An online rapid inspection system for oil pipes

Abstract

This utility model discloses an online rapid inspection system for oil pipes, including a frame with a scanning channel formed inside the frame for continuous passage of the oil pipe. A dual-energy X-ray emission unit is integrated into one inner wall of the scanning channel, and a detector array unit is integrated into the other inner wall. A data acquisition and processing unit and a control unit are integrated in a control room outside the scanning channel. The control unit is communicatively connected to the dual-energy X-ray emission unit, the data acquisition and processing unit, and the transmission mechanism that drives the oil pipe movement. This utility model, through the cooperation of the scanning channel and the transmission mechanism, allows the oil pipe to be inspected continuously without stopping the machine for disassembly. By using the dual-energy X-ray emission unit combined with the detector array unit to collect and analyze the penetration signal, it can accurately distinguish between defects such as corrosion, cracks, and perforations on the inner / outer wall of the oil pipe and interfering factors such as deposits and scale, based on the attenuation differences of different energy rays at the oil pipe material and defects.

Description

Technical Field

[0001] This utility model relates to the field of oil pipe inspection technology, and in particular to an online rapid inspection system for oil pipes. Background Technology

[0002] In oilfield production operations, tubing, as a critical piece of equipment, is subjected to complex alternating loads, chemical corrosion, and mechanical wear conditions over long periods. This makes it highly susceptible to defects such as internal and external wall corrosion, perforation, cracks, and wall thinning. These defects not only affect oil production efficiency but can also lead to serious safety accidents. Therefore, establishing an effective mechanism for regular tubing inspection is of great significance for ensuring safe oilfield production and reducing operation and maintenance costs.

[0003] Currently, non-destructive testing of pipelines mainly employs offline manual inspection or single X-ray technology. However, offline manual inspection requires the complete disassembly of the pipeline from its service environment and its transport to a dedicated inspection area, where operators use portable equipment to inspect each section. This method has inherent drawbacks: firstly, the inspection process is cumbersome, requiring downtime and severely disrupting normal production, resulting in extremely low inspection efficiency; secondly, the inspection results heavily rely on the operator's experience and condition, leading to strong subjectivity and a high risk of missed detections and misjudgments; and finally, it is difficult to achieve digital management and traceability of inspection data. While single X-ray technology can achieve a certain degree of internal defect detection, its imaging principle has inherent limitations: the grayscale of images obtained by single-energy X-ray imaging only reflects the integral effect of the attenuation coefficients of all materials along the ray path, resulting in severely insufficient sense of layering and contrast; it is difficult to effectively distinguish areas with similar X-ray attenuation characteristics on the pipeline inner wall, such as scale, uniform corrosion zones, and intact substrate, leading to very limited ability to identify minor damage, early corrosion, and changes in wall thickness. In addition, although technologies such as ultrasonic testing have been applied in specific scenarios, they usually require coupling agents and have high requirements for the surface condition of the workpiece; at the same time, their point or line scanning methods are difficult to achieve rapid coverage of the entire cross section, and cannot meet the needs of online, continuous and rapid testing. Summary of the Invention

[0004] The technical problem solved by this utility model is to provide an online rapid inspection system for oil pipes.

[0005] This application provides an online rapid inspection system for oil pipes, including a frame with a scanning channel formed inside the frame through which the oil pipe continuously passes. A dual-energy X-ray emitting unit is integrated within one inner wall of the scanning channel to emit high- and low-energy X-ray beams onto the oil pipe. A detector array unit is integrated within the other inner wall of the scanning channel to receive X-ray signals penetrating the oil pipe and convert them into electrical signals. A data acquisition and processing unit and a control unit are integrated in a control room outside the scanning channel. The data acquisition and processing unit communicates with the detector array unit to receive electrical signals and generate defect information of the oil pipe. The detector array unit communicates bidirectionally with the control unit to provide feedback on the detector's readiness status, fault signals, and health status parameters, and to receive trigger and control commands from the control unit. The control unit is communicatively connected to the dual-energy X-ray emitting unit, the data acquisition and processing unit, and the transmission mechanism that drives the movement of the oil pipe.

[0006] Furthermore, the dual-energy X-ray emitting unit is a dual low-power integrated X-ray source, and a vertical collimator for confining the X-ray beam is provided in front of its emitting end.

[0007] Furthermore, the detector array unit is a scalable modular linear detector array, and its detection surface is provided with a protective cover.

[0008] Furthermore, a radiation shielding layer is integrated inside the wall of the scanning channel, and the dual-energy X-ray emitting unit and detector array unit are embedded in the radiation shielding layer.

[0009] Furthermore, the control unit is configured to control the transmission mechanism to make the oil pipe pass through the scanning channel at a constant speed of not less than 20 cm / s.

[0010] Compared with existing technologies, this invention enables oil pipes to be inspected continuously through the cooperation of the scanning channel and the transmission mechanism, without the need for machine shutdown and disassembly. By using a dual-energy X-ray emission unit (high and low energy beams) and combining it with the detector array unit to collect and analyze the penetration signal, it can accurately distinguish between defects such as corrosion, cracks, and perforations on the inner / outer wall of the oil pipe and interference factors such as deposits and scale on the pipe by the attenuation difference of different energy rays at the oil pipe material and defects. Attached Figure Description

[0011] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model.

[0012] Fig. 1This is a schematic diagram of the structure of the online rapid inspection system for oil pipes of this utility model; Fig. 2 This is a structural block diagram of the online rapid inspection system for oil pipes according to this utility model.

[0013] The reference numerals in the attached figures include: 1. Frame; 2. Scanning channel; 3. Dual-energy X-ray emission unit; 4. Detector array unit; 5. Vertical collimator; 6. Protective cover; 7. Radiation shielding layer; 8. Data acquisition and processing unit; 9. Control unit; 10. Transmission mechanism; 11. Oil pipe. Detailed Implementation

[0014] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0015] like Figs. 1-2 As shown, the online rapid inspection system for oil pipes of this utility model includes a frame 1. A scanning channel 2 is formed inside the frame 1 for the oil pipe 11 to pass through continuously. A dual-energy X-ray emitting unit 3 is integrated in one inner wall of the scanning channel 2 for emitting X-ray beams of high and low energy to the oil pipe 11. The dual-energy X-ray emitting unit 3 is a dual low-power integrated X-ray source, and a vertical collimator 5 for confining the X-ray beam is provided in front of its emitting end. The other inner wall of the scanning channel 2 is integrated with a detector array unit 4, which is used to receive the X-ray signal after penetrating the oil pipe 11 and convert it into an electrical signal; the detector array unit 4 is an expandable modular linear detector array, and its detection surface is provided with a protective cover plate 6. The scanning channel 2 has a radiation shielding layer 7 integrated inside its wall, and the dual-energy X-ray emitting unit 3 and the detector array unit 4 are embedded in the radiation shielding layer 7. The control room outside the scanning channel 2 integrates a data acquisition and processing unit 8 and a control unit 9. The data acquisition and processing unit 8 communicates with the detector array unit 4 to receive electrical signals and generate defect information of the oil pipe 11 (using existing mature dual-energy X-ray imaging technology). The detector array unit 4 communicates bidirectionally with the control unit 9 to provide feedback on the detector's readiness status, fault signals, and health status parameters, and to receive trigger and control commands from the control unit 9. The control unit 9 monitors the system and displays the operating status based on the received signals and parameters. Before issuing the "permit X-ray emission" command, the control unit 9 must confirm that the detector array unit 4 is ready. If the detector is not ready, is powered off, or malfunctions, but X-rays are still emitted, not only will the detection be ineffective, but it will also cause a radiation safety accident. Once the detector array unit 4 reports a fault during operation (such as overheating, abnormal power supply, or communication interruption), the control unit 9 must be able to immediately cut off the X-ray emission and stop the transmission system to prevent continued operation in an ineffective or dangerous state. The control unit 9 is communicatively connected to the dual-energy X-ray emitting unit 3, the data acquisition and processing unit 8, and the transmission mechanism 10 that drives the movement of the oil pipe 11. That is, the control unit 9 communicates bidirectionally with the data acquisition and processing unit 8, the dual-energy X-ray emitting unit 3, and the transmission mechanism 10. It is used to control the start and stop of the data acquisition and processing unit 8, the acquisition frequency, the processing algorithm, etc., and to receive the defect judgment results (such as "qualified", "unqualified", "suspected corrosion") and specific information about the defects sent by the data acquisition and processing unit 8 based on real-time image analysis. These information include the type, size, and position coordinates on the oil pipe 11 (associated with the encoder position). The transmission mechanism 10 feeds back the actual speed to the control unit 9 and receives the target speed and fine-tuned output speed sent by the control unit 9. The dual-energy X-ray emitting unit 3 receives the high-voltage enable command, pipe voltage / pipe current set value, etc., from the control unit 9 and feeds back the ready status to the control power supply. Only after the control unit 9 confirms that the X-ray source is "ready" and fault-free can it issue an "enable" command. Any fault feedback must be able to immediately cut off the high voltage.

[0016] The output of the control unit 9 is connected to the transmission mechanism 10 and the dual-energy X-ray emission unit 3 respectively; the control unit 9 is configured to control the transmission mechanism 10 to make the oil pipe 11 pass through the scanning channel 2 at a speed of not less than 20cm / s; wherein, the transmission mechanism 10 can be a commonly used conveyor belt mechanism, which is existing technology and will not be described in detail here.

[0017] This invention, through the cooperation of the scanning channel 2 and the transmission mechanism 10, enables the oil pipe 11 to be inspected continuously without the need for machine shutdown and disassembly, fundamentally changing the traditional offline inspection mode. The scanning speed is no less than 20 cm / s, and at least 50 oil pipes 11 can be inspected per hour, significantly improving inspection efficiency and shortening the maintenance cycle of the oil pipe 11. The use of a low-power X-ray source combined with a shielding design within the channel wall ensures that the system's absorbed dose is ≤2 μGy and the boundary dose rate is ≤2 μGy / h, meeting international safety standards. Employing dual-energy X-ray imaging technology, the attenuation difference between high and low energy X-rays clearly distinguishes the oil pipe 11 substrate from defects such as corrosion and damage. Furthermore, through modular design, the X-ray emission unit and detector array unit 4 are integrated within the wall of the scanning channel 2, forming a stable inspection structure. The external data processing and control unit 9 avoids the impact of on-site vibration and temperature / humidity changes on the precision electronic equipment, ensuring the long-term stability of the system. In addition, the modular detector array can be flexibly expanded according to different pipe diameter requirements. The basic architecture and detection principle of this application are also applicable to the rapid detection of other tubular components such as chemical pipelines and urban water supply pipelines, and have broad application prospects.

[0018] Specifically, the scanning channel 2 is equipped with devices such as proximity switches and position sensors to detect the position of the oil pipe 11. After the oil pipe 11 reaches the detection position, it sends a detection signal to the control unit 9. After receiving the detection signal, i.e. confirming that the oil pipe 11 has reached the scanning position, the control unit 9 will simultaneously send a "start" signal to the X-ray source and the detector. The detector needs to receive or confirm this trigger signal to ensure that the image acquisition is strictly synchronized with the X-ray pulse and the position of the oil pipe 11.

[0019] Specifically, the model selection of the above-mentioned electrical components can be made according to the actual situation, as shown in the following example: The dual-energy X-ray emission unit 3 uses a dual-focus X-ray tube of the SAILRAY SRMWTX74-0.6 / 1.2-150 or Seifert Isovolt series; the detector array unit 4 uses a linear array detector module of the PerkinElmer XRD 0822 or Hamamatsu C10900D; the hardware configuration of the data acquisition and processing unit 8 includes a National Instruments PCIe-1433 acquisition card, an Intel Xeon W-1370P processor (which integrates a mature dual-energy X-ray imaging algorithm, therefore, its processing of electrical signals is existing technology), 32GB DDR4 memory, and 1TB NVMe SSD storage; the control unit 9 uses a Siemens S7-1200 or Beckhoff CX9020 PLC controller.

[0020] The pin connection relationship is explained using the Siemens S7-1200 controller as an example: The controller's external 24V DC power supply, external 5V DC power supply, ground GND pin, PLC DO0.0, PLC DI0.0, PLC DI0.6, PLC DI0.1, PLC DO0.5, PLC DO0.6, PLC AQ0.1, PLC AQ0.2, PLC AI0.0, PLC AI0.1, PLC RS485+, and PLC RS485- pins are respectively connected to the dual-energy X-ray emission unit's PWR_MAIN, PWR_CTRL, GND, ENABLE, HV_READY, TEMP_ALM, FAULT, MODE_SEL1, MODE_SEL2, HV_REF_H, HV_REF_L, CURRENT_MON, TEMP_MON, RS485_A, and RS485_B pins. The controller is connected to an external 24V DC power supply, an external 5V DC power supply, a ground pin (GND), and PLC DO0.3, PLC DI0.5, PLC DI0.4, PLC DO0.7, PLC DI0.1, PLC DI0.7, PLC DO0.2. The PLC PROFINET Port1 pin is connected to the PWR_12V, PWR_5V, GND, ACQ_START, ACQ_BUSY, ACQ_DONE, DATA_RDY, SYSTEM_RDY, ERROR_OUT, RESET_IN, and ETHERNET pins of the data acquisition and processing unit. The controller's DI0.1, DI0.7, AI0.0, AI0.1, RS485+, RS485-, and DI0.1 pins are respectively connected to the detector array unit's DET_READY, DET_FAULT, DET_TEMP, DET_BIAS, RS485_A, RS485_B, and POWER_GOOD pins; The data acquisition and processing unit's CL_X0+, CL_X0-, CL_X1+, CL_X1-, CL_X2+, CL_X2-, CL_X3+, CL_X3-, CL_SerTC+, CL_SerTC-, CL_FVAL+, CL_FVAL-, CL_LVAL+, CL_LVAL-, CL_DVAL+, CL_DVAL-, CL_CONTROL1, CL_CONTROL2, and CL_CO The NTROL3, CL_CONTROL4, GND, and +12V pins are connected to the X0+, X0-, X1+, X1-, X2+, X2-, X3+, X3-, SerTC+, SerTC-, FVAL+, FVAL-, LVAL+, LVAL-, DVAL+, DVAL-, CONTROL1, CONTROL2, CONTROL3, CONTROL4, GND, and +12V pins of the detector array unit, respectively.

[0021] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of this application are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0022] Furthermore, the use of terms such as "first" and "second" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed in this application.

[0023] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the present invention.

[0024] Obviously, those skilled in the art can make various modifications and variations to this utility model without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this utility model and their equivalents, this utility model also intends to include these modifications and variations.

Claims

1. An online rapid inspection system for oil pipes, characterized in that, The system includes a frame (1), inside which a scanning channel (2) through which an oil supply pipe (11) continuously passes is formed. A dual-energy X-ray emission unit (3) is integrated within one inner wall of the scanning channel (2) for emitting high and low energy X-ray beams to the oil pipe (11). A detector array unit (4) is integrated within the other inner wall of the scanning channel (2) for receiving X-ray signals penetrating the oil pipe (11) and converting them into electrical signals. A data acquisition and processing unit (8) and a control unit (9) are integrated in a control room outside the scanning channel (2). The acquisition and processing unit (8) communicates with the detector array unit (4) to receive electrical signals and generate defect information of the oil pipe (11). The detector array unit (4) communicates bidirectionally with the control unit (9) to feed back the detector's readiness status, fault signals and health status parameters to the control unit (9) and to receive trigger and control commands from the control unit (9). The control unit (9) is communicatively connected to the dual-energy X-ray emission unit (3), the data acquisition and processing unit (8), and the transmission mechanism (10) that drives the oil pipe (11) to move.

2. The online rapid inspection system for oil pipes as described in claim 1, characterized in that, The dual-energy X-ray emitting unit (3) is a dual low-power integrated X-ray source, and a vertical collimator (5) for confining the X-ray beam is provided in front of its emitting end.

3. The online rapid inspection system for oil pipes as described in claim 2, characterized in that, The detector array unit (4) is an expandable modular linear detector array, and its detection surface is provided with a protective cover plate (6).

4. The online rapid inspection system for oil pipes as described in claim 3, characterized in that, The scanning channel (2) has a radiation shielding layer (7) integrated inside its wall, and the dual-energy X-ray emission unit (3) and detector array unit (4) are embedded in the radiation shielding layer (7).

5. The online rapid inspection system for oil pipes as described in claim 4, characterized in that, The control unit (9) is configured to control the transmission mechanism (10) to make the oil pipe (11) pass through the scanning channel (2) at a speed of not less than 20 cm / s.

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