Flaw detection in tubular members

• US 6,748,808 B2
• Filed: 02/04/2003
• Issued: 06/15/2004
• Est. Priority Date: 08/14/2001
• Status: Active Grant

• Current Assignee: Varco I/P Incorporated (NOV, Inc.)
• Original Assignee: Varco I/P Incorporated (NOV, Inc.)
• Inventors: Kemper, Joseph Gregory, Manocchio, Antonio, Lam, Clive Chemo
• Primary Examiner(s): Williams, Hezron
• Assistant Examiner(s): MILLER, ROSE MARY
• Application Number:
  US10/358,122
• Publication Number:
  US 20030172735A1
• Time in Patent Office: 497 Days
• Field of Search: 736/02, 736/22, 736/23, 736/27, 736/20
• US Class Current: 73/622
• CPC Class Codes: G01N 2291/011 Velocity or travel time
• CPC Class Codes: G01N 2291/015 Attenuation, scattering
• CPC Class Codes: G01N 2291/02854 Length, thickness
• CPC Class Codes: G01N 2291/0421 Longitudinal waves
• CPC Class Codes: G01N 2291/0422 Shear waves, transverse waves, horizontally polarised waves
• CPC Class Codes: G01N 2291/0427 Flexural waves, plate waves, e.g. Lamb waves, tuning fork, cantilever
• CPC Class Codes: G01N 2291/044 Internal reflections (echoes), e.g. on walls or defects
• CPC Class Codes: G01N 2291/051 Perpendicular incidence, perpendicular propagation
• CPC Class Codes: G01N 2291/101 one transducer
• CPC Class Codes: G01N 2291/105 two or more emitters, two or more receivers
• CPC Class Codes: G01N 2291/2634 cylindrical from outside
• CPC Class Codes: G01N 2291/2636 cylindrical from inside
• CPC Class Codes: G01N 29/0609 Display arrangements, e.g. colour displays indicating or recording in connection with measuring in general G01D
• CPC Class Codes: G01N 29/07 by measuring propagation velocity or propagation time of acoustic waves
• CPC Class Codes: G01N 29/11 by measuring attenuation of acoustic waves
• CPC Class Codes: G01N 29/225 Supports, positioning or alignment in moving situation
• CPC Class Codes: G01N 29/265 by moving the sensor relative to a stationary material
• CPC Class Codes: G01N 29/38 by time filtering, e.g. using time gates
• CPC Class Codes: G01N 29/4445 Classification of defects

Abstract

A method, in at least certain aspects, for ultrasonically inspecting a tubular member, the tubular member having an inner surface, an outer surface, and two spaced-apart ends including a first end of the tubular member, the method including transmitting sonic beams to the tubular member with transducers such that sonic beams are reflected from the inner surface of the tubular member, the outer surface of the tubular member, and from the first end of the tubular member, sensing the first end of the tubular member, completing inspection of all or of substantially all of the outer surface of the tubular member for outer surface defects while continuing to inspect the inner surface of the tubular member for inner surface defects, continuing to inspect the inner surface of the tubular member for inner surface defects, the transducers continuing to transmit sonic beams for the inspection of the inner surface of the tubular member until the transducers are near the first end of the tubular member; and apparatus for such methods.

Claims

1. A method for ultrasonically inspecting a tubular member, the tubular member having an inner surface, an outer surface, and two spaced-apart ends including a first end of the tubular member, the method comprising

transmitting sonic beams to the tubular member with transducers such that sonic beams are reflected from:

the inner surface of the tubular member, the outer surface of the tubular member, and from the first end of the tubular member,

sensing the first end of the tubular member,

completing inspection of substantially all of the outer surface of the tubular member for outer surface defects while continuing to inspect the inner surface of the tubular member for inner surface defects,

continuing to inspect the inner surface of the tubular member for inner surface defects, the transducers continuing to transmit sonic beams for the inspection of the inner surface of the tubular member.

2. The method of claim 1 wherein the tubular member has an inner surface defect near the first end of the tubular member and the method further comprising

transmitting a sonic beam from the transducers such that the sonic beam reflected from the inner surface defect,

receiving the reflected beam from the inner surface defect of the tubular member,

producing a defect signal related to the sonic beam reflected from the inner surface defect, the defect signal for conveying information about the inner surface defect,

and transmitting the defect signal to signal analysis apparatus to analyze and indicate the inner surface defect.

3. The method of claim 1 further comprising

producing an end signal related to a beam reflected from the first end of the tubular, the end signal provided to alarm apparatus,

the alarm apparatus producing an alarm indicating sensing of the first end of the tubular member.

4. The method of claim 3 further comprising

following production of the end signal, ignoring all signals from or apparently from the outer surface of the tubular member.

5. The method of claim 3 further comprising

displaying at least a portion of the end signal on visual display apparatus.

6. The method of claim 5 wherein the entire end signal is visually displayed on the display apparatus.

7. The method of claim 3 wherein the end signal is produced by end signal production apparatus.

8. The method of claim 3 wherein the end signal production apparatus is not activated until the transducers are within one half inch of the first end of the tubular member.

9. The method of claim 1 wherein

the transducers are in communication with transducer control apparatus and means for receiving signals from the inner surface and the outer surface of the tubular member and signals from the first end of the tubular member,

the means for receiving signals from the inner surface and the outer surface and the first end of the tubular member including receiving means for receiving said signals only during a specified time period, including an ID time period for receiving signals reflected from the inner surface of the tubular member, and an OD time period for receiving signals from the outer surface of the tubular member, and an end time period for receiving signals from the first end of the pipe,

the method further comprising

receiving signals from the inner surface of the tubular member during the ID time period,

comprising receiving signals from the outer surface of the tubular member during the OD time period, and

receiving at least one signal from the first end of the tubular member during the end time period.

10. The method of claim 9 wherein the end time period occurs after the OD time period.

11. The method of claim 9 wherein signals received with the time period of the OD gate are ignored upon receipt of a signal from the first end of the tubular member by the receiving means.

12. The method of claim 9 wherein the transducers are in communication with inner surface alarm means for providing an alarm indicating that inspection of the inner surface up to a predetermined distance from the first end of the tubular member is completed, the method further comprising

providing an alarm indicating that said predetermined distance has been reached, and

ceasing inspection of the inner surface the tubular member.

13. The method of claim 9 wherein end time period occurs after the ID time period and the end time period occurs after the OD time period.

14. The method of claim 1 wherein each transducer has associated instrumentation for controlling each transducer.

15. The method of claim 14 wherein a programmable logic controller controls movement means that moves the tubular member during inspection of the tubular member and that moves the transducers with respect to the tubular member.

16. The method of claim 13 wherein a computer analyzes signal information and associated display apparatus displays inspection results.

17. The method of claim 1 further comprising the step of stopping relative motion between the tubular member and the transducers when inspection of the inner surface of the tubular member is substantially completed.

18. The method of claim 17 wherein an end of the tubular member is sensed with end sensor apparatus and the end sensor apparatus sends an end signal to a control system that controls movement of the transducers, the method further comprising

receipt of the end signal by the control system, and

stopping movement of the transducers by the control system upon completion of inspection of substantially all of the inner surface and the outer surface of the tubular member.

19. A method for ultrasonically inspecting a tubular member, comprising

transmitting sonic beams through the tubular member with at least one transducer so that sonic beams are reflected from an inner surface of the tubular member, from an outer surface of the tubular member, from defects of the tubular member if any,

receiving with the at least one transducer reflected beams from the surface defects of the tubular member if any, from the inner surface and from the outer surface of the tubular member,

sensing an end of the tubular member, and following said sensing ignoring reflections of beams from the outer surface and ignoring apparent reflections of beams from the outer surface, and

ceasing inspection of the tubular member when substantially all the inner surface and substantially all the outer surface is inspected.

20. An ultrasonic inspection device useful for inspecting a tubular member comprising

transducers for transmitting sonic beams and for receiving reflected beams thereof from inner and outer surfaces of the tubular member, from ends of the tubular member including a first end spaced apart from a second end, and from defects of the tubular member,

the reflected beams including beams reflected from an outer surface of the tubular member, from an inner surface of the tubular member, from the first end of the tubular member, and from an inner surface defect of the tubular member,

means for differentiating the reflected beams,

means for producing signals corresponding to information about the reflected beams, including a defect signal having information about the inner surface defect, and an end signal having information about the end of the tubular member,

means for continuing inspection of the inner surface of the tubular member for inner surface defects until substantially all the inner surface and substantially all the outer surface is inspected,

end sensing means for sensing an end of the tubular member, and

means for ignoring signals from the outer surface of the tubular member upon sensing the end of the tubular by the end sensing means.

21. The ultrasonic inspection device of claim 20 further comprising

means for indicating position of the transducers with respect to an end of the tubular member,

means for energizing and de-energizing the transducers to sequentially transmit and receive sonic beams,

wall thickness transducer apparatus for measuring tubular member wall thickness, and

means for moving the transducers in indexed steps with respect to the tubular member.