Method and apparatus for estimating the condition of a coating on an underground pipeline

• US 7,940,062 B1
• Filed: 12/10/2010
• Issued: 05/10/2011
• Est. Priority Date: 11/10/2008
• Status: Active Grant

• Current Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Original Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Inventors: Miller, Scott Downing, Davis, Thomas James, Perez, Jaime Paunlagui
• Primary Examiner(s): NGUYEN, HOAI AN D
• Application Number:
  US12/928,427
• Publication Number:
  US 20110101971A1
• Time in Patent Office: 151 Days
• Field of Search: 324/527, 324/512, 324/500, 324/557, 324/627, 324/456, 324/216, 324/217, 324/228, 324/229, 324/237, 324/238, 324/240, 324/700, 324/716, 324/718, 324/71.1, 324/71, 324/76.11, 205/775, 205/791, 205/790.5
• US Class Current: 324/700
• CPC Class Codes: G01N 17/02 Electrochemical measuring systems for weathering, corrosion or corrosion-protection measurement

Abstract

Methods are provided for reducing interference from stray currents in buried pipelines/metal structures during MEIS testing or other current-sensing applications in the pipeline. Methods are also provided for measuring bulk complex electrical impedance between a buried pipe and the soil, thereby rendering an indication of the quality of the anti-corrosive coating. Methods are also provided for measuring the complex propagation constant of AC voltages propagating along an attenuative pipeline. This information is useful for assessing the general condition of the anti-corrosive coating involved, or to enhance MEIS inspection of the pipeline. Methods are also provided for enhancements to MEIS testing, including (a) canceling magnetometer offset effects associated with the Earth'"'"'s magnetic field after the magnetometer is positioned for measurement, (b) implementing a separate sensing connection to the pipe so as to avoid interference from voltage loss in the pipe feed-line connection, (c) providing a power amplifier to excite the pipe with large-amplitude signals.

Claims

1. A method for estimating a condition of a coating on a portion of a coated pipeline buried in soil using a magnetometer, comprising:

conducting a magnetically-detected electrochemical impedance spectroscopy (MEIS) test at a location over a selected segment of the buried pipeline;

compensating for undesirable interfering and/or stray current signals flowing through the test location by generating at least one sinusoidal signal having a predominant amplitude and frequency and adding said sinusoidal signal to an output signal from the magnetometer; and

switching between operation modes of a dual-mode potentiostat for performing a calibration step and performing the MEIS test;

wherein the potentiostat includes a galvanostat and calibration mode of operation includes generating a complex calibration factor for each frequency by injecting a constant current from the galvanostat down the pipeline segment and measuring a resultant magnetometer output, and wherein during the MEIS mode of operation the calibration factor is used to compute actual on-pipe current at the location.

2. The method of claim 1, wherein the step of conducting a MEIS test comprises the steps of:

providing a voltage between a selected segment of the pipeline and the soil at a plurality of test frequencies; and

measuring on-pipe current at a respective pipe-to-soil junction for each of a plurality of locations along the segment of the pipeline using the plurality of test frequencies, wherein said interfering and/or stray current signals are canceled or suppressed from the measured currents at each location.

3. The method of claim 2, wherein the step of conducting a MEIS test comprises the steps of:

determining complex impedances of the respective pipeline-to-soil junction for any segment of the pipeline using the plurality of test frequencies, said complex impedances being used for estimating the condition of the coating on the respective segment; and

plotting pipe-to-soil impedance results at the plurality of frequencies as a graphical representation.

4. The method of claim 3, wherein the compensating step further comprises the steps of:

receiving an on-pipe test current signal and interfering current signal from a magnetometer;

passing the on-pipe current signal and the interfering current signal through a first band pass filter for enhancing the predominant frequency component of the interfering current signal;

sending the output of the first band pass filter to a phase-lock loop for generating phase-locked square wave at the predominant frequency;

performing a square-to-sine wave conversion of the phase-locked square wave at the predominant frequency;

inverting the converted sine wave at the predominant frequency; and

summing the inverted sine wave with the interfering current signal from the magnetometer to cancel the interfering current signal and pass the desired current signal through for performing the determining step.

5. The method of claim 4, wherein the predominant frequency is about 60 Hz or a harmonic of about 60 Hz.

6. The method of claim 4, further comprising the step of adjusting weighting of the inverted sine wave prior to performing the summing step so as to maximize suppression of the interference signal.

7. The method of claim 3, wherein the providing a sinusoidal signal step comprises providing a phase-lock loop for generating the sinusoidal signal at a predominant frequency to cancel or suppress the interfering current signal.

8. The method of claim 1, wherein said estimating the condition of the coating includes identifying at least one of normal bonding, disbonding, holidays and micro-cracking in the coating of the pipeline.

9. The method of claim 1, wherein the measuring step comprises the further step of canceling magnetometer offset effects associated with the Earth'"'"'s magnetic field after positioning a magnetometer proximate the pipe segment for measurement.

10. The method of claim 1, wherein the compensating step further comprises:

measuring a first on-pipe interfering current signal component and test current signal component from said segment using a first magnetometer;

measuring a second interfering current signal component from an adjacent structure; and

combining the first and second interfering current signal components to produce only the on-pipe current signal component for the determining step.

11. The method of claim 1, wherein the interfering current signals are power line ground-return current signals.

12. The method of claim 10, wherein the combining step comprises:

phase shifting and weight adjusting the first interfering current signal component to provide an equal but opposite interference signal component with respect to the second interfering current signal component;

passing the phase shifted first interfering current signal component to a combiner; and

passing the second interfering current signal component directly to a combiner for combination with the first interfering current signal component.

13. An apparatus for estimating a condition of a coating on a portion of a coated pipeline buried in soil using a magnetometer, comprising:

means for conducting a magnetically-detected electrochemical impedance spectroscopy (MEIS) test at a location over a selected segment of the buried pipeline;

means for compensating for undesirable interfering and/or stray current signals flowing through the test location by generating at least one sinusoidal signal having a predominant amplitude and frequency and adding said sinusoidal signal to an output signal from the magnetometer; and

means for switching between operation modes of a dual-mode potentiostat for performing a calibration step and performing the MEIS test;

wherein the potentiostat includes a galvanostat and calibration mode of operation includes generating a complex calibration factor for each frequency by injecting a constant current from the galvanostat down the pipeline segment and measuring a resultant magnetometer output, and wherein during the MEIS mode of operation the calibration factor is used to compute actual on-pipe current at the location.

14. The apparatus of claim 13, wherein the means for conducting a MEIS test comprises:

means for providing a voltage between a selected segment of the pipeline and the soil at a plurality of test frequencies; and

means for measuring an on-pipe current at a respective pipe-to-soil junction for each of a plurality of locations along the segment of the pipeline using the plurality of test frequencies, wherein said interfering and/or stray current signals are canceled or suppressed from the measured currents at each location.

15. The apparatus of claim 14, wherein the means for measuring further comprises means for canceling the magnetometer offset effects associated with the Earth'"'"'s magnetic field after the magnetometer is put into position for measurement.

16. The apparatus of claim 14, wherein the means for providing a voltage includes a power amplifier coupled between a ground-return electrode and a first end of the pipe via a feed line, said power amplifier being driven by an a/c voltage signal to excite the pipe with large-amplitude signals.

17. The apparatus of claim 16, further comprising a sense line for sensing the actual voltage at the first end of the pipe independently of interfering voltage drops in the feed line, said actual voltage being fed to a differential amplifier for providing an output signal representing the pipe-to-soil voltage.

18. The apparatus of claim 14, wherein the means for measuring comprises:

a magnetometer for measuring a magnetic field produced by current in said pipeline segment and providing the output signal from the magnetometer to the means for compensating, the output signal including an on-structure current signal component and the interfering current signal component at the predetermined frequency.

19. The apparatus of claim 18, wherein the means for compensating comprises:

a phase-locked loop (PPL) circuit coupled to the output of the magnetometer; and

a combiner for adding an inverted sinusoidal signal produced by the PPL to the interfering current signal component, wherein a modified output signal from the magnetometer excludes the interfering current signal component.

20. The apparatus of claim 18, further comprising a means for weighting the output signal from the PPL prior to being combined with the interfering current signal component at the combiner.

21. A method for estimating a condition of a coating of a pipeline buried in the soil using a coated pipeline test sample containing synthetic disbonds, the pipeline test sample comprising an elongated section of pipe having a predetermined diameter and length, an end cap disposed over each end of the pipe section, a low dielectric material wrapped around the pipe section between the end caps, the low dielectric material having characteristics that simulate disbonds, and a sealing tape wrapped over the low dielectric material, the balance of the pipe, and end caps, the method comprising the steps of:

burying the pipe section having the low dielectric material wrapped around the pipe section with the simulated disbonds in the soil at a predetermined depth;

applying current at varying frequencies between each end of the pipe section; and

measuring input and output currents from the sample pipe having said low dielectric material that simulates disbonds.

22. The method of claim 21, further comprising the steps of:

computing equivalent complex impedances at input and output locations on the sample pipe; and

storing the computed average complex impedances.