System and method for inspecting a tubular

The system addresses the challenge of inspecting tubulars in offshore locations by using a support hanger and inspection apparatus with a holding mechanism to maintain contact and collect reliable data, overcoming accessibility and environmental challenges.

GB2626556BActive Publication Date: 2025-04-09AISUS OFFSHORE LTD
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Patent Information

Application Number
GB2023001093
Authority / Receiving Office
GB · GB
Patent Type
Patents
Current Assignee / Owner
Filing Date
2023-01-25
Publication Date
2025-04-09
Estimated Expiration
2043-01-25

AI Technical Summary

Technical Problem

Inspection of tubulars in offshore locations is challenging due to accessibility issues and harsh environmental conditions, making it difficult to deploy inspection systems while obtaining reliable data.

Method used

A system comprising a support hanger secured to the tubular with a securing mechanism, an inspection apparatus suspended from the hanger, and a connecting member allowing movement relative to the hanger, equipped with sensors and a holding mechanism to maintain contact with the tubular, enabling reliable data collection despite external forces.

Benefits of technology

The system provides reliable and repeatable inspection of tubulars by allowing sensor data collection at different points while preventing separation from the tubular, suitable for offshore environments and various tubular sizes and configurations.

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Abstract

A system 10 for inspecting a tubular comprises a support hanger 37 secured to the tubular e.g. caisson, riser, j-tube, jacket leg. An inspection apparatus 12 is suspended from the support hanger via a
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Description

FIELD The present disclosure relates to a system and method for inspecting a tubular. 5 BACKGROUND Tubulars generally require inspection at some point in their operational lifetime to identify whether any defects are present. However, tubulars used in offshore locations, for example, can sometimes be difficult to access and may be subject to harsh 10 environmental conditions. It can therefore be a challenge to deploy inspection systems at the location of the tubular while obtaining reliable data on the tubular. SUMMARY An aspect of the present disclosure relates to a system for inspecting a tubular, the CO 15 system comprising: C\l a support hanger configured to be secured to the tubular, wherein the support 1^.^, hanger comprises one or more securing members for securing the support hanger to the tubular and centralising the support hanger on the tubular; an inspection apparatus suspended from the support hanger; 20 a connecting member connecting the inspection apparatus to the support hanger, the connecting member configured to permit movement of the inspection apparatus relative to the support hanger, wherein the inspection apparatus comprises: a sensor arrangement configured to obtain sensor data associated with the tubular; and 25 a holding mechanism configured to hold the inspection apparatus to the tubular. The support hanger may be secured to the tubular to provide a fixed reference point. The inspection apparatus may move relative to the support hanger along the tubular to 30 allow sensor data to be obtained at different points on the tubular while the holding mechanism holds the inspection apparatus to the tubular preventing any external forces that act on inspection apparatus (e.g. waves, air currents, etc.) from forcing the inspection apparatus to separate from the tubular and disrupt the inspection process. The system may therefore provide for reliable and repeatable inspection of the tubular. 35 The tubular may be associated with offshore energy production. The tubular may be located in a splash zone of an offshore drilling site. The tubular may be or comprise a caisson, a riser, a j-tube, a jacket leg, a etc. In other examples, however, the tubular may be located topside. The tubular may be or comprise a flowline in which 5 hydrocarbons, injecting fluids, etc., may flow to or from a wellbore. As such, the tubular may be any size. In some specific examples, however, the tubular may be a caisson having an outer diameter of approximately 254 mm (10 inches). The tubular may comprise a ferromagnetic material (e.g., steel). The tubular may be located in a subsea environment. As such, the inspection apparatus may be configured for use in a 10 subsea environment. In some specific examples, the inspection apparatus may be deployed to depths of 150 m below sea level. Accordingly, the inspection apparatus may be configured (e.g., equipped with appropriate seals, etc.) to withstand elevated, subsea pressures. 15 The tubular may define a longitudinal axis. The inspection apparatus may be configured to move along an external surface of the tubular. The inspection apparatus may be configured to move parallel to the longitudinal axis of the tubular. The inspection apparatus may be configured to move linearly. In some examples, the inspection apparatus may be configured to move around at least part of a circumference of the tubular. In some examples, the inspection apparatus may be configured to be lightweight (e.g., 70 kg or less). In other examples, however, where the inspection apparatus is for use in a subsea environment, the inspection apparatus may be provided with one or more 25 weights to counter buoyancy forces acting on the inspection apparatus. The holding mechanism may comprise one or more magnets. The one or more magnets may be configured to provide a magnetic force to hold the inspection apparatus to the tubular. The one or more magnets may comprise one or more 30 permanent magnets. Alternatively or additionally, the one or more magnets may comprise one or more electromagnets. In some examples, the one or more magnets may comprise one or more rare-earth magnets, such as samarium-cobalt magnets. The one or more magnets may be mounted to the inspection apparatus at a central location or other location(s) (e.g., at either side of the inspection apparatus) to provide 35 stability of the inspection apparatus. In other examples, however, the holding mechanism may take other forms. For instance, the holding mechanism may comprise one or more adhesives, e.g., located on an outer surface of the one or more wheels. Alternatively or additionally, the holding mechanism may comprise one or more straps for strapping the inspection apparatus to the tubular. In further examples, the holding mechanism may comprise a guide rail attached to the tubular. The inspection apparatus may comprise one or more wheels. The one or more wheels may be configured to permit the inspection apparatus to move along the tubular. The one or more wheels may comprise an axis of rotation perpendicular to the longitudinal axis of the tubular. In other examples, the inspection apparatus may comprise tracks instead of wheels. The one or more wheels may comprise one or more magnetic wheels. The one or more magnetic wheels may provide an electromotive force. The inspection apparatus may be configured to be propelled along the tubular by the electromotive force. Where the one or more wheels comprise one or more magnetic wheels, the one or more magnetic wheels may function or contribute to the function of the holding mechanism. The system may comprise an actuator. The actuator may be configured to move the inspection apparatus relative to the support hanger. The actuator may be configured to modify a length of the connecting member to move the inspection apparatus relative to the support hanger. In particular, the length of the connecting member may be shortened to move the inspection apparatus closer to the support hanger, and may be lengthened to move the inspection apparatus away from the support hanger. The actuator may comprise a hoist arrangement. The hoist arrangement may comprise one or more pulleys. The hoist arrangement may be configured to lift and / or lower the inspection apparatus. In some examples, the tubular may be arranged vertically such that the inspection apparatus is vertically suspended from the support hanger. In other examples, the tubular may be arranged at an angle from vertical such that the inspection apparatus is suspended from the support hanger at an angle from vertical. In either case, however, the orientation of the tubular may be such that downward movement of the inspection apparatus may be effected by gravity. The actuator may comprise a pneumatic actuator (e.g., a pneumatic or air hoist). The actuator may comprise a hydraulic actuator (e.g., a hydraulic hoist). Alternatively or additionally, the actuator may comprise a motor. The actuator may be mounted on the inspection apparatus. The motor may be operably connected to the hoist arrangement. The motor may be operably connected to the one or more wheels. The motor may be configured to provide rotational power to the one or more wheels to propel the inspection apparatus along the tubular. The one or more wheels may be provided with one or more tyres. The tyres may provide traction between the one or more wheels and the tubular. The sensor arrangement may comprise one or more sensors. The one or more sensors may comprise any type of sensor. The sensor arrangement may be configured for non-destructive testing (NDT). The sensor arrangement may comprise an ultrasonic module. The ultrasonic module may comprise one or more transducers. The ultrasonic module may be configured to transmit an ultrasonic wave to the tubular. The ultrasonic module may be configured to receive a portion of the ultrasonic wave reflected by the tubular, e.g., at a discontinuity, such as a crack, defect, etc. The ultrasonic module may be configured to transform the reflected wave into an electrical signal to provide the sensor data. The ultrasonic module may comprise a couplant to facilitate the transmission of ultrasonic waves to and from the tubular. The ultrasonic module may comprise a couplant inlet for receiving couplant from a supply source. The couplant may comprise water, gel or other suitable couplant material. In other examples, the ultrasonic module may comprise an electromagnetic acoustic transducer (EMAT), which may enable non-contact wave transmission and reception. In such examples, the ultrasonic module may not comprise a couplant, but may instead comprise one or more electromagnets to facilitate the transmission of ultrasonic waves to and from the tubular. The sensor arrangement may comprise an electromagnetic module, e.g. a pulsed eddy current (PEC) module. The electromagnetic module may comprise one or more transducers. The electromagnetic module may be configured to transmit an electromagnetic wave to the tubular. The electromagnetic module may be configured to receive a portion of the electromagnetic wave reflected by the tubular. The electromagnetic module may be configured to transform the reflected wave into an electrical signal to provide the sensor data. The sensor arrangement may comprise an acoustic module. The acoustic module may comprise one or more transducers. The acoustic module may be configured to transmit an acoustic wave to the tubular. The acoustic module may be configured to receive a portion of the acoustic wave reflected by the tubular. The acoustic module may be configured to transform the reflected wave into an electrical signal to provide the sensor data. The sensor arrangement may comprise a camera module. In some examples, the sensor arrangement may comprise a number of different sensor modules provided in a single unit. The system may comprise a cleaning mechanism. The cleaning mechanism may be configured to clean a portion of the tubular, e.g. as the inspection apparatus moves along the tubular. The cleaning mechanism may be mounted to the inspection apparatus. The cleaning mechanism may be mounted to the inspection apparatus in a leading position. The cleaning mechanism may be positioned in front of the sensor arrangement (relative to a direction of travel of the inspection apparatus). This may allow the sensor arrangement to move over and obtain sensor data from a portion of the tubular that has been cleaned. The cleaning mechanism may comprise a source of pressurised cleaning fluid (e.g., water). In some examples, the cleaning fluid may be provided at a pressure of around 1,000 bar. The cleaning mechanism may be configured to spray the cleaning fluid onto the tubular. In some examples, the cleaning mechanism may be configured to deliver cleaning fluid at a flowrate of 70-100 litres per minute. The cleaning mechanism may comprise a spray bar. The cleaning mechanism may comprise one or more nozzles. The cleaning mechanism may comprise a manipulator. The manipulator may be configured to move the cleaning mechanism (e.g., the one or more nozzles) into a particular orientation and position. The one or more nozzles may be arranged at an angle relative to the inspection apparatus (e.g., relative to a base of the inspection 5 apparatus). In some specific examples, the one or more nozzles may be arranged at an angle of approximately 30 degrees from parallel to the base of the inspection apparatus (so that the cleaning fluid is sprayed in a direction away from the inspection apparatus). This may increase the cleaning effectiveness, especially for marine growth and corrosion. 10 In other examples, however, the cleaning mechanism may comprise a scraper. The scraper may be configured to scrape dirt or debris off the tubular, e.g. as the inspection apparatus moves along the tubular. 15 The system may comprise a position sensor. The position sensor may be configured to monitor a position of the inspection apparatus. The position sensor may be configured to monitor a position of the inspection apparatus relative to the support hanger. 20 The position sensor may be mounted to the inspection apparatus. The position sensor may be mounted to the support hanger. The position sensor may be mounted to the actuator (e.g. the hoist arrangement). The position sensor may comprise an encoder, odometer, etc. The position sensor may comprise a transmitter and receiver, wherein the transmitter is mounted to the inspection apparatus and the receiver mounted to 25 support hanger, or vice versa. The position sensor may comprise an accelerometer, e.g. mounted to the inspection apparatus. In some examples, the position sensor may be configured to monitor a change in length of the connecting member (e.g., to determine a distance between the inspection apparatus and the support hanger). 30 The inspection apparatus may comprise a shape configured to conform to a circumference or arc of the tubular. The inspection apparatus may comprise a base configured to conform to a circumference or arc of the tubular. The inspection apparatus may comprise an adjustable frame. The adjustable frame may be configured to adjust a position and / or orientation of the sensor arrangement relative to the tubular. This may allow for the sensor arrangement to be moved into a particular orientation and position, as required, during the process of inspecting the tubular. The one or more wheels may be mounted to the inspection apparatus. The one or more wheels may be mounted to the inspection apparatus via one or more wheel mounts. The adjustable frame may be configured to adjust a position of the wheel mounts to modify a ride height of the inspection apparatus (i.e., a clearance between the base of the inspection apparatus and the tubular). The adjustable frame may be adjustable by one or more actuators and / or may be adjustable manually (e.g., via one or more screws and threaded holes). The wheel mounts may be adjustable to move the inspection apparatus radially towards or away from the tubular in real time, e.g., to optimise the sensor data obtained. The one or more wheels may be connected to the inspection apparatus via a wheel axle. A position of the wheel axle may be adjustable relative to the inspection apparatus. The one or more wheels may be detachable from the inspection apparatus. This may allow wheels of different sizes and / or taper angles to be mounted to the inspection apparatus, allowing the inspection apparatus to be used with tubulars of different diameter. The system may comprise a controller. The controller may be configured to control operation of the inspection apparatus. The controller may be located at a remote location. The controller may comprise a computer. The inspection apparatus may comprise a control module configured to communicate with the controller. The control module may be configured to receive sensor data from the sensor arrangement. The control module may be configured to transmit the sensor data to the controller. The controller may be configured to process the sensor data and provide one or more outputs, e.g. to an operator. The one or more outputs may represent one or more parameters of the sensor data. The one or more outputs may include defects in the tubular, the extent of the defects (such as, size, range, depth, etc.). The one or more outputs may be provided in graphical form. The control module may be configured to receive position data from the position sensor. The control module may be configured to transmit the position data to the controller. The controller may be configured to process the position data and provide one or more outputs, e.g. to an operator. The controller may be configured to correlate the sensor data and the position data. Alternatively, the control module may be configured to correlate the sensor data and the position data before transmitting the data to the controller. At least one of the controller and control module may be configured to control operation of at least one the sensor arrangement, the holding mechanism, the actuator, the one or more wheels, the cleaning mechanism and the adjustable frame. The connecting member may be connected to a first load coupling (e.g., a lug) of the inspection apparatus. The connecting member may be connected to a second load coupling (e.g., a lug) of the support hanger. The connecting member may comprise one or more of umbilical cords, ropes and lines. The connecting member may comprise any length. In some specific examples, the connecting member may comprise a length of approximately 80 m. The inspection apparatus may comprise one or more electrical couplings. The control module of the inspection apparatus may be connected to the controller via the one or more electrical couplings. Alternatively or additionally, the control module may communicate with the controller wirelessly, e.g. via radio transmission, etc. The support hanger may be configured to extend around a circumference of the tubular. The support hanger may be generally circular. The support hanger may comprise a ring. The one or more securing members of the support hanger may be for releasably securing the support hanger to the tubular. The securing members may comprise one or more arms. The one or more arms may be configured to extend inwardly to engage the tubular. The securing members may comprise one or more slips. The securing members may comprise one or more chain blocks. The securing members may comprise one or more caisson guides. The securing members may comprise one or more slings (e.g., extending from a fixed point on the tubular). The support hanger may be defined as a halo ring. The inspection apparatus described hereinabove may define a first inspection apparatus. The system may comprise a second inspection apparatus. The second inspection 5 apparatus may be suspended from the support hanger. A second connecting member may connect the second inspection apparatus to the support hanger. The second inspection apparatus may be suspended from the support hanger at a different location on the support hanger than the first inspection apparatus. This may allow sensor data to be obtained from different perspectives around the tubular. 10 The second inspection apparatus may be similar or identical to the first inspection apparatus. The second inspection apparatus may comprise one or more of the features described hereinabove in relation to the first inspection apparatus. 15 CO The first and second inspection apparatus may be configured to move exclusively linearly and parallel to the longitudinal axis of the tubular. 20 In some examples, the system may comprise three or more inspection apparatus. The three or more inspection apparatus may be suspended from the support hanger at different locations (e.g., around the circumference of the support hanger) to obtain sensor data from different perspectives around the tubular. Another aspect of the present disclosure relates to a method for inspecting a tubular, the method may comprising: 25 securing a support hanger to the tubular, wherein the support hanger comprises one or more securing members for securing the support hanger to the tubular and centralising the support hanger on the tubular; suspending an inspection apparatus from the support hanger via a connecting member; 30 holding the inspection apparatus to the tubular using a holding mechanism of the inspection apparatus; moving the inspection apparatus relative to the support hanger; and obtaining sensor data associated with the tubular using a sensor arrangement of the inspection apparatus. The method may comprise holding the inspection apparatus to the tubular with a magnetic force. The method may comprise monitoring a position of the inspection apparatus. The method may comprise performing non-destructive testing (NDT) of the tubular. The method may comprise transmitting an ultrasonic wave to the tubular and receiving a portion of the ultrasonic wave reflected by the tubular to obtain the sensor data. The method may comprise transmitting an electromagnetic wave to the tubular receiving a portion of the electromagnetic wave reflected by the tubular to obtain the sensor data. The method may comprise transmitting an acoustic wave to the tubular receiving a portion of the acoustic wave reflected by the tubular to obtain the sensor data. The method may comprise cleaning a portion of the tubular. The method may comprise manipulating a cleaning mechanism of the inspection apparatus into a particular orientation to allow cleaning fluid to be directed onto a particular region of the tubular. The method may comprise adjusting a frame of the inspection apparatus to adjust a position and / or orientation of the sensor arrangement relative to the tubular. The method may comprise extending inwardly one or more arms of the support hanger to engage the tubular and secure the support hanger to the tubular. The method may comprise actuating movement of the inspection apparatus relative to the support hanger, e.g., using a hoist arrangement. The method may comprise suspending a second inspection apparatus from the support hanger. The method may comprise suspending three or more inspection apparatus from the support hanger. An aspect of the present disclosure relates to a system for inspecting a caisson, the system comprising: a support hanger configured to be secured to the caisson; an inspection apparatus suspended from the support hanger; a connecting member connecting the inspection apparatus to the support hanger, the connecting member configured to permit movement of the inspection apparatus relative to the support hanger, wherein the inspection apparatus comprises: a sensor arrangement configured to obtain sensor data associated with the caisson; and a holding mechanism comprising one or more magnets configured to hold the inspection apparatus to the caisson. An aspect of the present disclosure relates to an inspection apparatus, the inspection apparatus comprising: a sensor arrangement configured to obtain sensor data associated with a tubular; a holding mechanism configured to hold the inspection apparatus to the tubular; and a load coupling for connecting to a connecting member of a support hanger, the support hanger secured to the tubular. Another aspect of the present disclosure relates to a method for inspecting a tubular, the method comprising: connecting an inspection apparatus to a connecting member of a support hanger via a load coupling of the inspection apparatus, the support hanger secured to the tubular; holding the inspection apparatus to the tubular using a holding mechanism of the inspection apparatus; moving the inspection apparatus relative to the support hanger; and obtaining sensor data associated with the tubular using a sensor arrangement of the inspection apparatus. It will be appreciated that features described in relation to one aspect may be equally combined with any other aspect described herein. BRIEF DESRIPTION OF THE DRAWINGS These and other aspects of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which: Figures 1 and 2 illustrate a system for inspecting a tubular; Figure 3 to 5 illustrate an inspection apparatus of the system; and Figures 6 and 7 illustrate the system comprising a second inspection apparatus. DETAILED DESCRIPTION Aspects of the present disclosure relate to systems and methods for inspecting a tubular 11. While multiple applications may be possible, for the purposes of providing an exemplary application, the following description relates to inspection of an oil-and-gas tubular 11, e.g., such as a caisson, riser, j-tube, jacket leg, etc., with the tubular 11 vertically oriented. Figures 1 and 2 illustrate a system 10 for inspecting a tubular 11. The system 10 includes a support hanger 14 secured to the tubular 11 and an inspection apparatus 12 suspended from the support hanger 14. A connecting member 16 connects the inspection apparatus 12 to the support hanger 14 and permits movement of the inspection apparatus 12 relative to the support hanger 14. The inspection apparatus 12 is illustrated in a first location in Figure 1 and a second location in Figure 2, in which the inspection apparatus 12 has moved a distance along the tubular 11. The inspection apparatus 12 includes a sensor arrangement 18 configured to obtain sensor data associated with the tubular 11. The inspection apparatus 12 further includes a holding mechanism 20 configured to hold the inspection apparatus 12 to the tubular 11. The support hanger 14 may be secured to the tubular 11 to provide a fixed reference point. The inspection apparatus 12 may move relative to the support hanger 14 along the tubular 11 to allow sensor data to be obtained at different points on the tubular 11. Furthermore, the holding mechanism 20 may hold the inspection apparatus 12 to the tubular 11 preventing any external forces that act on inspection apparatus 12 (e.g. waves, air currents, etc.) from forcing the inspection apparatus 12 to separate from the tubular 11 and disrupt the inspection process. In this example, the tubular 11 is located in a splash zone of an offshore drilling site just above sea level 22 (although, in other examples, the tubular 11 may be located at other locations, such as a topside or subsea location). The inspection apparatus 12 is configured to move along the tubular 11 parallel to a longitudinal axis of the tubular 11, and may move beyond the second position illustrated in Figure 2 entering a subsea environment. In some applications, the inspection apparatus 12 may be configured (e.g., equipped with appropriate seals, etc.) to withstand elevated, subsea pressures, and may be deployed to depths of 150 m below sea level 22. In some examples, the inspection apparatus 12 may be configured to be lightweight (e.g., 70 kg or less). In other examples, however, the inspection apparatus 12 may be provided with one or more weights to counter buoyancy forces acting on the inspection apparatus 12. The system 10 may include an actuator 26 configured to move the inspection apparatus 12 relative to the support hanger 14. In this example, the actuator 26 includes a hoist arrangement (e.g., a pneumatic or air hoist) configured to lift and lower the inspection apparatus 12 using one or more pulleys, thus modify a length of the connecting member 16. Here, the tubular 11 is arranged vertically such that the inspection apparatus 12 is vertically suspended from the support hanger 14. However, in other examples, the tubular 11 may be arranged at an angle from vertical such that the inspection apparatus 12 is suspended from the support hanger 14 at an angle from vertical. In either case, however, the orientation of the tubular 11 is such that downward movement of the inspection apparatus 12 may be effected by gravity. The inspection apparatus 12 may include a number of wheels 24 to permit the inspection apparatus 12 to move along the tubular 11. The support hanger 14 may be generally circular and extends around a circumference of the tubular 11. The support hanger 14 may include one or more securing members for securing the support hanger 14 to the tubular 11 and centralising the support hanger 14 on the tubular 11. In this example, the securing members comprise chain blocks 32, slings 34 and a caisson guide 36, where the slings 34 are suspended from a fixed point 37 on the tubular 11. In other examples, the securing members may comprise inwardly extending arms and / or slips. The system 10 may include a cleaning mechanism 28 comprising a spray bar configured to clean a portion of the tubular 11 by spraying pressurised cleaning fluid (e.g., water) onto the tubular 11 as the inspection apparatus 12 moves along the tubular 11. The cleaning fluid may be provided at a pressure of around 1,000 bar and sprayed onto the tubular 11 at a flowrate of 70-100 litres per minute. The cleaning mechanism 28 is mounted to a leading end of the inspection apparatus 12 (in front of the sensor arrangement 18) so that the sensor arrangement 18 moves over and obtains sensor data from a cleaned portion of the tubular 11. The cleaning mechanism 28 includes one or more nozzles 30 arranged at an angle a relative to a base 31 of the inspection apparatus 12, e.g. approximately 30 degrees from parallel to the base 31, as illustrated in Figures 4 and 5. This may increase the cleaning effectiveness, especially for marine growth and corrosion. The cleaning mechanism 28 may comprise a manipulator configured to move the cleaning mechanism 28 (e.g., the nozzles 30) into a particular orientation and position. Figure 2 to 5 illustrate the inspection apparatus 12 in more detail. In this example, the holding mechanism 20 includes two magnets 38 at either side of the inspection apparatus 12 configured to provide a magnetic force to hold the inspection apparatus 12 to the tubular 11 (although the holding mechanism 20 may comprise other numbers of magnets). In other examples, however, the holding mechanism 20 may take other forms. For instance, the holding mechanism 20 may comprise one or more adhesives, e.g., located on an outer surface of the wheels 24. Alternatively or additionally, the holding mechanism 20 may comprise one or more straps for strapping the inspection apparatus 12 to the tubular 11. In further examples, the holding mechanism 20 may comprise a guide rail attached to the tubular 11. The sensor arrangement 18 may include one or more sensors. In this example, the sensor arrangement 18 includes an ultrasonic module 40 configured to transmit an ultrasonic wave to the tubular 11 and receive a portion of the ultrasonic wave reflected by the tubular 11, e.g., at a discontinuity, such as a crack, defect, etc. The ultrasonic module 40 may comprise a couplant to facilitate the transmission of ultrasonic waves to and from the tubular 11. The ultrasonic module 40 may comprise a couplant inlet for receiving couplant from a supply source. The couplant may comprise water, gel or other suitable couplant material. In other examples, the ultrasonic module 40 may comprise an electromagnetic acoustic transducer (EMAT), which may enable noncontact wave transmission and reception. In such examples, the ultrasonic module 40 may not comprise a couplant, but may instead comprise one or more electromagnets 38 to facilitate the transmission of ultrasonic waves to and from the tubular 11. In addition, the sensor arrangement 18 includes an electromagnetic module 42 (e.g. a pulsed eddy current (PEC) module) configured to transmit an electromagnetic wave to the tubular and receive a portion of the electromagnetic wave reflected by the tubular. The sensor arrangement 18 further includes a camera module 44. In other examples, however, the sensor arrangement 18 may comprise only one or two of the ultrasonic module 40, electromagnetic module 42 and camera module 44. A position sensor 46 may be mounted to the inspection apparatus 12 and include an encoder configured to monitor a position of the inspection apparatus 12. In other examples, however, the position sensor 46 may be mounted to the support hanger 14 or actuator 26, including one or more of an encoder, transmitter and receiver, accelerometer, odometer, etc. The inspection apparatus 12 (in particular, the base 31 of the inspection apparatus 12) is configured to conform to an arc shape of the tubular 11. The wheels 24 are mounted to the inspection apparatus 12 via wheel mounts. The inspection apparatus 12 may include an adjustable frame configured to adjust a position of the wheel mounts to modify a ride height of the inspection apparatus 12 (i.e., a clearance between a base of the inspection apparatus 12 and the tubular 11). The position of the wheel mounts may be adjustable by one or more actuators and / or may be adjustable manually (e.g., via one or more screws and threaded holes). This may allow for the sensor arrangement 18 to be moved into a desired position and / or orientation, as required, during the process of inspecting the tubular 11. The wheels 24 may be detachable from the inspection apparatus 12 to allow wheels of different sizes and / or taper angles to be mounted to the inspection apparatus 12, allowing the inspection apparatus 12 to be used with tubulars of different diameter. The system 10 may include a controller 52 configured to control operation of the inspection apparatus 12 by communicating with a control module 50 of the inspection apparatus 12. The control module 50 is configured to receive sensor data from the sensor arrangement 18 (including the ultrasonic module 50, electromagnetic module 42 and camera module 44) and position data from the position sensor 46, and then transmit this data to the controller 52. The controller 52 is configured to process the data to provide one or more outputs, e.g. to an operator. The one or more outputs may represent one or more parameters of the data, which may indicate defects of the tubular 11. The controller 52 may also be in communicate with the actuator 26 to control movement of the inspection apparatus 12. The inspection apparatus 12 may include a load coupling 56 for connecting to the connecting member 16, and an electrical coupling 58 for connecting the control module 50 to the controller 52. In other examples, however, the control module 50 and the controller 52 may communicate wirelessly, e.g. via radio transmission, etc. The connecting member 16 may comprise a rope having a length of approximately 80 m. In other examples, however, the connecting member 16 may take other forms and may be of any length. Figures 6 and 7 illustrate the system 10 comprising a second inspection apparatus 60 suspended from the support hanger 14 at a different location, allowing sensor data to be obtained from different perspectives around the tubular 11. The second inspection apparatus 60 may be similar or identical to the first inspection apparatus 12, and may comprise one or more of the features described hereinabove in relation to the first inspection apparatus 12. In some examples, the system 10 may comprise three or more inspection apparatus 12, each suspended from the support hanger 14 at a different location.

Claims

1. A system for inspecting a tubular, the system comprising:a support hanger configured to be secured to the tubular, wherein the support 5 hanger comprises one or more securing members for securing the support hanger to the tubular and centralising the support hanger on the tubular;an inspection apparatus suspended from the support hanger via a connecting member, the connecting member configured to permit movement of the inspection apparatus relative to the support hanger, wherein the inspection apparatus comprises:10 a sensor arrangement configured to obtain sensor data associated with thetubular; anda holding mechanism configured to hold the inspection apparatus to the tubular.

2. The inspection apparatus of claim 1, wherein the holding mechanism comprises CO 15 one or more magnets.CM3. The inspection apparatus of claim 1 or 2, comprising an actuator configured to move the inspection apparatus relative to the support hanger.20 4. The inspection apparatus of claim 3, wherein the actuator comprises a hoistarrangement.

5. The inspection apparatus of any preceding claim, wherein the sensor arrangement comprises an ultrasonic module configured to transmit an ultrasonic wave 25 to the tubular and receive a portion of the ultrasonic wave reflected by the tubular.

6. The inspection apparatus of any preceding claim, wherein the sensor arrangement comprises a pulsed eddy current (PEC) module configured to transmit an electromagnetic wave to the tubular and receive a portion of the electromagnetic wave 30 reflected by the tubular.

7. The inspection apparatus of any preceding claim, wherein the sensor arrangement comprises a number of different sensor modules provided in a single unit.

8. The inspection apparatus of any preceding claim, comprising a cleaning mechanism configured to clean a portion of the tubular.

9. The inspection apparatus of claim 8, wherein the cleaning mechanism comprises a spray bar.

10. The inspection apparatus of claim 8 or 9, wherein the cleaning mechanism comprises one or more nozzles mounted to the inspection apparatus at an angle of approximately 30 degrees from parallel to a base of the inspection apparatus.

11. The inspection apparatus of any preceding claim, comprising a position sensor configured to monitor a position of the inspection apparatus.

12. The inspection apparatus of claim 11, wherein the position sensor is mounted to the inspection apparatus.

13. The inspection apparatus of claim 11 or 12, wherein the position sensor comprises an encoder.

14. The inspection apparatus of any preceding claim, wherein the inspection apparatus comprises one or more wheels configured to permit the inspection apparatus to move along to the tubular.

15. The inspection apparatus of claim 14, wherein the wheels are mounted to the inspection apparatus via one or more wheel mounts, and wherein the inspection apparatus comprises an adjustable frame configured to adjust a position of the one or more wheels mounts.

16. The inspection apparatus of any preceding claim, comprising a controller configured to control operation of the inspection apparatus.

17. The inspection apparatus of claim 16, wherein the inspection apparatus comprises a control module configured to receive sensor data from the sensor arrangement and transmit the sensor data to the controller.

18. The inspection apparatus of claim 16 or 17, when dependent on any one of claims 6 to 8, wherein the control module is configured receive position data from the position sensor and transmit the position data to the controller.5 19. The inspection apparatus of claim 18, wherein the controller is configured tocorrelate the sensor data and the position data and provide one or more outputs.

20. The inspection apparatus of any preceding claim, wherein the inspection apparatus defines a first inspection apparatus, and wherein the system comprises a 10 second inspection apparatus.152521. The inspection apparatus of claim 20, wherein the second inspection apparatus is suspended from the support hanger at a different location on the support hanger than the first inspection apparatus.

22. A method for inspecting a tubular, the method may comprising:securing a support hanger to the tubular, wherein the support hanger comprises one or more securing members for securing the support hanger to the tubular and centralising the support hanger on the tubular;suspending an inspection apparatus from the support hanger via a connecting member;holding the inspection apparatus to the tubular using a holding mechanism of the inspection apparatus;moving the inspection apparatus relative to the support hanger; andobtaining sensor data associated with the tubular using a sensor arrangement of the inspection apparatus.

23. The method of claim 22, comprising holding the inspection apparatus to the tubular with a magnetic force.

24. The method of claim 22, comprising transmitting at least one of an ultrasonic wave and an electromagnetic wave to the tubular and receiving a portion of the at least one of an ultrasonic wave and an electromagnetic wave reflected by the tubular to obtain the sensor data.

Citation Information

Patent Citations

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