Untethered Inspection Pig With Compressible Sensor Connectors
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Solution Overview
Problem
Conventional methods for inspecting tubular objects, such as pipelines, are limited by the need for manual intervention, costly downtime, and inability to effectively monitor closely packed tubes or subsea systems, often requiring unnecessary replacements and posing safety risks.
Innovation Solution
An untethered, single-bodied pig with a configuration of transducer casings, compressible electrical connectors, and a cylindrical body design that allows for efficient detection of tubular object conditions, including wall thickness and material build-up, while maintaining reliable electrical connections and compact size for navigating narrow pathways.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional inspection methods (manual NDT, radiography, thermal imaging) are used, then inspection coverage is limited and requires downtime or scaffolding, but the patent achieves comprehensive inspection without downtime or scaffolding using an untethered pig
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated untethered pig system that uses electronic sensors (ultrasonic, electromagnetic, optical) to detect tube conditions. This substitution eliminates the need for manual intervention, scaffolding, and system shutdown, allowing continuous operation while achieving comprehensive inspection coverage
Solution Approach 2:
The untethered pig is designed to autonomously navigate through the tube bundle, self-propel using wheels or tracks, and automatically collect inspection data without external control or support. The pig contains its own power supply, sensor array, and data storage, enabling it to perform the complete inspection task independently while the system remains operational
2Measurement precision
If manual NDT inspection is performed, then detailed wall thickness measurement is possible, but it requires 6-7 days and abrasive cleaning of outer walls
Solution Approach 1:
The patent replaces manual ultrasonic testing with automated ultrasonic sensors mounted on the untethered pig. These sensors continuously measure wall thickness as the pig moves through the tube bundle, providing equivalent measurement precision without requiring manual operation, abrasive cleaning, or extended inspection time
Solution Approach 2:
The inspection process is transformed from discrete manual measurements to continuous automated measurement as the pig traverses the tube bundle. The ultrasonic sensors continuously scan tube walls, providing uninterrupted data collection that maintains measurement precision while reducing inspection time from 6-7 days to a single operational cycle
3Difficulty of detecting and measuring
If thermal imaging is used to inspect tubes, then hotspots can be detected, but it cannot inspect closely packed tubes in convection heating sections
Solution Approach 1:
The patent divides the inspection function into multiple specialized sensors (ultrasonic, electromagnetic, optical) mounted on the pig, each capable of operating in the confined spaces between closely packed tubes. This segmentation allows the system to overcome the limitations of single-method thermal imaging and adapt to various tube configurations including convection heating sections
Solution Approach 2:
The untethered pig is designed as a multi-functional inspection platform that combines multiple detection methods (ultrasonic for wall thickness, electromagnetic for material degradation, optical for surface inspection). This universal system can inspect all tube types and configurations, including closely packed convection tubes where thermal imaging fails, while maintaining hotspot detection capability
4Volume of moving object
If the pig size is reduced to navigate narrow pathways, then accessibility to narrow tubes is improved, but electrical connection reliability may be compromised
Solution Approach 1:
The patent nests the electrical connectors, power supply, and electronics within the pig's compact structure. The connectors are integrated into the sensor housings and data storage units, allowing reliable electrical connections to be maintained within the constrained volume of a small pig designed to navigate narrow tube pathways
Solution Approach 2:
The patent combines multiple functions (sensing, power supply, data storage, electrical connection) into integrated modules mounted on the pig. This merging reduces the overall pig size while maintaining connection reliability, as the electrical connectors are directly integrated with the sensor assemblies rather than being separate external components
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
Enables comprehensive and accurate inspection of tubular objects with reduced size and complexity, avoiding the need for miniaturization compromises that would sacrifice performance, and facilitating safer, more efficient operation of industrial tubing systems.
Implementation Method 1
a plurality of compressible electrical connectors, each compressible electrical connector at least partially arranged inside a respective one of the plurality of receptacles, wherein each compressible electrical connector is configured to be in electrical contact with the electrical terminal of the transducer casing received in the corresponding receptacle
Data Source
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AI summary
There is provided an untethered, single-bodied pig for inspecting a tubular object. The pig comprises: a plurality of transducer casings (3), each transducer casing (3) including an electrical terminal (13); a plurality of transducers for detecting a condition of the tubular object, each transducer mounted on or in a respective one of the plurality of transducer casings (3); a transducer body defining a plurality of receptacles (12), each transducer casing (3) removably received in a respective one of the plurality of receptacles (12); and a plurality of compressible electrical connectors (14), each compressible electrical connector (14) at least partially arranged inside a respective one of the plurality of receptables (12), wherein each compressible electrical connector (14) is configured to be in electrical contact with the electrical terminal (13) of the transducer casing (3) received in the corresponding receptacle (12).