein the step of determining potential crack-like defects including listing data representative of potential crack-like defects responsive to the signal characteristics and critical flaw dimensions.

4. A computer-implemented method as defined in claim 2, wherein determining the optimal display settings on the display further comprises:

changing a length of data being displayed on the display screen; and

changing an amount of data representing a pipeline circumference begin displayed on the display screen, the amount of data representing no more than ninety degrees of the pipeline circumference.

5. A computer-implemented method as defined in claim 1, wherein the pipeline is comprised of steel and the potential crack-like defects are crack air gaps, the crack air gaps being a function of crack length and depth, steel properties and hoop stress.

6. A computer-implemented method as defined in claim 1, further comprising the step of determining a validation dig list containing one or more crack-like defects by use of the computer, whereby the list is used to identify areas along the pipeline to be visually inspected for defects.

7. A computer-implemented method as defined in claim 2, wherein the signal characteristics comprise one or more of the following:

(1) a smooth waveform;

(2) less than four anomaly channels;

(3) a non-erratic pattern; and

(4) being distinguished from other signals on the display screen when a gain of the pattern of magnetic flux leakage data increases.

8. A computer-implemented method defined in claim 2, wherein the analyzing of the magnetic flux data performed by the computer further comprises:

(1) determining whether the magnetic flux leakage data is consistent with a first predetermined anomaly level by use of the computer and responsive to the optimal display settings to thereby define a level one anomaly candidate, the first predetermined anomaly level having first selected signal characteristics consistent with the presence of longitudinal-seam anomalies;

(2) if the magnetic flux leakage data is consistent with the level one anomaly candidate, then determining if the level one anomaly candidate is consistent with a second predetermined anomaly level by use of the computer and responsive to the optimal display settings, the second predetermined anomaly level defining a level two anomaly candidate having second selected signal characteristics different than the first selected signal characteristics and still consistent with the presence of longitudinal-seam anomalies;

(3) if the level one anomaly candidate is consistent with the level two anomaly candidate, then determining if the level two anomaly candidate is consistent with a third predetermined anomaly level by use of the computer and responsive to the optimal display settings, the third predetermined anomaly level defining a level three anomaly candidate having third selected signal characteristics different than the first and second selected signal characteristics and yet still consistent with the presence of longitudinal-seam anomalies, the third selected signal characteristics also being indicative of the presence of the selected critical flaw dimensions of a pipeline weld; and

(4) if the level two anomaly candidate is consistent with the third level anomaly candidate, then determining if the level three anomaly candidate is consistent with a fourth predetermined anomaly level by use of the computer and responsive to the optimal display settings, the fourth predetermined anomaly level defining a level four anomaly candidate having fourth selected signal characteristics different than the first, second, and third selected signal characteristics and yet still consistent with the presence of longitudinal-seam anomalies.

9. A computer-implemented method to detect longitudinal-seam anomalies in a pipeline weld of a pipeline, the computer-implemented method comprising:

(a) receiving magnetic flux leakage data by a computer, the magnetic flux leakage data representative of potential crack-like defects in a longitudinal pipeline weld;

(b) displaying the magnetic flux leakage data on a display connected to the computer;

(c) analyzing the magnetic flux leakage data by use of the computer and responsive to signal characteristics and critical flaw dimensions of the magnetic flux leakage data that may be indicators of the potential crack-like defects, the critical flaw dimensions including at least a maximum length of the potential crack-like defects, the analyzing of the magnetic flux data performed by the computer including;

(1) determining whether the magnetic flux leakage data is consistent with a first predetermined anomaly level by use of the computer to thereby define a level one anomaly candidate, the first predetermined anomaly level having first selected signal characteristics consistent with the presence of longitudinal-seam anomalies,

(2) if the magnetic flux leakage data is consistent with the level one anomaly candidate, then determining if the level one anomaly candidate is consistent with a second predetermined anomaly level by use of the computer, the second predetermined anomaly level defining a level two anomaly candidate having second selected signal characteristics different than the first selected signal characteristics and still consistent with the presence of longitudinal-seam anomalies,

(3) if the level one anomaly candidate is consistent with the level two anomaly candidate, then determining if the level two anomaly candidate is consistent with a third predetermined anomaly level by use of the computer, the third predetermined anomaly level defining a level three anomaly candidate having third selected signal characteristics different than the first and second selected signal characteristics and yet still consistent with the presence of longitudinal-seam anomalies, the third selected signal characteristics also being indicative of the presence of the selected critical flaw dimensions of a pipeline weld, and

(4) if the level two anomaly candidate is consistent with the third level anomaly candidate, then determining if the level three anomaly candidate is consistent with a fourth predetermined anomaly level by use of the computer, the fourth predetermined anomaly level defining a level four anomaly candidate having fourth selected signal characteristics different than the first, second, and third selected signal characteristics and yet still consistent with the presence of longitudinal-seam anomalies; and

(d) determining potential crack-like defects by use of the computer and associated display responsive to the analyzing of the magnetic flux leakage data.

10. A computer-implemented method as defined in claim 9, wherein the step of analyzing comprises determining optimal display settings on the display, the display comprising a display screen and the optimal display settings being responsive to different magnetic flux leakage characteristics, the determining of the optimal display settings on the display screen including changing a gain and offset of the display screen in order to achieve a high contrast display so that the presence of the potential crack-like defects readily may be perceived on the display screen.

11. A computer-implemented method as defined in claim 9, wherein the step of determining potential crack-like defects including listing data representative of potential crack-like defects responsive to the signal characteristics and critical flaw dimensions.

12. A computer-implemented method as defined in claim 11, wherein determining the optimal display settings on the display further comprises:

changing a length of data being displayed on the display screen; and

changing an amount of data representing a pipeline circumference begin displayed on the display screen, the amount of data representing no more than ninety degrees of the pipeline circumference.

13. A computer-implemented method as defined in claim 12, wherein the pipeline is comprised of steel and the potential crack-like defects are crack air gaps, the crack air gaps being a function of crack length and depth, steel properties and hoop stress.

14. A computer-implemented method as defined in claim 13, further comprising the step of determining a validation dig list containing one or more crack-like defects by use of the computer, whereby the list is used to identify areas along the pipeline to be visually inspected for defects.

15. A computer-implemented method as defined in claim 14, wherein the signal characteristics comprise one or more of the following:

(1) a smooth waveform;

(2) less than four anomaly channels;

(3) a non-erratic pattern; and

(4) being distinguished from other signals on the display screen when a gain of the pattern of magnetic flux leakage data increases.

16. A computer-implement method to detect longitudinal-seam anomalies in a low frequency pipeline weld of a pipeline, the computer-implemented method comprising:

receiving magnetic flux leakage data related to one or more anomaly air gaps within a longitudinal pipeline weld by a computer;

displaying on a display associated with the computer the magnetic flux leakage data as one or more selected patterns of data representing selected signal characteristics of the pipeline weld; and

analyzing the magnetic flux leakage data responsive to the selected signal characteristic and selected critical flaw dimensions of the pipeline weld, the selected signal characteristics being indicators of potential longitudinal-seam anomalies in the pipeline weld and the selected critical flaw dimensions being at least a maximum length of the potential longitudinal-seam anomalies along a pattern of magnetic flux leakage data.

17. A computer-implemented method as defined in claim 16, wherein the analyzing of the magnetic flux data performed by the computer comprises:

determining optimal display settings on the display, the optimal display settings being responsive to different magnetic flux leakage characteristics; and

determining whether the magnetic flux leakage data is consistent with a first predetermined anomaly level responsive to the optimal display settings to thereby define a level one anomaly candidate, the first predetermined anomaly level having first selected signal characteristics consistent with the presence of longitudinal-seam anomalies.

18. A computer-implemented method as defined in claim 17, wherein the analyzing of the magnetic flux data performed by the computer further comprises if the magnetic flux leakage data is consistent with the level one anomaly candidate, then determining if the level one anomaly candidate is consistent with a second predetermined anomaly level responsive to the optimal display settings, the second predetermined anomaly level defining a level two anomaly candidate having second selected signal characteristics different than the first selected signal characteristics and still consistent with the presence of longitudinal-seam anomalies.

19. A computer-implemented method as defined in claim 18, wherein the analyzing of the magnetic flux data performed by the computer further comprises if the level one anomaly candidate is consistent with the level two anomaly candidate, then determining if the level two anomaly candidate is consistent with a third predetermined anomaly level responsive to the optimal display settings, the third predetermined anomaly level defining a level three anomaly candidate having third selected signal characteristics different than the first and second selected signal characteristics and yet still consistent with the presence of longitudinal-seam anomalies, the third selected signal characteristics also being indicative of the presence of the selected critical flaw dimensions of a pipeline weld.

20. A computer-implemented method as defined in claim 19, wherein the analyzing of the magnetic flux data performed by the computer further comprises:

if the level two anomaly candidate is consistent with the third level anomaly candidate, then determining if the level three anomaly candidate is consistent with a fourth predetermined anomaly level responsive to the optimal display settings, the fourth predetermined anomaly level defining a level four anomaly candidate having fourth selected signal characteristics different than the first, second, and third selected signal characteristics and yet still consistent with the presence of longitudinal-seam anomalies.

21. A computer-implemented method as defined in claim 20, wherein, if the level three anomaly candidate is consistent with the level four anomaly candidate, then generating an output of the level four candidate anomaly to further determine if the level four anomaly candidate is consistent with a fifth predetermined anomaly level, the fifth predetermined anomaly level defining a level five anomaly candidate having fifth selected signal characteristics different from the first, second, third and fourth selected signal characteristics and yet still being indicative of one or more longitudinal-seam anomalies in the pipeline weld potentially leading to fluid leakage within the pipeline when the pipeline contains fluid therein.

22. A computer-implemented method as defined in claim 21, wherein the first selected signal characteristics defining the level one anomaly candidate comprises a pattern of data representing the level one candidate anomaly having contrasting colors associated therewith.

23. A computer-implemented method as defined in claim 22, wherein the second selected signal characteristics defining the level two anomaly candidate comprises a pattern of data representing the level two anomaly candidate having a symmetrical pattern and one or more associated blooms.

24. A computer-implemented method as defined in claim 23, wherein the third selected signal characteristics defining the level three anomaly candidate comprises a pattern of data representing the level three anomaly candidate having an anomaly length, along an axis of the pattern of data, which is less than a maximum length defined within the selected critical flaw dimensions.

25. A computer-implemented method as defined in claim 24, wherein the level four anomaly candidate comprises a pattern of data having one or more of the selected signal characteristics when displayed on the display, the selected signal characteristics comprising the following:

(1) a smooth waveform;

(2) less than four anomaly channels;

(3) a non-erratic pattern;

or

(4) being distinguished from other signals on the display when a gain of the pattern of data is increased.

26. A computer-implemented method as defined in claim 25, wherein the output of the level four anomaly candidate comprises a listing of each level four anomaly candidate responsive to the presence of the fourth selected signal characteristics within the pattern of data representing the level four candidate anomaly