Patent Publication Number: US-2020284390-A1

Title: Rotatable inspection module and method for inspecting the conditions of the wall of a pipeline

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of Ser. No. 62/814,638, filed Mar. 6, 2019 in the United States and is incorporated herein by reference. To the extent appropriate, a claim of priority is made to the above-disclosed application. 
    
    
     TECHNICAL FIELD 
     The present invention relates to pipeline inspection devices and methods of using same. 
     BACKGROUND 
     Pipeline inspection devices are used to inspect the condition of the walls of the pipeline. Some known pipeline inspection devices used to assess the condition of the underground pipeline require excavation of the ground to expose the exterior of the pipeline. 
     Some pipeline inspection devices can operate inside the pipeline. In these cases, some of these devices will require the full or partial removal of the liquid in the pipeline in order to operate. Furthermore, there are some known devices that require access to the full diameter of the pipeline and such devices are difficult to insert, retract, and may require removing a pipe section or using a pressurized container for inserting full diameter inspection tools into the pipeline such as for example, a pig launcher. 
     There is a need to provide pipeline inspection devices and methods of pipeline inspection which allow for the inspection of the entire interior surface of the pipeline during flow conditions and which allow for the deployment in those pipelines that have various bends and inline valves. 
     SUMMARY OF THE INVENTION 
     It is an embodiment of the present invention to provide a pipeline inspection device and methods of using same to inspect the condition of the pipeline. 
     According to one aspect, the pipeline inspection device is deployable into the pipeline and comprises one or more modules for collecting information about the condition of the pipeline, specifically, for collecting information about various defects in the wall of the pipeline. 
     According to one aspect, there is provided a module securable to the pipeline inspection device, the module including equipment configured to detect one or more defects in a pipeline. 
     In one aspect, the module is configured to orient one or more equipment into a desired orientation to improve aspects of the collected information. 
     In one aspect, the module is configured to rotate the equipment about a longitudinal axis and/or to move the equipment into the desired position. In one aspect, the module is configured to move the equipment from a collapsed position close to the body of the module to an expanded position away from the body of the module to improve aspects of the collected information. 
     In one aspect, the equipment is a sensor. In further aspects, the sensor is a transducer and the provision of the ability to rotate and/or extend the transducers away from the body of the module improves the resolution of the transducers. 
     In one embodiment, there is provided a rotatable pipeline inspection module to assess the condition of a pipeline wall when the module is deployed into a pipeline containing a liquid, the module comprising:
     at least one sensor, the sensor configured to collect information useful for assessing the condition of a pipeline wall as the sensor is moved within the pipeline; and   a body configured to mount the at least one sensor, wherein the modules is operatively securable to a cable for tethering the module to a location outside of the pipeline; and wherein the body is actuatable to rotate in relation to the module when the module is secured to the cable.   

     In one aspect, the module comprises a first and a second end opposed to the first end, wherein the body is located between and moveable in relation to the ends, and wherein the cable is secured to one of the first and second ends. The module further comprises an intermediate portion between the first and second ends, the intermediate portion defining a passage therein which connects the first end to the second end, and the body is configured to rotate around the intermediate portion. 
     In one aspect, the module further comprises a motor, wherein actuation of the motor rotates the body in relation to the first and second ends. The motor is secured within the body, the motor operatively coupled to a driven gear secured to one of the first end or the second end. 
     In one aspect, the body has an outer diameter, the at least one sensor is configured to be moveable between a collapsed position where the at least one sensor is close to the body to an extended position where the least one sensor is away from the body and extends towards the pipeline wall. The at least one sensor is biased in the extended position and wherein an application of a force will move the at least one sensor to the collapsed position. When the at least one sensor is in the extended position, the at least one sensor is supported in a position substantially perpendicular to the longitudinal axis of the device. 
     In one aspect, the at least one sensor is configured to pivotally move between the extended position and the collapsed position. 
     In one aspect, the module further comprises a sensor housing moveably connected to the body and configured to mount the at least one sensor. 
     In one aspect, the sensor pivots about an axis orthogonal to the longitudinal axis of the module. 
     In one aspect, the least one sensor is a transducer. The transducer is an ultrasonic transducer that is configured to direct ultrasonic signals towards pipeline wall. In one aspect, there are two transducers and the two transducers are directed in opposed directions. 
     In one embodiment, there is provided a pipeline inspection device comprising a rotatable pipeline inspection module and a cable for tethering the device to a location outside of the pipeline. The device comprises at least one accessory module and a joint to flexibly connect the at least one accessory module to the rotatable pipeline inspection module. The at least one accessory module includes one or more of pipeline inspection components, buoyancy components, and electronic components. 
     In one embodiment, there is provided a method to assess the condition of a pipeline wall of a pipeline containing a liquid, the method comprising:
     deploying a pipeline inspection device into a pipeline, the device comprising at least one sensor, the sensor configured to collect information useful for assessing the condition of a pipeline wall; and a body configured to mount the at least one sensor;   rotating the body as the device is carried by the liquid within the pipeline; and   obtaining, from the at least one sensor, information about substantially the wall of the pipeline during the rotation of the body, wherein the information is useful to assess to the condition of the pipeline wall.   

     In one aspect, the liquid is a moving liquid and the pipeline inspection device is carried by the moving liquid in the direction of flow. 
     In one embodiment, there is provided a method to assess the condition of the wall of a pipeline containing a liquid, the method comprising: deploying a rotatable inspection module into a pipeline, the module comprising at least one sensor, the at least one sensor configured to collect information useful for assessing the condition of the wall as the sensor is displaced a distance within the pipeline; and rotating the sensor about the longitudinal axis of the rotatable inspection module as the device is carried by the liquid within the pipeline; and obtaining, from the at least one sensor, information about substantially the entire interior surface of the pipeline during one or more complete revolutions of the at least one sensor of the rotatable inspection module along the displaced distance. 
     In one aspect, the module comprises ends coupled to a cable tethering the device to a location outside of the pipeline, and wherein when the sensor is caused to rotate about the longitudinal axis of the rotatable inspection module, the at least one sensor rotates in relation to the ends of the module. 
     In one aspect, the cable is configured to resist twisting. 
     In one aspect, the at least one sensor is a transducer. In one aspect, the transducer is an ultrasonic transducer. 
     In one embodiment, there is provided a pipeline inspection device comprising a rotatable pipeline inspection module to assess the condition of a pipeline wall when the module is deployed into a pipeline containing a liquid, the module comprising:
     at least one sensor, the sensor configured to collect information useful for assessing the condition of a pipeline wall as the sensor is moved within the pipeline; and   a body configured to mount the at least one sensor; and   a cable secured to the device for tethering the device to a location outside of the pipeline; and wherein the body is actuatable to rotate in relation to the module.   

    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a pipeline inspection device including a plurality of modules in accordance with an embodiment of the invention; 
         FIG. 2  is an enlarged perspective view of the device of  FIG. 2  showing two modules, wherein one module in accordance with an embodiment of the invention is shown with equipment in an expanded position; 
         FIG. 3  is an enlarged view of the module of a pipeline inspection device of  FIG. 2 , shown with equipment in a collapsed position; 
         FIG. 4  is a perspective view of the module of  FIG. 2 , in which the portions of the body have been removed to show internal structure of one side of the module; 
         FIG. 5  is a cross sectional view along the line  5 - 5  in  FIG. 4 ; 
         FIG. 6  is a cross sectional view along the line  6 - 6  in  FIG. 4 ; and 
         FIG. 7  is a perspective view of the module of  FIG. 2 , in which the portions of the body have been removed to show internal structure of another side of the module. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will be made below in detail to exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals used throughout the drawings refer to the same or like parts. 
       FIGS. 1 to 7  show a pipeline inspection device  2  that is deployable into a pipeline (not shown) to assess the condition of the wall of pipeline. The pipeline may be partially or completely filled with liquid and the liquid can be flowing. The device  2  comprises a forward section  3  and a rear section  5  opposite to the forward section  3 . Device  2  further comprises one or more modules  10 ,  12 , and  14  between the forward section  3  and the rear section  5 . Modules  10 ,  12 , and  14  may include any equipment  20  useful for collecting information about the condition of the pipeline, specifically, this equipment is useful for collecting information about various defects in the wall of the pipeline, such defects include, for example, metallic wall loss. Device  2  may include any number of modules and each of modules  10 ,  12 , and  14  can contain similar equipment or different equipment, depending on the desired application. For example, module  10  can include sensory equipment  20  for collecting any one or all of optical, acoustic, and magnetic information useful for assessing the condition of the pipeline, module  14  can comprise video and fiber optic components, and module  12  can comprise buoyancy components that allow the device  2  to remain buoyant in the liquid containing pipeline and/or to house various electrical components to control and drive any components in module  10  and/or module  14  of device  2 . 
     A cable  6  is coupled to the rear section  5  and is configured to tether the device  2  to an external location (not shown) outside of the pipeline when the device  2  is deployed inside the pipeline. Cable  6  may also be configured to carry electrical and/or fiber optic signals from one or more of the modules  10 ,  12 , and  14  to the external location and/or deliver electrical power to one or more of the modules  10 ,  12 , and  14 . In some embodiments, while cable  6  is configured to have some flexibility, cable  6  can be configured to have some torsional rigidity so that cable  6  is be able to resist twisting or rotation. Cable  6  may be configured to withstand application of significant axial forces before breaking. Such a cable  6  will have a high breaking strength so that if the device  2  encounters and obstruction or is snagged, the operator may be able to apply a significant amount of force needed retract the device  2  before causing break. In one aspect, one or more axial loading members associated with cable  6  for increasing the breaking (tensile) strength are provided. 
     When a plurality of modules  10 ,  12 , and  14  are used, the modules  10 ,  12 , and  14  are connected to each other via connecting member (or joint)  4  which is configured to have some flexibility so that the modules  10 ,  12 , and  14  of the device  2  can bend in relation to each other such that the device  2  can conform to the various bends of the pipeline that may be encountered during the deployment. The connecting member  4  may also be configured to have some torsional rigidity to resist twisting of modules  10 ,  12 , and  14  in relation to each other. The connecting member  4  defines one or more internal passages (not shown) which are dimensioned to carry cabling (not shown), including for example, electrical cables for transmitting electronic signals between the plurality of modules  10 ,  12 , and  14  and/or power cables for carrying electrical power from the external location to the plurality of modules  10 ,  12 , and  14 . 
       FIG. 2  shows a device  2  that includes module  10  that includes transducers  20  useful for collecting information about the condition of the pipeline. With reference to  FIG. 2 , the module  10  is shown with two transducers  20 , with each transducer  20  being held in an extended position.  FIG. 3  shows the module  10  with the two transducers  20 , each transducer  20  maintained in a collapsed position. 
     With reference to  FIGS. 4 to 7 , module  10  is a substantially elongate member having a first end  30  and an opposed second end  32 , the ends  30 ,  32  being configured to connect to a respective connecting member  4 . The first and second ends  30 ,  32  are joined by an intermediate portion  34  that defines an internal passage  36  dimensioned to house cabling, such as for example, electrical cables for carrying various electronic signals or power cables from between the first and the second ends  30 ,  32 , and vice versa. 
     Module  10  comprises a body  38 , between the first and second ends  30 ,  32 . The body  38  is configured to rotate about the longitudinal axis of the device  2 . In the embodiment shown, when the body  38  is caused to rotate, the rotational movement can be understood having reference to ends  30 ,  32  which remain relatively stationary. The body  38  will also rotate around the intermediate portion  34  joining the ends  30 ,  32 . At least one of ends  30 ,  32  is operatively attached to cable  6 . Operatively attached means that at least one of ends  30 ,  32  is connected to cable  6  either directly or indirectly via one or more connecting members  4  and/or one or more other modules  10 ,  12  or  14 . 
     Body  38  includes at least one access hatch  40  for allowing access to interior portions of the body  38  where various components may be secured, as detailed below. 
     Module  10  comprises a motor  50  which can be secured within the body  38 , such as for example, a Maxon DC motor, for moving a drive gear  52 , such as a nylon spur drive gear  52 . A driven gear  54  can be secured to at least one of the ends  30 ,  32  by a sleeve bearing  56 , for example. The driven gear  54  is operatively coupled to the drive gear  52 , wherein when the motor  50  is actuated, the drive gear  52  will begin to rotate. Since the ends  30 ,  32  of the module are configured to remain resistant, or substantially resistant, to rotation, the rotation of the drive gear  52  will cause this gear to rotate around the driven gear  54  such that the body  38  will move relative to the ends  30 ,  32  and rotate around the intermediate portion  34 . Rotary seal  58  is provided to separate the motor  50  from the outside environment. A counter weight  60  is provided opposite the position of the motor  50  to balance the center of gravity and to reduce undesired vibration. 
     As shown in  FIGS. 1 to 7 , upon actuation of motor  50 , the body  38  will begin to rotate in relation to ends  30 ,  32  which will remain relatively stationary. This is because the ends  30 ,  32  are operatively attached to cable  6  which resists rotation and/or twisting. Accordingly, the body  38  will rotate (either clockwise or counterclockwise) about the longitudinal axis of the device  2  and since the device  2  is secured to cable  6 , the body  38  can also be seen as rotating in relation to cable  6 . 
     Module  10  includes one or more sensory equipment  20  useful for collecting information about the condition of the pipeline. In one embodiment, the sensory equipment  20  is one or more sensors  20 . As shown in  FIGS. 1 to 7 , the sensors  20  are transducers  20 . Transducers  20  are mounted to transducer housing  70  and the transducers are secured to the housing  70  by a transducer retainer  72 . Transducer housing  70  is moveable between a first position where the transducers  20  assume an extended position away from the body  38  and a second position where the transducers  20  assume a collapsed position close to the body  38 . As shown in  FIGS. 4 to 7 , transducer housing  70  is pivotally moveable in relation to the body  38  in either direction (i.e. in a direction towards the first end  30  and/or towards the second end  32 ). While transducer housing  70  and thus transducers  20  are shown to pivotally move between the extended position and the collapsed position, it will be understood that the movement can be any movement (e.g. sliding or rotation) that can move the transducers away from the body  38  and can retract the transducers  20  from the extended position into the collapsed position close to the body  38 . 
     In some embodiments, the extended position permits the transducers  20  to collect the sensory information required to assess the conditions of the pipeline, such as for example, the metallic wall loss of the interior and exterior walls of pipeline. In aspects, the extended position allows transducers  20  to be closer to the pipeline wall. 
     In the collapsed position, the transducers  20  can be substantially recessed into the body  38  and do not substantially extend beyond the outer diameter of the module  10 , which in some exemplary embodiments is about 2.25″. In some embodiments, the collapsed position allows the device  2  to be more easily transported and then inserted into the pipeline, and retracted out from the pipeline, which may only have narrow access points and/or travel within the pipeline such that transducers  20  do not become snagged on features of the pipeline. 
     According to one embodiment, in the extended position, the transducers  20  are arranged approximately perpendicular to a longitudinal axis of the module  10 . Two 90 degree torsion springs  76  keep each transducer  20  in the perpendicular position until it is desired to move the transducers  20  into the collapsed configuration. In an embodiment, the transducers  20  are biased into the extended position and can be caused to move into the collapsed position upon an application of a force and wherein removal of the force will cause the transducers  20  move back into the extended position. In certain embodiments, it may be desirable to collapse the transducers  20  during the pipeline insertion or removal process to minimize their contact with the features of the pipeline that may contact and/or damage the transducers  20 . Once the device  2  is deployed into the pipeline, the transducers  20  can then allowed to assume the extended position. 
     In some aspects, the transducers  20  direct ultrasonic signals towards the pipeline wall. Reflections, which may be in multiples, can also be received by the transducers  20 . The reflected signal(s) are then analyzed to obtain information about the conditions of the pipeline. The conditions can be, but are not limited to, variations in ovality, liner thickness and delamination, pipeline wall thickness and defects, and location of air pockets, valves, laterals or other pipeline features. 
     In some aspects, rotation of the transducers  20  may increase resolution because during one complete revolution of the body  38 , the transducers  20  will be able to direct and/or receive signals that span across substantially the entire interior surface of the pipeline wall in the area in which the device  2  is located. Since the device  2  is carried by the liquid in the pipeline and will travel some distance away from the point of deployment, the rotating transducers  20  will be able to obtain information about the conditions across the interior surface of the pipeline along the entire length of travel within the pipeline. 
     In some aspects, the movement of the transducers  20  into the extended position and away from the body  38  of the device  2  may increase resolution because the transducers  20  will be closer to the interior surface of the pipeline wall. 
     A cable channel  74  is formed in the body  38  and/or transducer housing  70  to operatively connect the transducers  20  to any cabling contained in the passage  36  defined by the intermediate portion  34  connecting the first end  30  to the second end  32 . 
     Module  10  includes a rotary electrical joint  78 . According to one embodiment, the rotary electrical joint is a MOOG SRA-73683 slip ring connector. Seals  80  are provided to keep moisture from entering into the passage of the intermediate portion  34  or otherwise interfere with any other electronic components. Access hatch  40  can be configured to allow direct access to the electrical joint  78 . 
     A rotary encoder (not shown) is used to provide the relative position of the transducers  20  during a transmitting and receiving sequence. 
     Module  10  is depicted with two sensors  20 , however, module  10  can have any number of sensors  20  as required for the particular application. The exemplary sensors  20  are transducers  20 , but transducers  20  are only one example of a suitable sensor  20 . It would be understood that the present application is not limited to transducers  20 , but the sensor  20  can be any equipment useful for collecting information about various defects in the wall of the pipeline. 
     Module  10  and/or body  38  can be made, for example, from HDPE or some other sufficiently durable material capable of protecting the various components from applied pressure and/or axial loads. Other suitable materials, include, but are not limited to aluminum. 
     The device  2  can also include one or more buoyancy components (not shown) configured to provide buoyancy to the device  2 . For example, buoyancy components may be included in any one or more of modules  10 ,  12 , and  14 . 
     In use, device  2  comprising a rotatable inspection module  10  including one or more transducers  20  is secured to cable  6 . Device  2  is then lowered and deployed into the liquid-containing pipeline with the cable  6  tethering the device  2  to the surface. The device  2  is carried by the liquid and is displaced a distance along a length of the pipeline. The transducers  20  are caused to rotate about the longitudinal axis of the module  10  during the displacement such that information useful to assess to the condition of the wall is obtained substantially across the wall of the pipeline during one or more complete revolutions of the transducers  20  of the module  10  along the displaced distance. 
     The embodiments of the present application described above are intended to be examples only. Those of skill in the art may effect alterations, modifications and variations to the particular embodiments without departing from the intended scope of the present application. In particular, features from one or more of the above-described embodiments may be selected to create alternate embodiments comprised of a subcombination of features which may not be explicitly described above. In addition, features from one or more of the above-described embodiments may be selected and combined to create alternate embodiments comprised of a combination of features which may not be explicitly described above. Features suitable for such combinations and subcombinations would be readily apparent to persons skilled in the art upon review of the present application as a whole. Any dimensions provided in the drawings are provided for illustrative purposes only and are not intended to be limiting on the scope of the invention. The subject matter described herein and in the recited claims intends to cover and embrace all suitable changes in technology.