Automated X-Ray Pipe Scanning for Corrosion Under Insulation
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Solution Overview
Problem
Current methods for inspecting insulated pipes, such as those used in the oil and gas industry, are time-consuming and inefficient, particularly in identifying corrosion under insulation, as they require manual operation and struggle with pipes over 10 inches in diameter.
Innovation Solution
A scanning system comprising a translating structure that moves axially and rotationally along the pipe, equipped with an x-ray scanner and a controller, allowing for automated inspection without the need for external guides or supports, and performs both axial and rotational scans to detect inconsistencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual x-ray inspection methods are used on insulated pipes, then the inspection can be performed externally without removing insulation, but the inspection process becomes extremely time-consuming and inefficient for pipes extending hundreds of miles
Solution Approach 1:
The patent replaces manual mechanical inspection operations with an automated scanning system that uses x-ray radiation to inspect pipes externally. The system includes a radiation source, detector, and positioning system that automatically moves along the pipe, eliminating the need for manual operation while maintaining external inspection capability without removing insulation.
Solution Approach 2:
The inspection system is designed to operate autonomously along the pipe length using its own positioning and scanning mechanisms. The system self-propels and performs inspections without requiring external support structures or manual intervention, enabling continuous automated inspection of hundreds of miles of pipe.
2Measurement precision
If profile radiography technique is used to inspect insulated pipes, then wall thickness can be calculated using a comparator block, but the technique becomes challenging and ineffective for pipes over 10 inches in diameter
Solution Approach 1:
The patent transitions from the traditional profile radiography method that measures in a single cross-sectional dimension to a three-dimensional scanning approach. The system moves the radiation source and detector along the pipe length while maintaining circumferential positioning, enabling inspection of large diameter pipes by scanning multiple cross-sections and reconstructing the full three-dimensional pipe geometry and wall thickness variations.
3Reliability
If insulation is removed for inspection to check surface condition and identify corrosion, then corrosion under insulation can be detected, but the process incurs additional cost and time loss for removal and replacement
Solution Approach 1:
The patent uses x-ray radiation as an intermediary to penetrate the insulation material and directly image the pipe surface and corrosion conditions underneath. The radiation passes through the insulation without removing it, allowing corrosion detection while the insulation remains in place, thus eliminating the time and cost of insulation removal and replacement.
4Ease of operation
If hand-operated x-ray scanning is performed by moving the source along the pipe, then inspection can be conducted, but the process is tedious and inefficient for hundreds of miles of pipe
Solution Approach 1:
The patent replaces hand-operated mechanical scanning with an automated positioning system that mechanically moves the radiation source and detector along the pipe at controlled speeds. The system includes motors, gears, and control mechanisms that automatically traverse the pipe length, enabling continuous high-speed inspection of hundreds of miles of pipe without manual intervention.
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 efficient, automated scanning of insulated pipes, reducing inspection time and cost by eliminating the need for manual operation and external supports, while providing high-resolution imaging of pipe conditions.
Implementation Method 1
x-rays are directed through the pipe from a source on one side of the pipe and detected by a detector on the opposite side of the pipe to generate an image
Data Source
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AI summary
A method and system for scanning an elongate structure. A scanner in a scanning system is moved axially along the elongate structure using a translating structure in the scanning system. The elongate member is scanned axially as the scanner moves axially along the elongate structure. The scanner is moved rotationally around the elongate structure at a location in which an inconsistency is detected at the location during an axial scan. The elongate structure is scanned rotationally at the location while the scanner moves rotationally around the elongate structure.