In-line tube detection

Abstract

A system for non-destructively testing a tube is provided. The system can include a tank filled with a fluid, such as water. The tank can define an axial passage within the tank for insertion of the tube, and the tank can include an opening to the axial passage. A transducer probe can be disposed inside the tank and oriented toward the opening to the axial passage. The system can also include a movable seal including a chamber and configured to move axially in the axial passage, and a membrane positioned in the opening of the tank. During testing, an acoustic path can be provided between the transducer probe and the tube, the path including the fluid in the tank, the membrane, and the fluid in the chamber.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Patent Application No. 15 / 930,038, filed May 12, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure generally relates to a non-destructive through-tube inspection system using an immersion transducer probe. Background Technology

[0004] After manufacturing but before installation, pipes can be inspected to ensure they are free of defects. Some inspection systems using non-destructive testing techniques require rotating the pipes to inspect them from various angles. However, in real-world inspection scenarios, the tubular structures being tested can be tens of meters long, so such rotating inspection systems require a large space. Furthermore, the pipes may need to be moved from the production environment to the designated testing area, slowing down production.

[0005] Some smaller, direct-insertion testing systems can utilize immersion water chambers. The ultrasonic transducer probe can be housed in a water tank, and the tube can be mounted on a direct-insertion track that moves through a hollow channel in the tank. Typically, the tank is open during testing, and water is poured from the tank onto the testing area of ​​the tube, providing a waterway for the ultrasonic signal. However, these immersion testing systems can be susceptible to significant drawbacks. For example, bubbling can be problematic. In these systems, water moves from the tank to the tube at relatively high speeds during testing, which can lead to the formation of bubbles in the water. These bubbles can, in turn, attenuate and diffract the ultrasonic signal, reducing measurement accuracy. Furthermore, the water poured from the tank during testing must be replaced between each tube test, potentially generating even more bubbles in the water. Fouling can be another potential problem. During production or other processing, the tube can accumulate fouling or other foreign matter. Moving water can displace this fouling from the tube onto the immersion transducer probe, resulting in less accurate results and increased wear on the transducer probe.

[0006] Furthermore, although the ends of the tube can be an important area for inspection due to potential defects from milling, these immersion testing systems may present difficulties in inspecting the ends of the tube. As discussed above, water is typically introduced after the front end of the tube has been inserted and traversed a certain distance through the tank. And because the methods mentioned above require a uniform interfacial water layer at the junction between the transducer and the tube being tested, testing on the tube generally does not begin until the front end has passed the inspection point in the tank. Similarly, because the water interface does not exist when the tube leaves the tank, the rear end of the tube may not be fully inspected. Attached Figure Description

[0007] The accompanying drawings are merely illustrative examples of implementations of this disclosure and should not be construed as limiting the scope of this disclosure.

[0008] Figure 1 The illustration shows a tube inspection system according to an example of the present invention.

[0009] Figure 2 The illustration shows a cross-section of a pipe inspection system according to an example of the present invention.

[0010] Figures 3A to 3D The illustration shows a detection method according to an example of the present invention.

[0011] Figure 4 The illustration shows a cross-section of a tube inspection system according to another example of the present invention.

[0012] Figure 5 The illustration shows a transducer configuration according to an example of the present invention.

[0013] Figure 6 The illustration shows a transducer configuration according to another example of the invention. Detailed Implementation

[0014] The inventors have recognized the need in the art for an inspection system that overcomes the challenges of pipe inspection discussed above. An example of the present invention provides a compact, direct-insertion inspection system. This compact, direct-insertion inspection system can therefore be placed in or near a pipe production line, allowing pipe inspection without slowing down production or requiring large dedicated spaces. An example of the invention achieves improved testing by providing a waterway for testing without requiring moving water that might interfere with the test. Furthermore, an example of the invention allows for the inspection of pipe ends by enabling ultrasonic testing of the pipe using the waterway.

[0015] This document describes a detection system comprising a can that defines an axial channel for tube insertion for detection, and the can includes an opening leading to the axial channel. The detection system further includes: a transducer probe disposed within the can and oriented toward the opening; and a movable seal comprising a chamber and configured to move axially within the axial channel. The detection system also includes a membrane positioned in the opening for detection of the tube using the transducer probe, thereby providing a path for an ultrasonic signal to be emitted from the transducer probe to the tube in response to the movable seal occupying the measurement position.

[0016] This document also describes a method involving traversing an axial channel defined by a tank using a tube under test. The traversal includes: probing the tube at an initial position within the axial channel; establishing fluid within a chamber included in a seal that occupies the initial axial position adjacent to the leading end of the tube; and moving the seal in the axial direction. The method also includes performing ultrasonic testing of the tube using a transducer probe located within the tank, in response to a chamber becoming aligned with an opening of a membrane-sealed tank.

[0017] This document further describes a system comprising a can that defines an axial channel for traversing a tube for testing, the can including multiple openings leading to the axial channel. The system also includes multiple transducer probes disposed within the can in a radial arrangement around the axial channel, each transducer probe oriented toward one of the multiple openings, and at least one movable seal configured to move axially within the axial channel. The system further includes multiple membranes, each membrane configured to be positioned at one of the multiple openings for testing of the tube by the multiple transducer probes, each transducer probe being used to transmit ultrasonic energy into the tube through fluid in the can, one of the membranes, and fluid in one of the chambers.

[0018] Figure 1 The illustration shows an example of a tube inspection system 100 according to the present invention. The tube inspection system 100 may include a tank 102 having a hollow axial channel 104 into which a tube can be inserted for inspection. The tank 102 may include one or more sets of transducer probes (not shown) immersed in water for ultrasonic inspection of the inserted tube. The one or more sets of transducer probes may be arranged radially around the axial channel 104.

[0019] The tube can traverse the axial channel 104 via a conveyor belt-type device, such as a straight-through track. The tube can enter the axial channel 104 through one end (e.g., the proximal end) and exit through the other end (e.g., the distal end). In another example, the tube can enter and exit the axial channel 104 from the same end. In this example, the tube can enter the axial channel 104 from one end and traverse the axial channel 104 for detection; after detection, the tube can return by traversing the axial channel 104 in the opposite direction and exit from the same end.

[0020] The detection system 100 may also include a sensor 106 disposed in the axial channel 104. The sensor 106 can detect the axial position of the tube as it traverses the axial channel. The sensor 106 may be configured as an integrated eddy current coil. For example, the sensor may be based on the principle of eddy current nondestructive sensing and may be incorporated into the axial channel 104 or a seal (not shown), for example, to detect the relative presence of the tube in the axial channel 104 (described in more detail below). For example, multiple sensors may be combined to provide detection of the front end of a tube being inserted and the rear end of a tube being withdrawn.

[0021] The detection system 100 may include a control panel 108. The control panel 108 may be coupled to one or more sets of transducer probes and may control the detection operations of the one or more sets of transducer probes. The control panel 108 may provide an interface for controlling the operation of the transducer probes. The control panel 108 may include input devices (e.g., keyboard, trackball, function keys or soft keys, mouse interface, touch screen, stylus, etc.) and output devices (e.g., a display for presenting configuration information or results) to provide the results of the ultrasonic detection performed by the transducer probes.

[0022] The inspection system 100 can be compact in size, allowing it to be placed in or near the production line used to inspect the tubes. Therefore, the inspection system 100 can be integrated into the production line. In another example, the tank 102 can be mounted on a wheeled platform 110, making the inspection system 100 portable. Thus, the inspection system 100 can be moved to different locations within the manufacturing plant, making tube inspection easier and more efficient.

[0023] Figure 2 A cross-section of a tube inspection system according to an example of the present invention is illustrated. A tank 202 may be provided and filled with water. The tank 202 may include transducer probes 204A and 204B immersed in the water. The tank 202 may include an opening leading to an axial channel into which a tube to be inspected is inserted. Membranes 206A and 206B may be disposed in the opening of the tank 202. Membranes 206A and 206B may have approximately the same acoustic impedance as water. For example, membranes 206A and 206B may be configured to use Aqualene. TM Elastomer coupling agent, acoustic coupling elastomer (ACE) TM As further described below, transducer probes 204A, 204B can be oriented toward corresponding openings in tank 202, for example toward membranes 206A, 206B, for ultrasonic testing.

[0024] Seals 208A and 208B can be provided in the axial channel. Seals 208A and 208B may include chambers 410A and 410B. Chambers 210A and 210B can be filled with water for detection. As described in further detail below, seals 208A and 208B can be configured to move within the axial channel. During the detection period, seals 208A and 208B can be positioned at a measurement location where chambers 210A and 210B are positioned in front of membranes 206A and 206B. Therefore, due to the presence of membranes 206A and 206B providing a physical barrier between tank 202 and chambers 210A and 210B, tank 202 and chambers 210A and 210B can be substantially fluid-isolated in the region near the opening of tank 202.

[0025] During the detection period, a path is provided for the ultrasonic signal to be emitted and / or received by the transducer probe. This path may include water in a tank immersing transducer probes 204A and 204B, corresponding membranes 206A and 206B, and water in corresponding chambers 210A and 210B. For example, transducer probe 204A may emit an ultrasonic signal for detecting a tube inserted in the axial channel. The ultrasonic signal may travel from transducer probe 204A through the water in tank 202, then through membrane 206A (which may have approximately the same acoustic impedance as the water), then through the water in chamber 210A, and then into the tube located in the axial channel. Similarly, the reflection or echo of an ultrasonic signal can travel the same path in reverse—for example, starting from the tube and then traveling through the water in chamber 210A, then through membrane 206A, and then through the water in tank 202, where the reflection or echo is received by transducer probe 204A.

[0026] Furthermore, during the testing process, the water in tank 202 and chambers 210A and 210B can be substantially still, for example, stationary. Therefore, this design allows for immersion ultrasonic testing without the need for water movement during the testing period, thereby reducing the number of air bubbles in the water along the ultrasonic signal path and thus improving the accuracy of the ultrasonic testing.

[0027] Figures 3A to 3D The illustration depicts a detection method according to an example of the present invention. For clarity and brevity, the detection method will be described using only the components illustrated in the upper half of the figures, such as component "A"; component "B" will operate in the same or similar manner as component "A". Figure 3A As shown, the tube can be inserted into the axial channel of tank 202. At this time, chamber 210A can be empty and positioned away from the corresponding opening in tank 202. The tube can, for example, begin to traverse the axial channel at a specific speed on a conveyor belt type device.

[0028] like Figure 3B As shown, the position of the pipe can be detected at various locations (e.g., by sensor 106) as the pipe traverses the axial channel. When the pipe reaches its initial position inside the axial channel (e.g., as detected by the sensor), water can build up in chamber 210A, for example, by filling chamber 210A with water. The water can be poured from a separate container and can be poured in slowly to reduce the bubble effect. The seal 208A, including chamber 210A, can then occupy the initial axial position. After water has built up in chamber 210A, seal 208A can move in the same direction as the pipe at the same specific speed as the pipe; therefore, seal 208A can move together with the pipe inside the axial channel. In another example, chamber 210A can be filled while seal 208A is moving.

[0029] like Figure 3C As shown, the seal 208A can move within the axial channel until the chamber 210A disposed in the seal 208A becomes aligned with the corresponding opening in the tank 202 sealed by the membrane 206A. At this point, the seal 208A can stop, and a path is provided for the ultrasonic signal to be transmitted into the tube by the transducer probe 204A and for the reflection and echo to be received by the transducer probe 204A; this path includes the water in the tank 202, the membrane 206A, and the water in the chamber 210A.

[0030] Next, ultrasonic testing of the tube can be performed using transducer probe 204A. Ultrasonic waves can be used to non-destructively inspect the tube from start to finish, including both ends. The tube can continue to be inspected across the axial channel until the inspection is complete.

[0031] Transducer probes 204A and 204B may include digital and analog circuitry, such as front-end circuitry including one or more transmit signal chains, receive signal chains, or switching circuitry (e.g., transmit / receive switching circuitry). The transmit signal chains may include amplifiers and filtering circuitry, for example, to provide transmission pulses for use in interconnected probe assemblies for acoustic transmission through the tube, such as for imaging or otherwise probing defects on or within the tube structure by receiving acoustic energy scattered or reflected in response to acoustic transmission.

[0032] Different probe configurations can be used, such as multiple probe assemblies connected to a single test instrument, or multiple transducer arrays used in conjunction with single or multiple probe assemblies for tandem detection. Similarly, test protocols can be executed using the coordination between multiple transducer probes 204A, 204B, such as in response to an overall test plan established from control panel 108 or in response to an overall test plan established via another remote system, such as a computing tool or a general computing device such as a laptop computer, tablet computer, smartphone, robotic drone, desktop computer, etc. As an illustrative example, test plans can be established according to published standards or regulatory requirements and can be performed during initial manufacturing or used for continuous monitoring on a repeatable basis.

[0033] The receiving signal chain of the front-end circuitry may include one or more filter or amplifier circuits, and analog-to-digital conversion facilities, for example, to digitize the echo signal received using a transducer probe. Digitization may be performed coherently, for example, to provide multiple digitized data channels aligned or referenced to each other in time or phase. The front-end circuitry may be coupled to and controlled by one or more processor circuits included as part of the detection circuitry. The processor circuitry may be coupled to memory circuitry, for example, to execute instructions that cause the detection system to perform one or more of the following: acoustic emission, acoustic acquisition, processing, or storage of data related to acoustic detection, or otherwise perform the techniques shown and described herein.

[0034] like Figure 3D As shown, when the ultrasonic test is complete, the tube can be withdrawn from the axial channel. Additionally, the movement of seal 208A can restart in the same axial direction as the tube. After chamber 210A passes the distal end of tank 202, water from chamber 210A can be drained. For example, chamber 210A can be open and the water can be emptied. Chamber 210A can be cleaned, for example, by pressurized air or water. Seal 208A can then return to its initial axial position, and another tube can be inserted into the proximal end of tank 202 for testing. Notably, the water in tank 202 does not need to be drained between tube tests, for example, when draining water from chamber 210A. This provides the additional benefits of water conservation and keeping the water in tank 202 stagnant.

[0035] During testing, the membrane and chamber can be aligned to provide a path for ultrasound waves with or approximately the same acoustic impedance as water (water-membrane-water). Furthermore, the water in the tank and chamber can be approximately still during testing, resulting in more accurate results.

[0036] The membrane can be aligned with the opening in the tank during the detection period, but does not need to be aligned with the opening at other times. Figure 4 The illustration shows a cross-section of a tube inspection system according to an example of the present invention. In this example, membranes 406A and 406B can be disposed in corresponding seals 408A and 408B adjacent to chambers 410A and 410B, which are also disposed in seals 408A and 408B. Thus, during non-inspection periods, the opening in tank 402 can be sealed by seals 408A and 408B, while during inspection periods, the opening in tank 402 can be sealed by membranes 406A and 406B when seals 408A and 408B are moved to the measuring position, thereby aligning membranes 406A and 406B (and adjacent chambers 410A and 410B) with the opening in tank 402.

[0037] like Figure 2 The description indicates that a tank 402 may be provided and filled with water. The tank 402 may include transducer probes 404A and 404B immersed in the water. The tank 402 may include an opening leading to an axial channel into which a tube is inserted. The transducer probes 404A and 404B may be oriented toward the corresponding opening in the tank 402.

[0038] Seals 408A and 408B may be disposed within the axial channel. Seals 408A and 408B may include membranes 406A and 406B disposed adjacent to chambers 410A and 410B. Membranes 406A and 406B may have an acoustic impedance substantially the same as that of water. For example, membranes 406A and 406B may use Aqualene. TM Elastomer coupling agent, acoustic coupling elastomer (ACE) TM The chambers 410A and 410B can be filled with water for testing. Seals 408A and 408B can be configured to move within the axial channel. During testing, seals 408A and 408B can be positioned at the measurement location where membranes 406A and 406B and adjacent chambers 410A and 410B are positioned in front of the corresponding openings in the tank. Therefore, due to the presence of membranes 406A and 406B providing a physical barrier between tank 402 and chambers 410A and 410B, tank 402 and chambers 410A and 410B can be substantially fluid-isolated in the region near the opening of tank 402. This provides a water interface for ultrasonic testing without the adverse effects of moving water, such as bubbling.

[0039] During the detection time, a path is provided for the ultrasonic signal to be emitted and / or received by the transducer probe. This path may include water in a tank immersing transducer probes 404A, 404B, corresponding membranes 406A, 406B, and water in corresponding chambers 410A, 410B. For example, transducer probe 404A may emit an ultrasonic signal for detecting a tube inserted in the axial channel. The ultrasonic signal may travel from transducer probe 404A through the water in tank 402, then through membrane 406A (which may have approximately the same acoustic impedance as the water), then through the water in chamber 408A, and then into the tube located in the axial channel. Similarly, the reflection or echo of an ultrasonic signal can travel the same path in reverse—for example, starting from the tube and then traveling through the water in chamber 408A, then through membrane 406A, and then through the water in tank 402, where the reflection or echo is received by transducer probe 404A at tank 402.

[0040] Furthermore, during the inspection, the water in tank 402 and chambers 410A and 410B can be substantially still, for example, stationary. Therefore, this design allows for immersion ultrasonic testing without the need for water movement during the inspection, thereby reducing the number of air bubbles in the water along the ultrasonic signal path and thus improving the accuracy of the ultrasonic testing.

[0041] The transducer probe described in this article can be housed within a casing while submerged in water. The transducer probe within the tank can be arranged radially around the axial channel. Figure 5 The illustration shows a transducer arrangement according to an example of the invention. Here, a set of transducer probes 502 is illustrated, and the transducer probes 502 can be arranged in a continuous manner. During detection, the transducer probes 502 can operate simultaneously, thus functioning as a single probe. The detection sequence can be clockwise, counterclockwise, or other constructible patterns.

[0042] Figure 6 The illustration shows a transducer arrangement according to an example of the invention. Here, a set of transducer probes 602 is illustrated, and the transducer probes 602 can be arranged in a staggered manner. During detection, the transducer probes 602 can perform detection sequentially, for example, one after another. The detection sequence can be clockwise, counterclockwise, or other constructible patterns. Furthermore, the detection system as described herein can include multiple sets of transducer probes, each set of transducer probes arranged radially around an axial channel at different axial positions.

[0043] Different detection modes can be provided. For example, detection modes can be provided for detecting volumetric defects, detecting dimensional pipe features, clockwise detection of cracks, and counterclockwise detection of cracks. Oblique and / or lateral crack detection can be provided by using a matrix probe with additional test modes. In the example using Phase Array Ultrasonic Testing (PAUT), multiple PAUT beams can be utilized. Furthermore, other detection schemes, such as full matrix acquisition / full focusing methods, can be used.

[0044] In the tube detection system described herein, fluids or coupling agents other than water can be used. For example, a water-based mixture can be used. In another example, glycerol can be used. The acoustic impedance of the membrane can be matched to the acoustic impedance of the fluid or coupling agent.

[0045] Several examples or implementations of the invention have been specifically described and / or illustrated herein. However, it will be understood that modifications and variations of the invention are covered by the foregoing teachings and are within the scope of the appended claims without departing from the intended scope of the invention.

[0046] Although implementations of this disclosure have been described with reference to specific examples, it will be apparent that various modifications and changes can be made to these implementations without departing from the broader scope of the subject matter. Therefore, this specification and the accompanying drawings should be considered illustrative rather than restrictive. The accompanying drawings, which form a part of this specification, illustrate, in an illustrative rather than restrictive manner, specific implementations of the subject matter that can be practiced. The illustrated implementations have been described in sufficient detail to enable those skilled in the art to practice the teachings disclosed herein. Other implementations, and other implementations derived therefrom, may be used, allowing for structural and logical substitutions and changes without departing from the scope of this disclosure. Therefore, this detailed specification should not be construed as restrictive, and the scope of the various implementations is defined only by the appended claims and the full scope of their equivalents.

Claims

1. A testing system comprising: a can defining an axial passageway for insertion of a tube for testing, and including an opening to the axial passageway; a transducer probe disposed inside the can and oriented toward the opening; a movable seal including a chamber, the movable seal configured to move axially inside the axial passageway; and a membrane positioned in the opening for testing of the tube using the transducer probe, to provide a path for ultrasound signals to be launched from the transducer probe to the tube in response to the movable seal occupying a measurement position, wherein the path includes fluid in the can, the membrane, and fluid in the chamber and wherein the can and chamber are substantially fluidically isolated.

2. The detection system of claim 1, wherein, the path includes water in the can, the membrane, and water in the chamber, and wherein the membrane includes a material having substantially the same acoustic impedance as water.

3. The detection system of claim 2, wherein, The film comprises Aqualene TM Elastomeric coupling agent.

4. The testing system of claim 1, further comprising: a sensor for sensing an axial position of the tube along the axial passageway.

5. The detection system of claim 4, wherein, the chamber configured to be filled with fluid based on sensing by the sensor of the tube at an initial position in the axial passageway.

6. The detection system of claim 4, wherein, the sensor includes a eddy current coil sensor.

7. The testing system of claim 1, further comprising: a plurality of transducer probes disposed inside the can in a radial arrangement around the axial passageway, wherein the transducer probe is one of the plurality of transducer probes, wherein the can includes a plurality of openings, one for each of the plurality of transducer probes.

8. The detection system of claim 7, wherein, the plurality of transducer probes are radially interleaved around the axial passageway.

9. The detection system of claim 1, wherein, the membrane is disposed in the opening of the can.

10. The detection system of claim 1, wherein, the membrane is disposed in the seal and configured to be positioned in the opening when the movable seal occupies the measurement position.

11. A method comprising: traversing by a tube being tested an axial passageway defined by a can, the traversing including: sensing the tube at an initial position inside the axial passageway; establishing fluid in a chamber included in a seal, the seal occupying an initial axial position adjacent a forward end of the tube; and moving the seal in an axial direction; in response to the chamber becoming aligned with an opening of the can sealed by a membrane, performing ultrasound testing of the tube using a transducer probe inside the can; and evacuating the fluid from the chamber without requiring evacuation of fluid from the can.

12. The method of claim 11, wherein, launching ultrasound energy by the transducer probe through a path including fluid in the can, the membrane, and fluid in the chamber to the tube.

13. The method of claim 11, wherein, the fluid is water, and wherein the membrane includes a material having substantially the same acoustic impedance as water.

14. The method of claim 13, wherein, The film comprises Aqualene TM Elastomeric coupling agent.

15. The method of claim 11, further comprising: removing the tube from the axial passageway upon completion of the ultrasound testing; evacuating the fluid from the chamber; and ​ The chamber is cleaned prior to detection of another tube.

16. A system comprising: a tank defining an axial passageway for a tube to traverse for detection, the tank including a plurality of openings to the axial passageway; a plurality of transducer probes disposed inside the tank in a radial arrangement about the axial passageway, each transducer probe oriented toward one of the plurality of openings; at least one movable seal configured to move axially inside the axial passageway; and a plurality of membranes, each membrane configured to be positioned at one of the plurality of openings for detection of the tube by the plurality of transducer probes, each transducer probe to emit ultrasonic energy into the tube through a fluid in the tank, one of the plurality of membranes, and a fluid in one of a plurality of chambers, wherein the tank and the plurality of chambers are substantially fluidically isolated.

17. The system of claim 16, wherein, The fluid is water, and wherein the membranes include a material having substantially the same acoustic impedance as water.

18. The system of claim 17, wherein, The film comprises Aqualene TM Elastomeric coupling agent.

19. The system of claim 16, further comprising: a sensor to detect an axial position of the tube along the axial passageway.

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