Deformable Pipeline Gauging Tool for Dent and Bend Detection
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Solution Overview
Problem
Pipeline inspection tools often get stuck in pipelines due to dents and imperfections, leading to significant operational disruptions and potential damage, as existing tools lack the ability to accurately identify multiple issues before more sophisticated equipment is deployed, resulting in safety concerns and revenue losses.
Innovation Solution
A pipeline gauging tool with a foam pig equipped with magnetic, acoustic, laser, or fiber optic capabilities that can detect changes in pipeline geometry, allowing operators to safely navigate through pressurized lines and identify potential obstructions, ensuring the safe passage of more expensive inspection tools by deforming and resetting to avoid getting stuck.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sophisticated inspection tool is deployed to detect pipeline geometry changes, then measurement precision and detection capability are improved, but the risk of tool entrapment and operational disruption increases
Solution Approach 1:
A deformable body is launched ahead of the sophisticated inspection tool to preliminarily detect and characterize pipeline geometry changes such as dents and bends. This preliminary action identifies potential entrapment zones before the expensive inspection tool encounters them, allowing operators to take preventive measures or adjust tool deployment strategies.
Solution Approach 2:
The deformable body serves as a low-cost, expendable probe that can be sacrificed if necessary. Since it is inexpensive compared to sophisticated inspection tools, multiple deformable bodies can be launched to clear pipeline issues, ensuring that the expensive inspection tool passes safely without risk of entrapment.
2Strength
If a rigid inspection tool is used to maintain structural integrity, then strength and durability are improved, but the ability to navigate dents and bends without getting stuck deteriorates
Solution Approach 1:
The inspection tool incorporates a deformable body made of flexible material that can elastically deform to navigate pipeline geometry changes such as dents, bends, and egg-shaped sections. This flexibility allows the tool to conform to irregular pipeline shapes and pass through obstructions that would trap rigid tools, while maintaining sufficient structural integrity to perform measurements.
Solution Approach 2:
The deformable body transitions between different structural states - rigid enough to maintain shape for accurate measurements during normal operation, but flexible enough to deform elastically when encountering pipeline irregularities. This dynamic adaptability allows the tool to navigate challenging pipeline conditions without permanent deformation or entrapment.
3Difficulty of detecting and measuring
If aluminum gauge plates are used to detect dents, then the ability to identify single impacts is improved, but the capability to identify multiple impacts and provide precise measurements deteriorates
Solution Approach 1:
The patent replaces the simple mechanical aluminum gauge plate with a deformable body incorporating electronic sensors (such as capacitive, inductive, or optical sensors) that can precisely measure geometry changes. This substitution enables continuous, quantitative measurement of multiple pipeline irregularities with high precision, rather than仅提供 binary bent/not-bent information from gauge plates.
Solution Approach 2:
The deformable body with integrated sensors serves multiple functions: it detects various types of pipeline geometry changes (dents, bends, egg-shape, out-of-roundness), provides precise quantitative measurements, locates defects along the pipeline, and can navigate through these defects without damage. This multi-functional capability replaces the limited single-purpose aluminum gauge plate.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The tool effectively identifies and measures pipeline geometry changes, including dents and bends, reducing the risk of tool entrapment and ensuring the safety of both the equipment and the surrounding population by allowing for informed decision-making on tool deployment and operation, while minimizing costly interruptions.
Implementation Method 1
the deformable portion compressible between a first size and a second smaller size; the signal source configured to have a first strength when the deformable portion is in the first size and a second different strength when the deformable portion is in the second smaller size
Implementation Method 2
the sensor configured to detect the first strength and the second different strength
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A pipeline inspection tool (10) including a cylindrical tool body (11) that includes a deformable portion (13) with a plurality of sensors (25) located near or on an external circumferential surface (12) of the deformable portion. A sealed unit (60) contains a corresponding signal source (25). Pipeline gauging relies upon the compressibility and elasticity inherent in the deformable portion as it encounters anomalies in pipeline geometry and moves between a first size and a second size, the signal strength of the source detected by the sensors changing as a result. The sensors may be arrayed in a circumferential band (47) about the deformable portion or along its length. In some embodiments, the sensors and source are magnetic or acoustic (e.g., transceivers or radar integrated chips). In other embodiments, the sensors and source are light or fiber optic.