Tubular Pig Propulsion Control with Recorded Operator Runs
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Solution Overview
Problem
Conventional methods for inspecting and maintaining tubular objects like pipes and pipelines are inefficient and risky, often requiring manual intervention, which can lead to costly downtime and safety hazards, especially in complex or inaccessible systems.
Innovation Solution
An apparatus with a propulsion device and a controller that records and replicates a human-controlled reference run of a pig through a tubular object, enabling automated control and improved efficiency by adapting to variable conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection methods are used, then flexibility and adaptability to variable conditions are maintained, but productivity is reduced and human error increases
Solution Approach 1:
The system records a reference run performed by an operator and creates a digital copy of the operating steps and parameters. This recorded sequence is then automatically executed during subsequent inspection runs, eliminating the need for manual operation while preserving the expertise of the original operator. The copying principle resolves the contradiction by transferring human skill to an automated system.
Solution Approach 2:
The inspection system performs self-service by automatically executing the recorded reference run without requiring continuous human intervention. The controller autonomously controls the propulsion device based on the stored operating sequence, enabling the system to service itself and eliminating productivity losses associated with manual operation and human error.
2Productivity
If automated control is implemented, then productivity and consistency are improved, but adaptability to unexpected conditions deteriorates
Solution Approach 1:
The system incorporates feedback mechanisms through detection devices that monitor the actual run conditions. When deviations from the reference run are detected, the system can adjust the automated control sequence accordingly. This feedback loop enables the automated system to adapt to variable conditions while maintaining high productivity and consistency.
3Reliability
If manual operation is used, then adaptability to conditions is maintained, but reliability decreases due to human error
Solution Approach 1:
By copying the operator's expert performance into a recorded reference run, the system captures the nuanced decision-making and adaptive responses that would otherwise require complex real-time control algorithms. This copying approach achieves high reliability by reproducing proven operational patterns consistently, without requiring the control system to replicate human cognitive processes.
4Measurement precision
If inspection frequency is increased, then detection precision is improved, but loss of time and productivity decrease
Solution Approach 1:
The automated system enables continuous or near-continuous inspection operations by eliminating the downtime associated with manual setup, operation, and transition between inspection cycles. The recorded reference run can be executed repeatedly without interruption, maintaining continuous useful action while achieving high detection precision through consistent, repeatable measurement conditions.
Data Source
AI summary
There is provided an apparatus for controlling a run of a pig (20) through a tubular object (22), the apparatus comprising:a propulsion device (32) for propelling the pig (20) inside the tubular object (22);a recording device (30) configured to, in real-time, record operating steps and operating parameters of a human-controlled reference run of the pig (20) through the tubular object (22); anda controller (30) programmed to selectively carry out an automatic control mode in which the controller (30) automatically controls a subsequent run of the pig (20) through the tubular object (22) in accordance with the recorded operating steps and operating parameters of the reference run, wherein the automatic control mode includes control of the propulsion device (32) to propel the pig (20) through the tubular object (22).