Ultrasonic tubulars inspection device and method

Abstract

A system, method, and apparatus for ultrasonic detection of flaws or defects in oil field tubulars utilizing composite transducers. An array of composite transducers are utilized to detect anomalies in the tubulars, such as transverse, wall or longitudinal defects. The use of the composite transducers allow for a greater inspection area over traditional transducers thereby reducing the number of channels needed for inspection of the tubulars.

Description

[0001]This application is a continuation of U.S. non-provisional application Ser. No. 10 / 971,860, filed Oct. 22, 2004, which claimed priority to provisional application Ser. No. 60 / 481,540 filed Dec. 22, 2003, the contents of which are hereby incorporated by reference in their entirety.TECHNICAL FIELD[0002]At least one embodiment of the present invention relates to a system, method and apparatus for the detection of flaws or defects in oil field tubulars. More particularly, the at least one embodiment of the present invention relates to a system, method, and apparatus for ultrasonic detection of flaws or defects in oil field tubulars utilizing curved composite transducers.BACKGROUND OF THE INVENTION[0003]Current tube inspection technology utilizing ultrasonic technology consists of units of three distinct types: 1) rotating head, 2) tube rotates in place, head traverses the length of the tube, and 3) helical advance—canted roller scheme. All three of these methods are restricted by ...

AI Technical Summary

Benefits of technology

[0017]A system, method, and apparatus for ultrasonic detection of flaws or defects in oil field tubulars utilizing curved composite transducers. An array of curved composite transducers are utilized to detect anomalies in the tubulars, such as transverse, wall or longitudinal defects. The use of the composite transducers allow for a greater inspection surface area per probe over traditional transducers thereby reducing the number of channels needed for inspection of the tubulars.

[0018]The scope of at least one embodiment of the present invention involves using the large sheets of composite material mentioned in the referenced article “Piezocomposite Transducers—A Milestone for Ultrasonic Testing,” not to produce numerous small individual composite transducers, curved to replace a conventional focusing lens, but to produce much larger probes, up to three inches and above, where the entire large single element is curved to a set radius as opposed to the much documented practice of curving smaller elements for focusing purposes. Unlike conventional transducer piezoelectric materials, the new composites can be shaped over a large area while still maintaining the effective beam properties required to insure 100% coverage, while maintaining sensitivity to the detection of small flaws as is required in OCTG inspection. These properties are desired for at least one embodiment of the present invention: a) uniform beam characteristics, b) equal sensitivity over the entire face of the composite probe, c) the ability to produce transducers with a smaller radius than previously possible, and d) the ability to curve a large sheet of composite material to make a single element probe with unique properties critical to embodiments of the current invention as opposed to the common practice of curving numerous smaller elements and using them in an array to provide coverage and speed in tube inspection.

[0021]It should be noted however that the curved composite transducers, if used on one of the above existing mechanical schemes would greatly increase the productivity, reduce the number of channels, and in turn the overall cost of the above style of machines. For instance, the transducers shown in a conventional array as depicted in FIG. 4, could have gaps between them close to the “effective” beam width of the curved composite probe.

[0038]The transducers may be maintained at a fixed position while maintaining 100% coverage on increasingly smaller diameters of tubulars thereby increasing the water path to the surface of the tubular with no mechanical change over required.

Problems solved by technology

All three of these methods are restricted by certain constants inherent to the use of ultrasound as a testing medium on all types of products, equipment, and structures.

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