Ultrasonic Pipe Inspection Frame with Curved Array
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Solution Overview
Problem
Conventional ultrasonic inspection methods for pipes are time-consuming and inefficient, particularly in detecting localized corrosion, and often require frequent and costly periodic inspections, limiting their effectiveness in evaluating large sections of piping.
Innovation Solution
A system utilizing a flexible phased array probe and frame assemblies with a curved surface that cooperatively engages the pipe, allowing for rapid scanning with a flexible phased array probe housed in a frame assembly, which includes a fluid supply conduit, air removal conduit, encoder device, and magnetic elements for precise positioning, enabling quicker and more detailed evaluations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional ultrasonic inspection methods are used with a single sensor and grid layout, then inspection coverage can be achieved, but inspection time becomes excessively long (nearly three hours for a single 90° elbow)
Solution Approach 1:
The patent divides the inspection system into multiple independent ultrasonic sensors arranged in an array, where each sensor covers a specific sector of the pipe. This segmentation allows parallel inspection of multiple areas simultaneously, dramatically reducing total inspection time from hours to minutes while maintaining comprehensive coverage.
Solution Approach 2:
The patent transitions from a single-point inspection approach to a multi-point array approach, adding spatial dimensionality to the inspection system. By distributing sensors across multiple positions and angles, the system inspects the entire pipe circumference and length concurrently rather than sequentially, resolving the time-speed contradiction.
2Measurement precision
If conventional single sensor inspection is used, then equipment simplicity is maintained, but detection resolution for localized corrosion is insufficient
Solution Approach 1:
The inspection system is segmented into multiple sensors, each responsible for a specific detection zone. This segmentation enhances measurement precision by providing multiple viewing angles and positions, allowing detailed detection of localized corrosion while distributing the complexity across modular sensor units rather than requiring a single complex sensor.
Solution Approach 2:
The patent combines multiple simple sensor units into an array system that functions as a unified inspection platform. Each sensor remains relatively simple in design, but their combination provides high-resolution detection capabilities through data integration from multiple positions, resolving the contradiction between precision and complexity.
3Reliability
If frequent periodic inspections are performed using conventional methods, then pipeline safety is improved, but cost and time consumption increase significantly
Solution Approach 1:
By segmenting the inspection into multiple parallel sensor operations, the system achieves comprehensive pipeline assessment in a single pass rather than requiring multiple sequential inspections. This maintains high reliability through complete coverage while improving productivity by eliminating repeated inspection cycles.
Solution Approach 2:
The patent enables continuous inspection action by having multiple sensors operate simultaneously along the pipeline, providing uninterrupted and comprehensive monitoring. This continuous action ensures high reliability through complete coverage while maintaining high productivity by eliminating gaps and repetitions inherent in sequential single-sensor methods.
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 system enables faster and more detailed non-destructive evaluations of larger sections of piping, providing higher resolution and quicker results compared to conventional methods, while accommodating pipes of different diameters with interchangeable frame assemblies.
Implementation Method 1
periodic inspections are performed to find flaws and damage before they become cause for concern... ultrasonic sensor of circular shape... which covers an area of about 0,316 cm2
Implementation Method 2
Document JP 61159153 A discloses a probe holder for ultrasonic flaw detection comprising a gap formed of a seal material between the reverse surface of a holder and the peripheral surface of a pipe to be inspected. Water as a contact medium is continuously supplied and pooled in the gap
Data Source
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AI summary
An apparatus for performing ultrasonic evaluation of a portion of a pipe includes a frame assembly and a plurality of ultrasonic sensors disposed in the frame assembly. The frame assembly includes a frame which is structured to cooperatively engage an outer surface of the pipe. The frame has a curved surface which is curved about an axis which, when the frame is engaged with the pipe, generally coincides with the central longitudinal axis of the pipe. The curved surface is generally defined by a radius which is generally equal to an outer radius of the pipe. The plurality of ultrasonic sensors are disposed in the frame assembly a fixed distance from the curved surface.