U.S. patent application number 14/527616 was filed with the patent office on 2015-02-19 for floating brush train for external cleaning of tubulars.
The applicant listed for this patent is Thomas Engineering Solutions & Consulting, LLC. Invention is credited to Perry J. DeCuir, JR., Kenny Perry, JR., William J. Thomas, III, William C. Thomas.
Application Number | 20150050867 14/527616 |
Document ID | / |
Family ID | 50384060 |
Filed Date | 2015-02-19 |
United States Patent
Application |
20150050867 |
Kind Code |
A1 |
Thomas; William C. ; et
al. |
February 19, 2015 |
FLOATING BRUSH TRAIN FOR EXTERNAL CLEANING OF TUBULARS
Abstract
Enhanced methods are disclosed for performing operations such as
cleaning, inspection or data acquisition on an external surface of
a hollow cylindrical tubular. Preferred embodiments include
providing a fluid dispenser and an abrasion assembly on a buggy
that travels up and down the length of the tubular as the tubular
rotates. The fluid dispenser includes nozzles that dispense
cleaning fluids onto the tubular's external surface. The abrasion
assembly includes a swivel brush and a brush train providing
different styles of abrasion cleaning of the tubular's external
surface. Preferred embodiments of the buggy also carry a range
finding laser and an optical camera generating samples that may be
processed in real time into data regarding the surface contours and
the diameter variations on the tubular's external surface. Cleaning
and inspection variables such as tubular rotational speed, or buggy
speed, may be adjusted responsive to measured surface contour
data.
Inventors: |
Thomas; William C.;
(Lafayette, LA) ; Thomas, III; William J.; (New
Iberia, LA) ; DeCuir, JR.; Perry J.; (Rochester
Hills, MI) ; Perry, JR.; Kenny; (Youngsville,
LA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Thomas Engineering Solutions & Consulting, LLC |
New Iberia |
LA |
US |
|
|
Family ID: |
50384060 |
Appl. No.: |
14/527616 |
Filed: |
October 29, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14042683 |
Sep 30, 2013 |
|
|
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14527616 |
|
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|
|
61799425 |
Mar 15, 2013 |
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Current U.S.
Class: |
451/295 ;
451/294 |
Current CPC
Class: |
B24B 27/0076 20130101;
B24B 51/00 20130101; B08B 9/023 20130101; B24B 27/0015 20130101;
B24B 27/033 20130101; E21B 37/02 20130101; B24B 5/36 20130101; E21B
41/00 20130101; B24B 5/04 20130101 |
Class at
Publication: |
451/295 ;
451/294 |
International
Class: |
B24B 27/033 20060101
B24B027/033; B24B 27/00 20060101 B24B027/00; B24B 5/36 20060101
B24B005/36 |
Claims
1. An abrader train assembly, comprising: a vertically-adjustable
mounting mechanism including a horizontally disposed mounting
member, the mounting member attached to the mounting mechanism such
that, responsive to first user instructions, the mounting mechanism
adjusts the mounting member to a predetermined abrader train
elevation above a preselected horizontal datum plane; at least one
abrader assembly, each abrader assembly in independent
spring-biased floating suspension from the mounting member, the
floating suspension for each abrader assembly providing spring
dampening of both upward vertical displacement and downward
vertical displacement of the abrader assembly relative to the
mounting member; each abrader assembly further including a
rotatable abrader configured to rotate about its own abrader
rotation axis, wherein each abrader rotation axis is parallel to
the datum plane; each rotatable abrader including an abrasive
surface at an outer periphery thereof; a drive axle, each rotatable
abrader in separate rotational power communication with the drive
axle, the drive axle disposed to rotate at user-selected speeds
about a drive axle rotation axis also parallel to the datum plane;
and wherein concurrent operational contact on the abrasive surface
of each rotatable abrader causes independent vertical displacement
of the corresponding abrader assembly against its spring dampening
while each rotatable abrader rotates at a common user-selected
speed.
2. The abrader train assembly of claim 1, in which at least one
abrader assembly is in independent spring-biased floating
suspension from the mounting member via the abrader assembly being
suspended from two opposing compression springs separated by the
mounting member.
3. The abrader train assembly of claim 1, comprising a plurality of
abrader assemblies, and in which the abrader rotation axes of each
of the rotatable abraders are parallel.
4. The abrader train assembly of claim 1, comprising a plurality of
abrader assemblies, in which the abrader rotation axes of the
rotatable abraders are substantially collinear when the abrader
assemblies are in an equilibrium position suspended from the
mounting member without operational contact on the abrasive
surfaces.
5. The abrader train assembly of claim 1, further comprising a
drive motor, the drive motor in rotational power communication with
the drive axle.
6. The abrader train assembly of claim 5, in which the drive motor
is selected from the group consisting of: (a) an electric motor;
(b) a hydraulic motor; and (c) a pneumatic motor.
7. The abrader train assembly of claim 5, in which the rotation
communication between the drive motor and the drive axle includes a
drive belt.
8. The abrader train assembly of claim 1, in which the rotation
communication between the drive axle and at least one rotatable
abrader includes a drive belt.
9. The abrader train assembly of claim 5, in which the drive motor
is mounted on the mounting member.
10. The abrader train assembly of claim 1, in which the drive axle
is mounted on the mounting member.
11. The abrader train assembly of claim 3, in which the drive axle
rotation axis is parallel to the abrader rotation axes of the
rotational abraders.
12. The abrader train assembly of claim 1, in which the abrasive
surface on at least one rotational abrader is selected from group
consisting of: (a) a brush; (b) a flap wheel; (c) an abrasive stone
wheel; and (d) a composite wheel.
13. The abrader train assembly of claim 1, in which the drive axle
is configured to reverse rotational direction responsive to second
user instructions.
14. The abrader train assembly of claim 1, in which at least one
rotational abrader has an oblate spheroid shape.
15. The abrader train assembly of claim 1, comprising a plurality
of abrader assemblies, in which there is a gap of about 1/16''
between neighboring abrader assemblies.
16. An abrader train assembly, comprising: a vertically-adjustable
mounting mechanism including a horizontally disposed mounting
member, the mounting member attached to the mounting mechanism such
that, responsive to first user instructions, the mounting mechanism
adjusts the mounting member to a predetermined abrader train
elevation above a preselected horizontal datum plane; a plurality
of abrader assemblies, each abrader assembly in independent
spring-biased floating suspension from the mounting member via the
abrader assembly being suspended from two opposing compression
springs separated by the mounting member, the floating suspension
for each abrader assembly providing spring dampening of both upward
vertical displacement and downward vertical displacement of the
abrader assembly relative to the mounting member; each abrader
assembly further including a rotatable abrader configured to rotate
about its own abrader rotation axis, wherein each abrader rotation
axis is parallel to the datum plane; each rotatable abrader
including an abrasive surface at an outer periphery thereof;
wherein the abrader rotation axes of the rotatable abraders are
substantially collinear when the abrader assemblies are in an
equilibrium position suspended from the mounting member without
operational contact on the abrasive surfaces; a drive axle, each
rotatable abrader in separate rotational power communication with
the drive axle, the drive axle disposed to rotate at user-selected
speeds about a drive axle rotation axis also parallel to the datum
plane; and wherein concurrent operational contact on the abrasive
surface of each rotatable abrader causes independent vertical
displacement of the corresponding abrader assembly against its
spring dampening while each rotatable abrader rotates at a common
user-selected speed.
17. The abrader train assembly of claim 16, further comprising a
drive motor, the drive motor in rotational power communication with
the drive axle.
18. The abrader train assembly of claim 16, in which the drive axle
is configured to reverse rotational direction responsive to second
user instructions.
19. An abrader train assembly, comprising: a vertically-adjustable
mounting mechanism, the mounting mechanism having an upper surface
and a lower surface; a plurality of independently-rotatable abrader
assemblies attached to the mounting mechanism such that, responsive
to first user instructions, the mounting mechanism adjusts the
abrader assemblies to a predetermined abrader assembly elevation
above a preselected horizontal datum plane; each abrader assembly
further comprising an abrader, a vertical support, an upper brush
train spring, and a lower brush train spring; each abrader assembly
suspended from the mounting mechanism by its vertical support, each
vertical support penetrating and perpendicular to the mounting
mechanism, the upper brush train spring separating the vertical
support from the upper surface of the mounting mechanism such that
the abrader assembly is in floating suspension from the mounting
mechanism via the upper brush train spring, the lower brush train
spring separating the vertical support from the lower surface of
the mounting mechanism such that the abrader assembly is also in
floating suspension from the mounting mechanism via the lower brush
train spring; each abrader assembly, responsive to operational
contact on its abrader, disposed to move vertically while the
abrader is rotated at a user-selectable speed about an abrader
rotation axis, wherein the abrader rotation axis for each abrader
assembly is parallel to the datum plane; wherein further the
abrader rotation axes are substantially collinear when the abrader
assemblies are in an equilibrium position suspended from the
mounting mechanism without operational contact on the abraders; and
a drive axle, each abrader in separate rotational power
communication with the drive axle, the drive axle disposed to
rotate at user-selected speeds about a drive axle rotation axis
also parallel to the datum plane.
20. The abrader train assembly of claim 19, further comprising a
drive motor, the drive motor in rotational power communication with
the drive axle.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of co-pending, commonly
assigned U.S. patent application Ser. No. 14/042,683, filed Sep.
30, 2013, which in turn claims priority to now-expired, commonly
assigned U.S. Provisional Patent Application 61/799,425, filed Mar.
15, 2013. This application claims priority to, and the benefit of,
Ser. No. 14/042,683 and Ser. No. 61/799,425, and incorporates the
entire disclosure of Ser. Nos. 14/042,683 and 61/799,425 by
reference.
FIELD OF THE INVENTION
[0002] This disclosure is directed generally to technology useful
in tubular cleaning operations in the oil and gas exploration
field, and more specifically to a multi-purpose buggy for cleaning
and inspecting the external surfaces of tubulars such as drill
pipe, workstring tubulars, and production tubulars.
BACKGROUND
[0003] Throughout this disclosure, the term "Scorpion" or "Scorpion
System" refers generally to the disclosed Thomas Services Scorpion
brand proprietary tubular management system as a whole.
[0004] One drawback of conventional tubular cleaning apparatus is
that, with the cleaning apparatus stationary and the tubular drawn
longitudinally across, the apparatus requires a large building.
Range 3 drilling pipe is typically 40-47 feet long per joint, which
means that in order to clean range 3 pipe, the building needs to be
at least approximately 120 feet long
[0005] A further drawback of the prior art is that external
cleaning operations are generally completely separate operations
from inspection or other data gathering operations regarding the
tubular.
SUMMARY
[0006] Aspects of the Scorpion System disclosed and claimed in this
disclosure address some of the above-described drawbacks of the
prior art. In preferred embodiments, the Scorpion System rotates
the tubular to be cleaned (hereafter, also called the "Work" in
this disclosure) while keeping the Work stationary with respect to
the cleaning apparatus. The Scorpion then moves the cleaning
apparatus up and down the length of the Work while the Work
rotates.
[0007] In currently preferred embodiments, the Work is typically
rotated at speeds in a range of about 100-300 rpm, and potentially
within a range of between about 0.01 rpm and about 1,750 rpm under
certain criteria. However, nothing in this disclosure should be
interpreted to limit the Scorpion System to any particular
rotational speed of the Work. Currently preferred embodiments of
the Scorpion System further draw the cleaning apparatus up and down
the length of the Work at speeds within a range of about 0.001
linear inches per second and about and 10.0 linear feet per second,
depending on the selected corresponding rotational speed for the
Work. Again, nothing in this disclosure should be interpreted to
limit the Scorpion System to any particular speed at which the
cleaning apparatus may move up or down the length of the Work.
[0008] The Scorpion System provides an outer delivery system (ODS)
to clean and inspect the external surface of the Work. The ODS
generally comprises a "buggy"-like device that travels back and
forth above the Work while the Work rotates beneath. Embodiments of
the ODS are disclosed in which the buggy travels on a track. The
buggy carries structure for performing operations on the external
surface of the Work as the buggy travels above the Work. Such
structure includes jets for delivery of fluids such as, for
example, steam, fluid-borne abrasives, high and low pressure water,
compressed air and drying gas (e.g. nitrogen). Such structure
further includes brushes and other abrasives for abrasive cleaning
or buffing. Such structure further includes data acquisition
structure for inspecting and measuring the tubular, such as, for
example, lasers, optical cameras, sensors and probes.
[0009] It is therefore a technical advantage of the disclosed ODS
to clean the exterior of pipe and other tubulars efficiently and
effectively. By passing different types of interchangeable cleaning
apparatus on a track-mounted assembly over a stationary but
rotating tubular, considerable improvement is available for speed
and quality of external cleaning of the tubular over conventional
methods and structure.
[0010] A further technical advantage of the disclosed ODS is to
reduce the footprint required for industrial tubular cleaning. By
moving cleaning apparatus over of a stationary but rotating
tubular, reduced footprint size is available over conventional
cleaning systems that move a tubular over stationary cleaning
apparatus. Some embodiments of the ODS may be deployed on mobile
cleaning systems.
[0011] A further technical advantage of the disclosed ODS is to
enhance the scope, quality and reliability of inspection of the
exterior of the tubular before, during or after cleaning
operations. Data acquisition structure such as sensors, probes and
lasers may be deployed on the track-mounted assembly passing over
the stationary but rotating tubular. Such data acquisition
structure may scan or nondestructively examine the exterior of the
tubular, either while the tubular is rotating, and/or while the
exterior is being cleaned, or otherwise.
[0012] A further technical advantage of the disclosed ODS is to
reduce the incidence of damage to tubulars during brushing or other
abrasive contact operations. Stresses occur when brushing structure
passes over a rotating tubular where the tubular's local contour or
diameter is greater than nominal. The disclosed ODS provides
brushing structure configured to adapt to local variations in
contour and diameter of the tubular, including suspending brushes
on springs in user-controllable spring equilibrium above the
tubular. The brushing pressure for a nominal tubular diameter may
be set, per user selection, and the spring suspensions then enable
the brushing structure to adapt to local variations in contour and
diameter of the tubular. The disclosed ODS also provides other
contour-adapting structure such as an articulated drive shaft for a
train of brushes, and a swiveling brush including an oblate
spheroid-shaped brush profile.
[0013] A further technical advantage of the disclosed ODS is to
reduce the incidence of areas or features on the external surface
of the rotating tubular that may be "missed" by brushing structure
as it passes by. Local variations in contour or diameter of the
tubular, or sag or bow of the tubular, may cause areas of the
tubular's external surface to lose brushing contact (or lose the
desired brushing pressure). The features described in the
immediately preceding paragraph for brush structure to adapt to
local variations in the tubular's contour or diameter are also
useful for causing brushing structure to maintain contact (or
pressure) with the external surface of the tubular when the
external surface momentarily "moves away" from the brushing
structure.
[0014] A further technical advantage of the disclosed ODS is to
maintain an optimal distance between fluid jets operating on the
tubular and the external surface of the tubular. Fluid jets are
provided on the ODS in order deliver fluids (in liquid or gaseous
state) for cleaning and other operational purposes. An electronic
control system gathers real time data regarding the local contours
in the tubular's external surface and maintains an optimal distance
between the fluid jets and the external surface, so that the
operating effectiveness of the fluid jets is maximized without
causing damage to the tubular's surface.
[0015] The foregoing has outlined rather broadly some of the
features and technical advantages of the present invention in order
that the detailed description of the invention that follows may be
better understood. Additional features and advantages of the
invention will be described hereinafter which form the subject of
the claims of the invention. It should be appreciated by those
skilled in the art that the conception and the specific embodiment
disclosed may be readily utilized as a basis for modifying or
designing other structures for carrying out the same purposes of
the present invention. It should be also be realized by those
skilled in the art that such equivalent constructions do not depart
from the spirit and scope of the invention as set forth in the
appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] For a more complete understanding of the present invention,
and the advantages thereof, reference is now made to the following
descriptions taken in conjunction with the accompanying drawings,
in which:
[0017] FIG. 1 is a functional-level general arrangement of one
embodiment of the ODS in a combination deployment with an MLI
100;
[0018] FIG. 2 is an enlargement of FIG. 1 in isometric view;
[0019] FIG. 3 depicts the underside of one embodiment of the ODS
from the view of arrow 210 on FIG. 2;
[0020] FIG. 4 illustrates one embodiment of the ODS in elevation
view;
[0021] FIG. 5 illustrates another embodiment of the ODS in
elevation view;
[0022] FIG. 6 is an end view as shown on FIG. 5;
[0023] FIG. 7 illustrates the ODS embodiment of FIG. 5 disposed to
operate on tubular W;
[0024] FIGS. 8 and 9 illustrate the ODS embodiment of FIGS. 5-7 in
different isometric views;
[0025] FIG. 10 is a further isometric view of ODS embodiment of
FIGS. 5-7, with a propulsion drive and track detail added;
[0026] FIG. 11 is an isolated elevation view of fixed brush train
240;
[0027] FIGS. 12A and 12B are isolated elevation views of swivel
brush assembly 260;
[0028] FIG. 12C is a cutaway view of swivel brush assembly 260;
[0029] FIGS. 12D and 12E are stroboscopic views of swivel brush
assembly 260;
[0030] FIGS. 13A and 13B are isolated elevation views of fluid jet
assembly 280;
[0031] FIG. 14 is an isometric view of ODS buggy 320, an
alternative embodiment to the buggy aspects of ODS assembly 220
illustrated generally on FIG. 5;
[0032] FIGS. 15A, 15B, 15C and 15D are elevation views of ODS buggy
as shown on FIGS. 14 and 15A;
[0033] FIG. 16A isolates brush train 340 from the elevation view of
FIG. 15C;
[0034] FIG. 16B is an isometric view of the section shown on FIG.
16A;
[0035] FIGS. 16C, 16D and 16E show aspects of brush train 340
close-up in isolation, in which FIGS. 16C and 16D are isolated from
FIGS. 15C and 15D respectively, and FIG. 16E is an isometric view
as shown generally on FIG. 16D;
[0036] FIGS. 17A, 17B and 17C are isolated views of swivel brush
assembly 360, in which FIGS. 17A and 17B are isolated from FIGS.
15C and 15A respectively, and FIG. 17C is an isometric view of FIG.
17A;
[0037] FIGS. 18A and 18B are isolated views of fluid jet assembly
380, in which FIGS. 18A and 18B are isolated from FIGS. 15C and 15B
respectively;
[0038] FIG. 18C is an isometric view of the section shown on FIG.
18A;
[0039] FIGS. 18D and 18E show aspects of fluid jet assembly 380
close-up in isolation, in which FIG. 18D is an enlargement of the
isometric view of FIG. 18C, and FIG. 18E is an isometric view shown
generally on FIG. 18D;
[0040] FIG. 19A is an isolated view of camera assembly 390, in
which FIG. 19A is isolated from FIG. 15C;
[0041] FIG. 19B is an isometric view of the section shown on FIG.
19A;
[0042] FIGS. 19C and 19D show aspects of camera assembly in
close-up isolation, in which FIG. 19C is shown generally on FIG.
19B, and in which FIG. 19D is the same as FIG. 19C except with
sliding door 396 illustrated as open;
[0043] FIG. 19E is a plan view of FIG. 19D; and
[0044] FIGS. 19F and 19G are further isometric views of aspects of
camera assembly 390 in close-up isolation, in which FIG. 19F is
shown generally on FIG. 19E, and FIG. 19G is the same as FIG. 19F
except with containment cover 395 in place.
DETAILED DESCRIPTION
[0045] FIGS. 1 through 4 illustrate a first embodiment of an ODS
assembly (or "buggy"), designated generally on FIGS. 1 through 4 as
ODS assembly 201. FIGS. 5 through 13B illustrate a second
embodiment of an ODS assembly, designated generally on FIGS. 5
through 13B as ODS assembly 220. Nothing in this disclosure should
be interpreted to limit the ODS to the embodiments of ODS
assemblies 201 and 220 or the structural features and aspects
disclosed thereon.
[0046] FIG. 1 is a general arrangement drawing that illustrates, in
an elevation view, an exemplary embodiment in which the ODS
assembly 201 is disposed above tubular W (the Work). It will be
seen and understood on FIG. 1 that ODS assembly 201 travels along
track 202 while tubular W rotates. As will be described in greater
detail further on, ODS assembly 201 provides a plurality of
shrouded heads 203 comprising tooling that may perform a
user-selected sequence of operations (including cleaning and data
acquisition operations) on tubular W. As ODS assembly 201 travels
along track 202 while tubular W rotates, it will be seen from FIG.
1 that ODS assembly 201 enables such user-selected sequence of
operations by providing heads and associated tooling in a
corresponding sequence as ODS assembly 201 comes to bear upon
tubular W.
[0047] The exemplary embodiment illustrated in FIG. 1 also shows,
solely for reference purposes, guide tubes 101 from a Multi-Lance
Injector (MLI) assembly 100 in "curved tube" mode, as is fully
disclosed in U.S. Provisional Application Ser. No. 61/707,780,
priority to which Provisional Application is claimed herein (see
disclosure in such Provisional Applications under the heading
"Interior Cleaning of the Work"). In this way, FIG. 1 illustrates
an embodiment of the Scorpion System, in which both MLI structure
and ODS structure are provided together in one machine. It will be
appreciated however, that nothing in this disclosure should be
interpreted to require that MLI structure be combined with ODS
structure in one machine. Other embodiments, not illustrated or
described in this disclosure in any detail, may provide MLI
structure and/or ODS structure in stand-alone machines
[0048] Referring again to FIG. 1, it will be understood that
certain conventional structure has been omitted for clarity. For
example, ODS assembly 201, track 202 and guide tubes 101, for
example, are advantageously supported by structural steel and other
conventional support means (including, in some embodiments, a
gantry for maintenance access), all of which has been omitted for
clarity. Operation of the ODS is advantageously accomplished using
conventional hydraulic, pneumatic or electrical apparatus
(including geared drive motor apparatus to cause ODS assembly 201
to travel track 202 as illustrated by arrow 204 on FIG. 1), all of
which has been also omitted for clarity.
[0049] Turning now to FIG. 2, an embodiment of ODS assembly 201 is
illustrated in more detail. It will be appreciated that FIG. 2 is a
perspective view of the embodiment shown on FIG. 1, looking back at
ODS assembly 201 from tubular W, slightly from underneath. The
embodiment of FIG. 2 illustrates ODS assembly 201 operable to move
up and back along track 202 via motorized gear wheels 208 on either
side of ODS assembly 201 (only one side's gear wheel 208 visible on
FIG. 2), whereby motorized gear wheels 208 run in geared rails 209
deployed on track 202. It will be understood, however, that the
motorized gear propulsion mechanism for ODS assembly 201
illustrated on FIG. 2 is exemplary only, and any other operable
propulsion mechanism for ODS assembly 201 is within the scope of
this disclosure.
[0050] FIG. 2 also depicts shrouded heads 203 in more detail. Each
of shrouded heads 203 comprises tooling surrounded by a shroud. A
primary purpose of the shroud is to prevent by-products from the
operation of the tooling (e.g. steam, water, dirt and rust removed
from the outside of tubular W) from dispersing excessively into the
airspace surrounding ODS assembly 201.
[0051] The tooling included in shrouded heads 203 is
user-selectable according to operational needs. In the exemplary
embodiment illustrated in FIG. 2, shrouded heads 203 comprise
nozzle head 205, then six abrasive heads 206, and then probe head
207. Nothing in this disclosure should be interpreted, however, to
limit the ODS to any particular type or amount of tooling, or the
number of shrouded heads on which it is embodied, or the sequence
in which it is brought to bear on tubular W.
[0052] Reference is now made to FIG. 3, which illustrates the
tooling in the exemplary embodiment of FIG. 2 in more detail. FIG.
3 depicts shrouded heads 203 as also shown on FIGS. 1 and 2 from
underneath, in the direction of arrow 210 as shown on FIG. 2.
Nozzle head 205, abrasive heads 206 and probe head 207 may be seen
on FIG. 3, as also seen on FIG. 2. FIG. 3 also depicts each
shrouded head 203 comprising tooling surrounded by a shroud (the
shrouds labeled reference numeral 211 on FIG. 3).
[0053] Referring back briefly to FIGS. 1 and 2 together, it will be
seen that when ODS assembly 201 begins its travel in the direction
of arrow 204 on FIG. 1 and comes to bear on tubular W, the
currently preferred embodiment of the ODS provides nozzle head 205
as the first of shrouded heads 203 to operate on tubular W.
Abrasive heads 206 follow nozzle head 205, and probe head 207
follows abrasive heads 206. This exemplary user-selected sequence
of shroud heads 203 reflects the following sequence of tubular
cleaning and data acquisition operations (although nothing herein
should be construed to limit the ODS to the following operational
sequence):
[0054] Nozzle Head 205--First Nozzle Group:
[0055] High pressure water blast (nominally at about 20,000 psi but
not limited to any such pressure) for concrete removal and general
hydroblasting operations, especially if tubular W has a severely
rusted or scaled outer surface.
[0056] Nozzle Head 205--Second Nozzle Group:
[0057] Low pressure/high temperature wash, nominally at 3,000
psi/300 deg F but not limited to any such pressure or temperature),
for general tubular cleaning operations, including salt wash and
rust inhibitor coating.
[0058] Abrasive Heads 206:
[0059] Abrasive surface cleaning and treatment of outer surface of
tubular W via steel wire brush and/or flap wheels for removal, for
example, of protruding steel burrs on the outer surface of tubular
W.
[0060] Probe Head 207:
[0061] Data acquisition devices and/or sensors examining outer
surface of tubular W.
[0062] Looking now at FIG. 3 in greater detail, it will be seen
that nozzle head 205 comprises one or more nozzles 212. FIG. 3
depicts four (4) nozzles 212, in a line off center. However, such
configuration of nozzles 212 on FIG. 3 is exemplary only, and
nothing in this disclosure should be construed to limit nozzle head
205 to provide any particular number of nozzles 212 in any
particular configuration. Other embodiments, consistent with the
scope of this disclosure, might provide fewer or greater than four
(4) nozzles 212, and might deploy them on center or in different
locations off center.
[0063] Relating nozzle head 205 as shown on FIG. 3 to the exemplary
ODS operational sequence described above, it will be seen that
nozzles 212 on nozzle head 205 may enable both the high pressure
wash and the low pressure wash. It will be further appreciated that
different embodiments of nozzle head 205, wherein each nozzle head
205 provides different numbers, locations and configurations of
nozzles 212, may enable different combination of operations (such
as steam clean, wash, rinse, spray, coat, etc.) according to user
selection.
[0064] Relating abrasive heads 206 as shown on FIG. 3 to the
exemplary ODS sequence described above, it will be appreciated that
abrasive heads 206 may provide steel brushes, rattling heads, flap
wheels or any other abrasive tooling in any combination or sequence
to further clean, treat or smooth the outer surface of tubular W.
FIG. 3 depicts abrasives 213 on abrasive heads 206 in generic form
for this reason. In a currently preferred embodiment of the ODS,
for example only, the three (3) abrasive heads 206 nearest nozzle
head 205 provide abrasives 213 in the form of rotating steel
brushes, while the three (3) abrasive heads 206 nearest probe head
207 provide abrasives 213 in the form of rotating flap wheels. In
this embodiment, optionally, a nozzle 212 on neighboring nozzle
head 205, or on any of abrasive heads 206 themselves, may also be
provided and dedicated to cleaning the steel brushes embodying
abrasives 213. Nothing in this disclosure should be construed,
however, to limit the ODS to this embodiment, or to any
configuration, type or number of abrasives 213 or abrasive heads
206.
[0065] Probe head 207 as shown on FIG. 3 provides data acquisition
probes and sensors for examining and acquiring information about
tubular W's outer surface, condition, wall thickness and other
parameters. This examination and information gathering process is
disclosed in greater detail below in paragraphs near the end of
this disclosure describing the Data Acquisition System ("DAS").
Probe head 207 may provide all types of sensors, including, without
limitation, magnetic, ultrasonic, laser and other types of sensors.
Nothing in this disclosure should be interpreted to limit the type
or number of sensors provided by probe head 207.
[0066] Although not illustrated, other embodiments of the ODS may
supplement the data acquisition capability of probe head 207 by
optionally providing additional sensors on the inside of shrouds
211. For reference, shrouds 211 are called out on FIG. 3.
[0067] Sensor data from probe head 207 and shrouds 211 may be
further enhanced or supplemented by the optional addition of
imaging technology positioned to scan tubular W's outer surface
during ODS operations (such optional imaging technology not
illustrated). For example, a thermal imaging camera ("infrared
thermography") may be used to detect, record and quantify
temperature differentials in the outer surface of tubular W. Such
temperature differentials may typically (1) indicate excess
moisture found in cracks and pores in tubular W, and (2) measure
rates of heat exchange in steel densities and volumes. The imaging
data may thus be used easily and conventionally to detect cracks,
thickness variations, and porosity in the wall or on the surface of
tubular W.
[0068] Advantageously, the imaging data may be in the form of a
Gaussian (i.e. rainbow) color swath, conventionally displaying
lower temperatures in "cooler" colors such as blue, green and cyan,
and higher temperatures in "hotter"/"brighter" colors such as red,
yellow and magenta. Anomalies in tubular W such as a surface crack,
subsurface crack, porous pipe wall (i.e. less dense wall), and/or
variation in wall thickness may be identified via detection of a
corresponding temperature gradient (caused by excess moisture and
thus lower temperatures in and around the anomaly) when compared to
the temperature gradient of a healthy/continuous run of steel.
While such temperature gradient analysis is available at ambient
temperatures, the sensitivity (and corresponding efficacy) of the
analysis is enhanced if hot water is applied prior to scanning.
[0069] Referring back now to FIG. 1, it will be appreciated that
although not illustrated in FIG. 1, the Scorpion System's ODS is
operable via conventional positioning apparatus to position tubular
W with respect to ODS assembly 201 ready for operations. In a
preferred embodiment, such positioning apparatus may move ODS
assembly 201 with respect to tubular W so as to correctly position
the operational tooling on ODS assembly 201 with respect to the
external surface of tubular W. In other embodiments, such
positioning apparatus may alternatively, or also, position the
tubular W with respect to ODS assembly 201.
[0070] FIG. 4 illustrates additional, more precise positioning
apparatus once ODS assembly 201 is initially positioned with
respect to tubular W by conventional positioning apparatus, per the
previous paragraph. FIG. 4 is an enlargement of ODS assembly 201
shown more generally on FIG. 1, and depicts aspects of ODS assembly
201 in greater detail. FIG. 4 further depicts ODS assembly 201,
nozzle head 205, abrasive heads 206, probe head 207 and gear wheel
208 consistent with the correspondingly-numbered features shown on
FIGS. 1 and 2 (and such features' accompanying disclosure
herein).
[0071] Referring now to FIG. 4, it will be seen that nozzle head
205 is suspended on nozzle head piston 215, while probe head 207 is
suspended on probe head piston 217. Abrasive heads 206 generally,
as a group, are suspended on abrasive head piston 216. Abrasive
heads 206 are then further suspended individually via corresponding
abrasive head springs 214. In this way, each of nozzle head 205,
abrasive heads 206 and probe head 207 may be more precisely
positioned, independently of one another, with respect to the outer
surface of tubular W (tubular W omitted for clarity on FIG. 4)
according to user selection.
[0072] With respect to nozzle head 205, FIG. 4 shows that
independent extension and retraction of nozzle head piston 215, as
required, will allow nozzle head 205 to be positioned to a precise
user-selected location above the outer surface of tubular W.
Likewise, FIG. 4 shows that independent extension and retraction of
probe head piston 217, as required, will allow probe head 207 to be
positioned to a precise user-selected location above the outer
surface of tubular W.
[0073] With respect to abrasive heads 206, as a group, FIG. 4 shows
that extension and retraction of abrasive head piston 216 will
allow abrasive heads 206, as a group, to be positioned to a precise
user-selected location above the outer surface of tubular W.
Further, via compression and release of abrasive head springs 214,
FIG. 4 shows that abrasives 213 on abrasive heads 206 (see FIG. 3)
may be kept in spring pressure contact with the outer surface of
tubular W while abrasive heads 206 operably move along tubular W.
Further, the independent suspension of each abrasive head 206 on
its own abrasive head spring 214 allows each abrasive head 206 (and
corresponding abrasives 213) to conform to the local shape or
contour of the outer surface of tubular W as it operably moves
along tubular W.
[0074] Although FIG. 4 illustrates an embodiment of ODS assembly
201 in which each abrasive head 206 has one corresponding abrasive
head spring 214, it will be understood that the scope of this
disclosure is not limited in this regard. It will be appreciated
that suspension on additional springs may allow individual abrasive
heads 206 to conform yet more closely (e.g., via pivoting) to the
local shape or contour of the outer surface of tubular W as it
operably moves along tubular W. In other embodiments, some
described with reference to FIGS. 5 through 11, neighboring
individual abrasive heads 206 may be connected together via, for
example, an articulated connection, to create a similar effect.
[0075] Referring again to nozzle head piston 215, abrasive head
piston 216 and probe head piston 217 on FIG. 4, it will be
understood that the scope of this disclosure is not limited to
extending or retracting these pistons to position their
corresponding heads solely prior to commencing operations. It will
be appreciated that further extensions or retractions of pistons
215, 216 and/or 217 may alter, as required, the precise position of
nozzle head 205, abrasive heads 206 and probe head 207 with respect
to the outer surface of tubular W while ODS assembly 201 is moving
with respect to tubular W. It will be further understood, however,
that in some embodiments, lasers and magnetic proximity sensors
(not illustrated) are a primary means of adjustment for contours in
the outer surface or tubular W, rather than extensions or
retractions of pistons 215, 216 and/or 217 on the fly.
[0076] Reference is now made to FIGS. 5 through 13B, which
illustrates ODS assembly 220 as an alternative embodiment to ODS
assembly 201 as illustrated on FIGS. 1 through 4. It will be
appreciated that the disclosure above to general principles,
features and aspects of the ODS, regardless of the embodiment of
ODS assembly or "buggy", applies equally to the embodiments
disclosed below with reference to FIGS. 5 though 13B.
[0077] Further, for the avoidance of confusion on FIGS. 5 though
13B, it will be understood that, for illustration purposes on this
disclosure only, alternative ODS assembly embodiments 201 and 220
are illustrated to run in opposite directions from a default rest
position (such default resting position defined for purposes of
this paragraph only as resting ready to begin engaging a tubular).
ODS assembly 201 embodiment on FIGS. 1 through 4 is illustrated to
run right-to-left on the page from a default rest position (see
arrow 204 on FIG. 1 and associated disclosure above). In contrast,
ODS assembly 220 embodiment of FIGS. 5 though 13B is illustrated to
run left-to-right on the page from such a default rest
position.
[0078] Thus, with reference to FIG. 5, as ODS assembly 220 moves
and engages a tubular beneath, ODS laser 222 first detects the end
of the tubular and then ODS laser 222's field of view 223 begins to
scan the external surface of the tubular below as the tubular
rotates. Information from scanning by ODS laser 222 is used by ODS
assembly 220's control system (not illustrated) to inspect and
analyze characteristics of the tubular as described in greater
detail below. Currently-preferred embodiments of ODS assembly 220
further include an optical camera also deployed in combination with
ODS laser 222. The optical camera also scans the tubular beneath
within field of view 223 as illustrated on FIG. 5 (and other
Figures) and receives corresponding images of the tubular for
processing in combination with information from ODS laser 222. For
the avoidance of doubt, the term "ODS laser 222" as used hereafter
in this disclosure refers to a combination of a laser and an
optical camera scanning the tubular in field of view 223. The
operation of the laser and optical scanner in combination is
discussed further below in this disclosure.
[0079] FIG. 5 further depicts ODS assembly 220 providing fluid jet
assembly 280 next to ODS laser 222. Fluid jet assembly 280 provides
jets 282, which spray or blast fluids (in gaseous or liquid state)
onto the external surface of a rotating tubular beneath. Individual
jets 282 are user-selectable according to operational needs. By way
of example only, and without limitation, jets 282 may provide: (1)
a steam blast, a high pressure water blast (nominally at about
20,000 psi but not limited to any such pressure) or even a
fluid-borne abrasive blast for operations such as concrete removal
or hydroblasting operations, especially if tubular W has a severely
rusted or scaled outer surface; (2) a low pressure/high temperature
wash (nominally at 3,000 psi/300 deg F but not limited to any such
pressure or temperature), for general tubular cleaning operations,
including salt wash and rust inhibitor coating; and/or (3) a
compressed air or gas (such as nitrogen) blast, for drying or (in
the case of compressed air) removal of surface debris. Fluid jet
assembly 280 is described in greater detail below with reference to
FIGS. 13A and 13B.
[0080] FIG. 5 further depicts swivel brush assembly 260 next to
fluid jet assembly 280 on ODS assembly 220. Swivel brush assembly
260 provides swivel brush 262 (which may, per further disclosure
below, be a laminate of planar brushes) at the point of contact
with the external surface of a rotating tubular beneath. Swivel
brush assembly 260 further provides axle structure and conventional
power apparatus (such as hydraulic, electric or pneumatic motors)
to power-rotate the swivel brush 262 at user-selected speeds on
user-selected speed cycles. Swivel brush 262 may be of any suitable
size, profile or construction, per user selection, and this
disclosure is not limited in this regard. In the embodiments
illustrated on FIGS. 5 though 13B, swivel brush assembly 260
provides one swivel brush 262 having an oblate spheroid shape and
profile, although swivel brush 262 is not limited to a single brush
in other embodiments.
[0081] Swivel brush assembly 260 may further be rotated, per user
control and selection, about its vertical axis 261 as shown on FIG.
5. In this way, swivel brushes (including, on FIG. 5, swivel brush
262) may be caused to abrade the external surface of a tubular at
any user-selected angle relative to the axis of the tubular's
rotation. Changes may be made to the angle of abrasion on the fly.
This feature acknowledges that certain common oilfield tubulars,
such as drill pipe, are conventionally turned in a clockwise
direction as drilling into the earth progresses. This drilling
rotation causes helical scratching and scarring on the external
surface of the tubular. The ability to set and adjust the angle of
abrasion on swivel brush assembly 260 permits a more effective
cleaning of external surfaces that may have a helical scratch or
scar pattern.
[0082] Swivel brush assembly 260 on FIG. 5 is also disposed to
"tilt" or pivot so that swivel brush 262 follows the contour of a
rotating tubular beneath. Such "tilting" or pivoting is about a
substantially horizontal axis. Once the general height of swivel
brush assembly 260 above a tubular is set, "tilting" or pivoting
structure takes over to allow swivel brush assembly 260 to follow
the contour of the tubular, while spring structure on swivel brush
assembly 260 permits the swivel brush (or brushes) to maintain a
substantially constant contact on the surface of the tubular as
they pass over local variations in the tubular's diameter. Swivel
brush assembly 260 (including the "tilting"/pivoting feature and
the contouring feature) is described in greater detail below with
reference to FIGS. 12A through 12E.
[0083] FIG. 5 further depicts fixed brush train 240 next to swivel
brush assembly 260 on ODS assembly 220. Fixed brush train 240
comprises fixed brushes 242, each configured to rotate generally
about an axis parallel to the longitudinal axis of a tubular
beneath. In illustrated embodiments, fixed brushes 242 provide
circular ("wheel"-like) brushes at the point of contact with the
external surface of a rotating tubular beneath. Fixed brush train
240 further connects fixed brushes 242 together into a concatenated
train thereof via articulated brush joints 244. Embodiments of
articulated joints may include conventional u-joints or any other
structure suitable for connecting neighboring fixed brushes 242 in
articulated fashion. As shown on FIG. 5 (and subsequent Figures),
articulated brush joints 244 form an articulated drive shaft which
drives fixed brushes 242 to rotate in unison. Individual fixed
brushes 242 are thus permitted to move vertically
semi-independently of one another, while still all being driven in
unison by the articulated drive shaft formed by articulated brush
joints 244. Conventional power apparatus (such as hydraulic,
electric or pneumatic motors) at either or both ends of fixed brush
train 240 may power-rotate all of the fixed brushes in unison at
user-selected speeds on user-selected speed cycles. Fixed brushes
242 may be of any suitable number, size, profile or construction,
per user selection, and this disclosure is not limited in this
regard. In the embodiments illustrated on FIGS. 5 through 11, fixed
brushes 242 have a conventional cylindrical shape and profile.
Alternatively one or more fixed brushes 242 may have the oblate
spheroid ("football") shape described above with respect swivel
brush 262 elsewhere in this disclosure, or any user-selected
design. It will be also understood that this disclosure is not
limited to the number of fixed brushes 242 that may deployed on
fixed brush train 242. In the embodiments illustrated on FIGS. 5
though 13B, fixed brush train 240 provides five (5) fixed brushes
242 concatenated into an articulated train, separated by
articulated brush joints 244 and driven by two fixed brush motors
246. Nothing in this disclosure should be interpreted, however, to
limit fixed brush train 240 to any specific number of fixed brushes
242 and/or brush motors 246.
[0084] The concept of the term "fixed" on fixed brush train 240 (as
opposed to the term "swivel" on swivel brush assembly 260 described
above) refers to the fact that fixed brushes 242 on fixed brush
train 240 do not rotate about a vertical axis normal to the axis of
rotation of the tubular, and are further constrained from doing so
by the interconnection provided by articulated brush joints 244.
Fixed brushes 242 on fixed brush train 240 instead form a series of
abrading surfaces that rotate in unison on the external surface of
the rotating tubular beneath, where the angle of abrasion is
consistently normal to the longitudinal axis of the tubular.
[0085] FIG. 5 further illustrates that fixed brush train 240
suspends fixed brushes 242 from shock absorbers 248. In the
embodiments illustrated on FIGS. 5 to 13B, shock absorbers 248 are
spring mechanisms, and fixed brush train 240 provides one shock
absorber 248 for each fixed brush 242, although this disclosure is
not limited in this regard. It will be appreciated from FIG. 5 that
shock absorbers 248 further regulate the semi-independent vertical
movement provided to each fixed brush 242 by articulated brush
joints 244. The semi-independent vertical movement permits each
individual fixed brush 242 the independent freedom to follow the
local contour of the rotating tubular beneath as fixed brushes 242
pass over the tubular. Fixed brush motors 246 may nonetheless still
drive all fixed brushes 242 in unison. Shock absorbers 248 regulate
the independent vertical movement of each fixed brush 242,
requiring each fixed brushes 242 to maintain a substantially
constant contact on the surface of the tubular as it passes over
local variations in the tubular's diameter. Once the general height
of fixed brush train 240 above a tubular is set, shock absorbers
248 take over to allow each fixed brush 242 to follow the local
contour of the tubular as it passes by beneath. Fixed brush train
240 is described in greater detail below with reference to FIG.
11.
[0086] It should be noted that although the above disclosure has
referred, with respect to FIG. 5, to swivel brush assembly 260 and
fixed brush train 240, nothing in this disclosure should be
interpreted to limit swivel brush assembly 260 and fixed brush
train 240 to "brushes" in the sense of an abrasion tool with
bristles. Swivel brush 262 and fixed brushes 242 may be any
abrasive tool, including, but not limited to, wire brushes, flap
wheels, or abrasive stone or composite wheels.
[0087] FIG. 5 further illustrates top shroud 250 covering structure
above fixed brush train 240, swivel brush assembly 260 and fluid
jet assembly 280. Top shroud 250 protects against steam, dust,
debris, fluid overspray and other by-products of cleaning
operations below. Fluid jet assembly 280 is also advantageously
covered by a shroud (omitted on FIGS. 5 through 13B for clarity)
during operations in order to contain steam, fluid overspray,
debris, etc., caused by the operation of jets 282. A further
containment structure advantageously deployed about the entire
operation of ODS assembly 220 (again, omitted on FIGS. 5 though 13B
for clarity) restrains steam, fluid overspray, dust, debris, etc.
from contaminating the general surroundings, and further enables
recycling of recyclable fluids after jets 282 may have administered
them.
[0088] FIG. 6 is an end view of ODS assembly 220 as shown on FIG.
5. FIG. 6 illustrates features and aspects of ODS assembly 220 as
also shown on FIG. 5. FIG. 6 also illustrates features and aspects
of ODS assembly 220 that were omitted from FIG. 5 for clarity.
Fluid jet assembly 280, however, which was shown and described
above with reference to FIG. 5, is omitted for clarity from FIG. 6
so that features and aspects of swivel brush assembly 260 may be
better seen.
[0089] FIG. 6 depicts ODS assembly with top shroud 250, ODS laser
222 and laser field of view 223, as described above more fully with
reference to FIG. 5. Swivel brush assembly 260 may also be seen on
FIG. 6, including swivel brush 262, as also described above with
reference to FIG. 5. It will be seen on FIG. 6 more clearly that in
the ODS assembly embodiment of FIGS. 5 though 13B, swivel brush 262
has been user-selected to be in the shape and profile of an oblate
spheroid (although swivel brush 262 as disclosed herein is not
limited to such a shape and profile). The oblate spheroid shape may
be created by laminating together a plurality of planar circular
brushes of gradually varying diameter. The laminate may vary from
smallest diameter at the ends up to largest diameter in the
middle.
[0090] The oblate spheroid (or colloquially, "football") shape and
profile gives advantageous results when the angle of abrasion is
rotated towards normal to the longitudinal axis of the tubular
underneath. An optimal angle of attack may be found for abrading
the external surface of the tubular, where the oblate spheroid
shape maximizes contact and abrasive efficiency in view of the
local contour or diameter of the tubular immediately below swivel
brush 262. It will be appreciated that as the angle of abrading
attack approaches normal (90 degrees) to the longitudinal axis of
the tubular, the more the coned edge of the oblate spheroid shape
comes to bear on contours on the tubular, reducing the potential
brush pressure of swivel brush 262 on contours that increase the
local diameter of the tubular. Tilting structure on swivel brush
assembly 260, as described in more detail below, with reference to
FIGS. 12A through 12E, further mitigates against damage to the
tubular from swivel brush 262 contacting the external surface of
the tubular too hard (especially during tubular contour changes
that increase the tubular's local diameter). Tilting springs 264
(which are part of the tilting structure described in more detail
with reference to FIGS. 12A through 12E) may be seen on FIG. 6,
although partially hidden from view. Likewise swivel brush motor
263 (for power rotating swivel brush 262) may also be seen on FIG.
6, although again partially hidden from view. As noted above with
reference to FIG. 5, swivel brush motor 263 may be any conventional
power apparatus (such as a hydraulic, electric or pneumatic motor)
to power-rotate swivel brush 262 at user-selected speeds on
user-selected speed cycles.
[0091] It is useful to highlight some of the advantages provided by
the ability of swivel brush assembly 260 and fixed brush train 240
to adapt to local variations in contour and diameter of the tubular
beneath, as described above with reference to FIGS. 5 and 6.
Without such ability to adapt to local variations in contour and
diameter, "forcing" a rotating tubular under swivel brushes or
fixed brushes may place undesirable local stress on, for example,
the tubular, the ODS assembly, the structure for rotating the
tubular, and the structure for supporting the tubular while it
rotates. Over time, such undesirable stress may cause failures, or
at least premature wear and tear on the tubular and/or the
surrounding ODS and related structure. The ability of swivel brush
assembly 260 and fixed brush train 240 to adapt to local variations
in contour and diameter of the tubular thus mitigates against such
stresses, wear and tear, and/or failures.
[0092] A further advantage provided by the ability of swivel brush
assembly 260 and fixed brush train 240 to adapt to local variations
in contour and diameter of the tubular is that, in combination with
the ability to power-rotate swivel brush 262 and fixed brushes 242
in either direction, substantial improvements in the operational
life of brushes become available. The ability of swivel brush
assembly 260 and fixed brush train 240 to adapt to local variations
assists in keeping swivel brush 262 and fixed brushes 242 at (or
near) optimal brush pressure on the external surface of the
tubular, avoiding premature brush wear by "crushing" the brushes
and wear surfaces together. Further, the ability to periodically
reverse the direction of rotation of swivel brush 262 and fixed
brushes 242 during brushing operations (as may be required in ODS
cleaning operation cycles anyway) further serves to enhance brush
life by distributing brush wear more evenly.
[0093] FIG. 6 also illustrates exemplary propulsion structure for
ODS assembly 220. It will be appreciated that ODS assembly may be
propelled back and forth above the external surface of a stationary
but rotating tubular by any conventional method and/or structure.
The propulsion structure illustrated on FIG. 6 (and elsewhere in
FIGS. 5 though 13B) is by way of example only. FIG. 6 illustrates
ODS propulsion motors 291 deployed either side of ODS assembly 220.
Propulsion motors 291 may be any conventional power apparatus (such
as hydraulic, electric or pneumatic motors). Propulsion motors 291
rotate roller pinions 292, which in turn are engaged on geared
tracks 293. Note that on FIG. 6, geared tracks 293 may only be seen
in section. However, with momentary reference to FIG. 10, geared
tracks 293 may be seen in isometric view from above. FIG. 10 also
illustrates propulsion motors 291, although roller pinions 292 are
hidden from view on FIG. 10. It will be further appreciated from
FIGS. 6 and 10 that in the embodiments of ODS assembly 220
illustrated and described, an example of four (4) propulsion motors
291 propel ODS assembly 220 up and back along two (2) geared tracks
293. This disclosure is not limited in this regard, however, and
other embodiments may deploy other numbers of propulsion motors 291
in various configurations on various numbers of geared tracks 293,
per user design. Although not illustrated in detail on FIGS. 6 and
10, it will be understood that the travel of ODS assembly 220 is
further kept in a straight line parallel to the longitudinal axis
of a tubular beneath by bearings and related conventional structure
rolling on and between guide rails.
[0094] It will be also understood from FIGS. 6 and 10 that the
operation of propulsion motors 291 may be controlled closely to
allow a high level of corresponding control over the movement (and
speed thereof) of ODS assembly 220 above a rotating tubular.
Movement may be directed at any time, per user control, in a
forward or backward direction at user-selected speeds. Such control
over movement of ODS assembly 220 (and corresponding control over
ODS operations) may be combined with control over concurrent
internal tubular (MLI) operations and over rotation of the tubular
to give a highly controlled cleaning, inspection and/or data
analysis of the tubular at an enterprise level.
[0095] Reference is now made to FIGS. 7, 8 and 9 together. FIGS. 7,
8 and 9 illustrate substantially the same structure from different
views. FIG. 7 is an elevation view. FIGS. 8 and 9 are isometric
views from different angles.
[0096] FIGS. 7, 8 and 9 depict ODS assembly 220 in substantially
identical form to ODS assembly 220 as depicted on FIG. 5 (including
ODS laser 222, fluid jet assembly 280, swivel brush assembly 260,
fixed brush train 240 and top shroud 250), except that on FIGS. 7,
8 and 9 also depict rotating tubular W beneath ODS assembly 220 and
on which ODS assembly is operating. Tubular W includes at least one
joint J. FIGS. 7, 8 and 9 further depict fixed lasers 224 beneath
tubular W, whose fields of view scan the underside of tubular W as
it rotates. It will be understood that fixed lasers 224 are
stationary in user-selected fixed locations. Information gained
from scans of fixed lasers 224 is advantageously combined with
laser and optical camera information from ODS laser 222 as it moves
back and forth above tubular W and coincides with (co-locates with)
individual fixed lasers 224. The processing and use of laser and
optical camera information is discussed in greater detail
below.
[0097] All the disclosure above describing aspects and features of
ODS 220 with reference to FIGS. 5 and 6 applies equally to ODS 220
as depicted on FIGS. 7, 8 and 9. With particular reference to
swivel brush assembly 260, it will be seen on FIGS. 8 and 9 that
swivel brush assembly 260 has been rotated about vertical swivel
brush assembly axis 261 (shown on FIGS. 7 and 8) so that the plane
of rotation of swivel brush 262 is at an angle to the longitudinal
axis of tubular W. Referring back to disclosure associated with
FIGS. 5 and 6, such rotation allows swivel brush 262 to take up a
user-selected angle of attack when abrading the external surface of
rotating tubular W, to account for features such as, for example,
surface defects, helical wear patterns or discontinuities in
diameter (such as at pipe joints J, described in more detail
immediately below) on tubular W.
[0098] Pipe joints J illustrated on FIGS. 7, 8 an 9 illustrate
examples of the variations in local contour and diameter that ODS
assembly 220 may encounter during its travel back and forth while
operating on the external surface of tubular W. Other changes in
contour may be caused by, for example (and without limitation), bow
or sag in tubular W, local out-of-roundness in the diameter of
tubular W, or excessive wear, scarring or pitting at local points.
As noted in earlier disclosure with reference to FIGS. 5 and 6, ODS
assembly 220 is disposed to account for such local variations in
contour and diameter of tubular W via articulated brush joints 244
and shock absorbers 248 on fixed brush train 240 (described in more
detail below with reference to FIG. 11), and via tilting springs
264 and related structure on swivel brush assembly 260 (described
in more detail below with reference to FIGS. 12A through 12E).
[0099] Propulsion features and aspects illustrated on FIG. 10
(including propulsion motors 291 and geared tracks 293) have
already been described in association with earlier disclosure
making reference to FIG. 6. Other features and aspects of ODS
assembly 220 illustrated on FIG. 10 are substantially as also
described above with reference to FIGS. 5 through 9. Features
illustrated on FIG. 10 that are also illustrated on FIGS. 5 through
9, carry the same numeral throughout.
[0100] FIG. 11 illustrates additional features of fixed brush train
240 from FIGS. 5 through 10, with some enlargement and in
isolation, and with top shroud 250 removed. All earlier disclosure
regarding fixed brush train 240 with reference to FIGS. 5 through
10 applies equally to FIG. 11. It will be recalled from such
earlier disclosure that the concatenation of articulated brush
joints 244 forms an articulated drive shaft for fixed brushes 242
driven by fixed brush motors 246 at either or both ends thereof.
The articulated nature of the connections between fixed brushes 242
allows for semi-independent vertical movement of individual fixed
brushes 242 while still permitting fixed brush motors 246 to rotate
all fixed brushes 242 in unison. It will be further recalled that
shock absorbers 248 further regulate the semi-independent vertical
movement of individual fixed brushes 242 to enable fixed brushes
242 to maintain contact with the external surface of a tubular
below despite local variations in tubular contour or tubular
diameter.
[0101] FIG. 11 further illustrates fixed brush train lifts 243 for
setting fixed brush train 240 at a general height above a tubular,
according to user-selection. Fixed brush train lifts 243 may be any
conventional lifting mechanism, such as a hydraulically-actuated
cylinder, as illustrated on FIG. 11. It will be appreciated that
fixed brush train lifts 243 may be actuated to set a desired
elevation for fixed brushes 242 with respect, for example, to a
desired amount of brush pressure on a tubular having a nominal
diameter. Fixed brush train lifts 243 actuate against fixed brush
train lift springs 245 in order to provide spring resistance to the
actuation of train lifts 243. This spring resistance assists with
smooth and precise actuation, which in turn assists with smooth and
precise application of brush force by fixed brushes 242 on an
expected nominal diameter tubular. As noted above, variations in
local contour or diameter of the tubular may then be accounted for
by semi-independent vertical movement of individual fixed brushes
242 provided by articulated joints 244 and shock absorbers 248.
[0102] It will be further appreciated from FIG. 11 that fixed brush
lifts 243 are not limited to setting an elevation for fixed brushes
242 that is parallel to the longitudinal axis of the tubular.
Angles for fixed brush train 240 may be set such that fixed brushes
242 may apply greater pressure to the tubular at one end rather
than the other. It will also be understood that this disclosure is
not limited to deploying three (3) fixed brush train lifts 243 on
one installation, as illustrated on FIG. 11. The example of FIG. 11
is suitable for the exemplary fixed brush train 240 embodiment also
illustrated on FIG. 11 with five (5) fixed brushes 242. Other
embodiments of fixed brush train 240 may deploy more or fewer than
two (3) fixed brush train lifts 243, and this disclosure is not
limited in this regard.
[0103] FIGS. 12A through 12E should be viewed together. FIGS. 12A
through 12E illustrate additional features of swivel brush assembly
260 from FIGS. 5 through 10, with some enlargement and in
isolation, and with top shroud 250 removed. FIG. 12B is an
elevation view of swivel brush assembly 220 as shown on FIG. 12A.
FIG. 12C is a cutaway view of swivel brush assembly 220 also as
shown on FIG. 12A. All earlier disclosure regarding swivel brush
assembly 260 with reference to FIGS. 5 through 10 applies equally
to FIGS. 12A through 12E. It will be recalled from such earlier
disclosure (in particular with reference to FIGS. 5 and 6) that
swivel brush 262 may be set to rotate and abrade at an angle to the
longitudinal axis of a tubular beneath, per user selection via
rotation of swivel brush assembly 262 about vertical swivel brush
axis 261. It will also be recalled from earlier disclosure that
illustrated embodiments of swivel brush assembly 260 deploy swivel
brush 262 with an oblate spheroid (colloquially, "football") shape
and profile for advantageous performance over variations in the
tubular's local contour and diameter.
[0104] Earlier disclosure also described a "tilt" (or pivot)
feature on swivel brush assembly 260 to assist swivel brush 262 in
maintaining brush pressure while following the local contour of a
rotating tubular beneath. FIGS. 12A through 12E describe the
tilting feature in more detail. Referring to FIGS. 12A through 12E,
tilting is about swivel brush assembly tilting axis 265 on FIG.
12A, also represented by pivot 266 on FIGS. 12B and 12C. Such
tilting will thus be seen to be about a substantially horizontal
axis. Tilting is regulated by tilting springs 264, seen on FIG. 12B
to hold swivel brush 262 (and connected structure) in spring
equilibrium about pivot 266. In this way, once the general height
of swivel brush assembly 260 above a tubular is set, tilting
springs 264 allow swivel brush 262 to tilt about pivot 266 as it
encounters local variations in the contour or diameter of the
tubular beneath. During such tilting, responsive to compression
pressure from tilting springs 264, swivel brush 262 may still
maintain a substantially constant contact on the surface of the
tubular.
[0105] FIGS. 12A through 12E further illustrate swivel brush
assembly lift 267 for setting swivel brush assembly 260 at a
general height above a tubular, according to user-selection. Swivel
brush assembly lift 267 may be any conventional lifting mechanism,
such as a hydraulically-actuated cylinder, as illustrated on FIGS.
12A through 12B. It will be appreciated that swivel brush assembly
lift 267 may be actuated to set a desired elevation for swivel
brush 262 with respect, for example, to a desired amount of brush
pressure on a tubular with nominal diameter below. As shown best on
FIG. 12C, swivel brush assembly lift 267 actuates against swivel
brush assembly lift spring 268 in order to provide spring
resistance to the actuation of swivel brush assembly lift 267. This
spring resistance assists with smooth and precise actuation, which
in turn assists with smooth and precise application of brush force
by swivel brushes 262 on an expected nominal diameter tubular. As
noted above, variations in local contour or diameter of the tubular
may then be accounted for by tilting springs 264 holding swivel
brush 262 in spring equilibrium about pivot 266.
[0106] FIGS. 12A through 12E further illustrate structure to enable
controlled rotation of swivel brush 262 about vertical swivel brush
axis 261, further to more general disclosure above regarding such
rotation. Swivel rotation motor 269 on FIGS. 12A through 12E
operates swivel rotation gears 270 to rotate swivel brush 262 about
axis 261. Swivel rotation motor 269 may be any conventional power
apparatus (such as a hydraulic, electric or pneumatic motor) to
power-rotate swivel brush 262 about axis 261 per user control.
[0107] FIGS. 12D and 12E illustrate, in stroboscope or
"freeze-frame" style, the various motions available to swivel brush
assembly 260 during normal operation. FIGS. 12D and 12E illustrate
(with further reference to FIGS. 12A through 12C): (1) actuation of
swivel brush assembly lift 267 to set a general height for swivel
brush 262, (2) rotation of swivel brush 262 about vertical swivel
axis 261, and (3) tilting of swivel brush 262 about pivot 266.
[0108] FIGS. 13A and 13B should be viewed together. FIGS. 13A and
13B illustrate additional features of fluid jet assembly 280 from
FIGS. 5 through 10, with some enlargement and in isolation, and
with top shroud 250 removed. FIG. 13B is an elevation view of fluid
jet assembly 280 as shown on FIG. 13A. All earlier disclosure
regarding fluid jet assembly 280 with reference to FIGS. 5 through
10 applies equally to FIGS. 13A and 13B. It will be recalled from
such earlier disclosure (in particular with reference to FIG. 5)
that fluid jet assembly 280 provides jets 282, which spray or blast
fluids (in gaseous or liquid state) onto the external surface of a
rotating tubular beneath. Individual jets 282 are user-selectable
according to operational needs.
[0109] FIGS. 13A and 13B further illustrate fluid jet assembly lift
286 for setting fluid jet assembly 280 at a general user-desired
height above a tubular. Electronic control systems then, on the
fly, make small changes in the elevation of jets 282 above the
external surface of the tubular by actuating jet height control
cylinders 284. In this way, a user-selected distance between jets
282 and the external surface of the tubular may be maintained,
notwithstanding local variations in contour or diameter of the
tubular that jets 282 may encounter during their travel along the
length of the tubular.
[0110] FIGS. 14 through 19G illustrate ODS buggy 320, which is an
alternative embodiment to the buggy aspects of ODS assemblies
previously disclosed herein, including ODS assembly 201 described
generally above with reference to FIG. 1, and ODS assembly 220
described generally above with reference to FIG. 5. FIG. 14 is an
isometric view of ODS buggy 320. It will be appreciated ODS 320
includes many of the buggy aspects disclosed earlier with respect
to ODS assembly 220 (see FIG. 5). Variations and improvements of
ODS buggy 320 over corresponding or prior-generation features of
ODS assembly 220 are described below with reference to FIGS. 14 to
19G. The disclosure of ODS buggy 320 below with reference to FIGS.
14 to 19G should be read in conjunction with the disclosure above
of ODS assembly 220 with reference to FIGS. 5 through 13B. Where
not inconsistent, features of ODS buggy 320 that are not disclosed
below with reference to FIGS. 14 to 19G are incorporated into buggy
320 from corresponding, or functionally equivalent, features of ODS
assembly 220 disclosed on, and with reference to, FIGS. 5 through
13B.
[0111] It will be appreciated with reference to FIGS. 14 though 19G
that ODS buggy is illustrated with many of its conventional
operational features omitted for clarity. For example, covers and
parts of housings are omitted to assist in illustration of the
internal features of various assemblies and mechanisms. Similarly,
other conventional items and features such as hydraulics,
electrical apparatus, supply hoses, safety guards, etc., etc., are
omitted on FIGS. 14 through 19 for clarity.
[0112] FIG. 14 illustrates ODS buggy 320 with four (4) separate
tool assemblies: camera assembly 390, fluid jet assembly 380, brush
train 340 and swivel brush assembly 360. Each tool assembly is
deployed in its own tool "chamber". Each tool assembly operates
(and is controlled) within its own chamber, separately and
independently from the other tool assemblies, and each tool
assembly's elevation is adjustable within the chamber independently
from the elevation of other tool assemblies in other chambers. It
will be appreciated that the embodiment of ODS buggy 320 disclosed
on FIGS. 14 through 19G provides an exemplary number of four (4)
tool "chambers" in an arrangement as illustrated. For the avoidance
of doubt, it will be appreciated that these chambers in their
relative arrangement are exemplary only, and nothing in this
disclosure should be construed to limit ODS buggy 320 to any number
of chambers, to the chambers containing any type of tools or
equipment, or to the tools or equipment in the chambers being in
any sequence.
[0113] As noted above with reference to FIGS. 5-10, the disclosed
ODS laser 222 generates samples from which surface contour data may
be mapped regarding the tubular. As further noted above, one of the
uses to which the DAS puts this surface contour data is to
regulate, independently and in real time "on the fly", the height
of each of the tool chambers on ODS buggy 320 above the external
surface of the tubular as the tools or equipment in each chamber
operate on the tubular's surface. In this way, as the laser
recognizes substantial changes in the tubular's contour (such as,
for example, at a pipe joint), the DAS regulates the height of the
tools or equipment in each chamber to an optimum preselected height
above tubular's external surface as the contour change in the
tubular passes beneath.
[0114] Viewing the orientation of ODS buggy 320 as depicted on FIG.
14, the right-hand end may be considered a "leading" end, and the
left-hand end a "trailing" end. This means that if ODS buggy 320 is
considered on FIG. 14 to be depicted in a "rest" position just
before commencing work on a tubular, the right-hand "leading" end
will lead movement of the buggy and encounter the tubular first,
and the left-hand "trailing end" will bring up the rear.
[0115] In such an orientation, it will be seen from FIG. 14 that
brush train 340 on ODS buggy 320 immediately follows fluid jet
assembly 380, and that swivel brush assembly 360 follows brush
train 340. By comparison with ODS assembly 220 on FIG. 5, swivel
brush assembly 360 and brush train 340 on ODS buggy 320 have
switched positions. Similarly, it will be seen from FIG. 14 that
camera assembly 390 on ODS buggy 320 now immediately leads fluid
jet assembly 380. By comparison with ODS assembly 220 on FIG. 5,
ODS assembly 220 does not have a separately disclosed camera
assembly.
[0116] The advantage sought in switching the respective positions
of swivel brush assembly 360 and brush train 340 on ODS buggy 320
(as opposed to their corresponding relative position on ODS
assembly 220) is related to cleaning operations when ODS buggy 320
is brought back over a tubular in "reverse", i.e. swivel brush
assembly 360 leads the movement of ODS buggy 320. In such reverse
operations, it is advantageous to rinse off the tubular after
cleaning operations in the "forward" direction. This rinsing
operation is facilitated by having swivel brush assembly 360 lead
brush train 340 (as happens when ODS buggy 320 travels in
"reverse"). Brushing residue is likely to be left on the tubular
after cleaning operations in the "forward" direction (in which the
brushing operations bring up the rear). When ODS buggy 320 is
placed in "reverse", a light brushing operation may be prescribed,
followed by a low pressure rinse provided by fluid jet assembly 380
(bringing up the rear when ODS buggy 320 is in "reverse"). This
rinse assists removal of brushing residue from the tubular.
[0117] It will be further appreciated by comparison between FIG. 5
and FIG. 14 (and other views of ODS 320) that ODS 320 is not
illustrated with a laser assembly. Refer and compare to disclosure
above associated with FIG. 5 for discussion of ODS laser 222 on ODS
assembly 220. It will be understood that ODS buggy 320 provides a
laser assembly, which has been omitted on FIG. 14 (and subsequent
Figures) for clarity. The discussion throughout this disclosure of
ODS laser 222 and its functions and capabilities (including,
without limitation, all the disclosure herein regarding acquisition
of contouring data) apply equally to ODS buggy 320. The primary
difference is that ODS laser 222 on ODS 220 on FIG. 5 was described
above as a combination laser and optical camera. On ODS buggy 320
illustrated on FIG. 14 (and subsequent Figures), optical camera is
deployed in its own separate, independently controllable tool
"chamber". See camera assembly 390 on FIG. 14.
[0118] As noted above, ODS buggy 320 on FIG. 14 provides camera
assembly 390, fluid jet assembly 380, brush train 340 and swivel
brush assembly 360 each in its own separate,
independently-controllable tool "chamber". One
independently-controllable feature in each tool chamber is the
elevation that tools in the chamber may be set above the tubular
below. It will be seen on FIG. 14 that each tool chamber provides
its own elevation plate whose specific elevation is controlled by
extension and retraction of corresponding elevation plate pistons.
In more detail on FIG. 14, the elevation of camera elevation plate
391 is set by actuation of camera elevation pistons 392, the
elevation of fluid jet elevation plate 381 is set by actuation of
fluid jet elevation pistons 382, the elevation of brush train
elevation plate 341 is set by actuation of brush train elevation
pistons 342, and the elevation of swivel brush elevation plate 361
is set by actuation of swivel brush elevation pistons 362.
[0119] Independent control over the elevation of each tool
chamber's tools above the tubular facilitates precise cleaning and
inspection operations, as well as other advantages. Actuation of
camera elevation pistons 392 allows precise control over focal
distance between the optical cameras on camera assembly 390 and the
external surface of the tubular below. Actuation of fluid jet
elevation pistons 382 allows precise control over spraying distance
between the fluid nozzles on fluid jet assembly 380 and the
external surface of the tubular below. Actuation of brush train
elevation pistons 342 allows precise control over contact pressure
of the brushes in brush train 340 on the external surface of the
tubular below. Actuation of swivel brush elevation pistons 362
allows precise control over contact pressure between the swivel
brush on swivel brush assembly 360 and the external surface of the
tubular below.
[0120] Further, as described above in detail with reference to FIG.
5 for ODS assembly 220, and below in detail with reference to the
disclosed Data Acquisition System ("DAS"), the independent control
of the elevation of tools in tool chambers on ODS buggy 320 may
also be responsive in real time to "contour data" and other data
acquired regarding the external surface and diameter of the
tubular. As described in such other disclosure, the laser assembly
and/or the optical camera are configured, in preferred embodiments,
to acquire, process and generate such "contour data" and other data
regarding the external surface and diameter of the tubular.
[0121] With further reference to FIG. 14, therefore, it will be
appreciated that, responsive to contour data and related data
acquired in real time as ODS buggy 320 travels along the tubular,
adjustments to the elevations of camera assembly 390, fluid jet
assembly 380, brush train 340 and swivel jet assembly 360 may be
made on the fly to suit changes in contour or diameter in the
tubular as they arise and are detected. Such adjustments may be
made, responsive to contour data and related data, by extending or
retracting pistons in each tool chamber independently as
required.
[0122] FIGS. 15A through 15D are elevation views of ODS buggy 320
as shown on FIGS. 14 and 15A. As described earlier, FIG. 15A
depicts the "trailing" end of ODS buggy 320, in which swivel brush
assembly 360 is in the foreground, with brush train assembly 340
(partially hidden) immediately behind swivel brush assembly 360,
and portions of camera assembly 390 visible behind brush train
assembly 340. FIG. 15B depicts the "leading" end of ODS buggy 320,
in which camera assembly 390 is in the foreground, with brush train
340 visible behind camera assembly 390, and portions of swivel
brush assembly 360 visible further behind brush train assembly 340.
Note that fluid jet assembly 380 is substantially hidden from view
in FIGS. 15A and 15B.
[0123] FIGS. 15C and 15D illustrate the "front" and "back" of ODS
buggy 320, respectively, as viewed from the orientation of FIG. 14.
FIGS. 15C and 15D show camera assembly 390, fluid jet assembly 380,
brush train 340 and swivel jet assembly 360 in their respective
tool chambers. FIGS. 15C and 15D also point out the following
features (to be discussed in greater detail below with reference to
additional figures): (1) cameras 393 and lights 394 on camera
assembly 390; (2) lower and upper brush train springs 344L and
344U, and brush wheels 343 on brush train 340; (3) camera elevation
plate 391 and camera elevation pistons 392; (4) fluid jet elevation
plate 381 and fluid jet elevation pistons 382; (5) brush train
elevation plate 341 and brush train elevation pistons 342; and (6)
swivel brush elevation plate 361, and swivel brush elevation
pistons 362.
[0124] FIGS. 16A through 16E describe brush train 240 in greater
detail. FIG. 16A isolates brush train 340 from the elevation view
of FIG. 15C, and shows the same parts and features as FIG. 15C. It
will be understood from FIG. 16A that brush wheels 343 are each
suspended independently from brush train elevation plate 341 by
upper and lower brush train springs 344U and 344L. Although not
visible on FIG. 16A, there is a small gap between neighboring brush
wheels 343, indicated on FIG. 16A (and subsequent Figures) by gaps
G. In preferred embodiments gaps G are about 1/16'' wide, although
brush train 340 is not limited in this regard.
[0125] FIG. 16B is an isometric view of the section shown on FIG.
16A. The section of FIG. 16B is taken at one of the gaps G. In
addition to structure already described with respect to previous
FIGURES, FIG. 16B shows brush train drive shaft 345. As will be
described with reference to other Figures, a single brush train
drive shaft 345 drives all brush wheels 343 via drive belts (such
drive belts hidden from view on FIG. 16B). This drive belt linkage
permits brush wheels 343 to be rotationally independent from one
another, and all independently suspended from brush train elevation
plate 341 by upper and lower brush train springs 344U and 344L. The
independently-suspended nature of each of brush wheels 343 allows
each brush wheel 343, upon contact with a rotating tubular below,
to self-adjust its own elevation by small amounts in response to
small changes in the profile, diameter or contour of the tubular,
all without affecting the elevation of other brush wheels 343. This
ability to make of brush wheels to make small, independent
elevation changes is in addition to any elevation adjustments made
to the entire brush train 340 by raising or lowering brush train
elevation plate 341 in response to contour data and other
information from the DAS (refer to disclosure associated with FIG.
14 above). The combination of (1) small changes to brush wheel 343
elevation via independent suspension, (2) changes in elevation of
the entire brush train 340 via adjustment of brush train elevation
plate 341, and (3) the fact that brush wheels 343 are each
suspended from two independently-acting brush train springs 344U
and 344L, enables a precise contact pressure to be prescribed and
maintained by brush wheels 343 on the external surface of a
rotating tubular below. In preferred embodiments, this brush
pressure is about 50 lbs of pressure, although this disclosure is
not limited in this regard. The prescribed precise brush pressure
may be maintained despite changes encountered in the profile,
contour or diameter of the tubular as brush train 340 moves over
the tubular. This precise brush pressure in turn allows a more
effective clean, and prolongs the life of brush wheels 343.
[0126] With further reference to FIG. 16B, the positioning of brush
train drive shaft 345 away from the individual brush wheels 343
also makes brush train 340 easier to maintain. When brush wheels
343 require replacement, they may be removed independently from
brush train 340 (as opposed to, for example, threading them off a
common axle shared with other brush wheels).
[0127] FIGS. 16C, 16D and 16E illustrate aspects of brush train 340
close-up in isolation, in which FIGS. 16C and 16D are isolated from
FIGS. 15C and 15D respectively, and FIG. 16E is an isometric view
as shown generally on FIG. 16D. In addition to features and parts
of brush train 340 already described, FIGS. 16C, 16D and 16E show
brush train motor 346, brush train drive belt 347, and brush wheel
drive belts 348. FIGS. 16C, 16D and 16E and the drive linkage
illustrated thereon are self-explanatory, consistent with
disclosure above.
[0128] FIGS. 17A, 17B and 17C are isolated views of swivel brush
assembly 360, in which FIGS. 17A and 17B are isolated from FIGS.
15C and 15A respectively, and FIG. 17C is an isometric view of FIG.
17A. FIGS. 17A, 17B and 17C, in combination, illustrate swivel
brush elevation plate 361, swivel brush elevation piston 362,
swivel brush motor 363, tilting springs 364, swivel brush 365,
pivot 366, swivel brush rotation motor 367 and swivel rotation
gears 368. By comparison to the disclosure above of swivel brush
assembly 260 on ODS assembly, with reference to FIGS. 6, 12A, 12B
and 12C, it will be appreciated that swivel brush assembly 360 on
ODS buggy 320 is structurally and functionally similar to swivel
brush assembly 260 on ODS assembly 220. The disclosure above
regarding swivel brush assembly 260 on ODS assembly 220 is
incorporated herein and applied to swivel brush assembly 360 on ODS
buggy 320, where not inconsistent. One difference has been
described above with reference to FIG. 14, in that adjustments to
the elevation of swivel brush assembly 360 on ODS buggy 320 are
made via extension and retraction of swivel brush elevation pistons
362 acting on swivel brush elevation plate 361. As also noted above
with reference to FIG. 14, in preferred embodiments, such elevation
adjustments of swivel brush assembly 360 are made responsive to
profile, contour, diameter and other data regarding the external
surface of the tubular on which swivel brush assembly 360 is
acting, as measured by the DAS.
[0129] FIGS. 18A and 18B are isolated views of fluid jet assembly
380, in which FIGS. 18A and 18B are isolated from FIGS. 15C and 15B
respectively. FIG. 18C is an isometric view of the section shown on
FIG. 18A. FIGS. 18D and 18E show aspects of fluid jet assembly 380
close-up in isolation, in which FIG. 18D is an enlargement of the
isometric view of FIG. 18C, and FIG. 18E is an isometric view shown
generally on FIG. 18D.
[0130] FIG. 18A through 18E, in combination, illustrate fluid jet
elevation plate 381, fluid jet pistons 382, fluid jet manifold 383,
fluid inlet 384, fluid jet bracket 385, fluid jet piston bracket
386, fluid jet screw drive 387, fluid jet openings 388 and fluid
jet pivot 389. The operation of fluid jet assembly 380, as
illustrated, is to deliver selected cleaning (and other) fluids
from a prescribed distance and angle onto the external surface of a
tubular below as the tubular rotates. It will be appreciated that
fluid jet manifold 383 is made of suitable conventional
corrosion-resistant material, such as stainless steel, and provides
fluid inlet 384 to receive fluids selectably delivered by
conventional apparatus. Fluids pass within fluid jet manifold 383
from fluid inlet 384 through to exit via fluid jet openings 388.
Fluid jet openings 388 are shaped to encourage a conical-shaped
delivery of fluids, in order to maximize coverage on the external
surface of a tubular below. As shown on FIG. 18E, fluid jet
openings 388 are also advantageously in offset formation, in order
to minimize interference between the conical-shaped delivery from
each fluid jet opening 388. Preferred embodiments of fluid jet
manifold 383 provide eight (8) fluid jet openings 388 of about
1/2'' diameter in fluid jet manifold 383, although this disclosure
is not limited in these regards.
[0131] It will be further seen from FIG. 18B, for example, that
fluid jet manifold 383 is anchored to the underside of fluid jet
elevation plate 381 via fluid jet bracket 385. Fluid jet manifold
383 is positioned to be above the centerline of a tubular beneath,
with its pattern of fluid openings oriented longitudinally with
respect to such a tubular. It will be seen from FIGS. 18D and 18E,
for example, that fluid jet 383 manifold is further attached to
fluid jet bracket 385 so that it may tilt about fluid jet pivot
389. In this way, fluid jet openings 388 may dispense fluid
laterally across a tubular rotating underneath as ODS buggy 320
travels along the length of the tubular.
[0132] FIGS. 18B through 18E show fluid jet screw drive 387
interposed between fluid jet manifold 383 and fluid jet screw
bracket 386. Fluid jet screw bracket 386 is also anchored to the
underside of fluid jet elevation plate 381. In preferred
embodiments, fluid jet screw drive 387 is electrically actuated (as
opposed to a hydraulically actuated piston, for example), although
this disclosure is not limited in these regards. It will be
understood that by actuation of fluid jet screw drive 387, fluid
jet manifold 383 may be tilted back and forth about fluid jet pivot
389. Fluid jet manifold 383 may thus dispense fluids laterally
across a tubular on-the-fly according to selectable control of
fluid jet screw drive 387. In preferred embodiments, fluid jet
screw drive 387 is configured to control fluid jet manifold 303 to
dispense fluids in a sweep of about 30 degrees either side of
vertical, although this disclosure is not limited in this
regard.
[0133] It will be therefore appreciated that in combination with
control over the height from which fluid jet manifold 383 dispenses
fluid on-the-fly (via fluid jet elevation plate 381 adjusted by
fluid jet elevation pistons 382 controlled by the DAS, per earlier
disclosure), a user may also control the extent and speed of the
lateral sweep of the fluid jets on-the-fly. This gives excellent
control over fluid cleaning operations.
[0134] Although not illustrated on FIGS. 18A through 18E,
alternative embodiments of fluid jet assembly may also provide
structure to allow fluid jet manifold 383 to slide laterally in a
controlled fashion. Other alternative embodiments may allow fluid
jet assembly to rotate horizontally. Slotted or shaped bolt holes
in the anchoring of fluid jet bracket 385 to fluid jet elevation
plate 381 could enable such alternative embodiments. Alternatively,
additional fluid jet drive screws (or hydraulic pistons), anchored
to fluid jet elevation plate 381 and attached to fluid jet manifold
383 or fluid jet bracket 385 via conventional linkage, could also
enable such alternative embodiments.
[0135] FIG. 19A is an isolated view of camera assembly 390, in
which FIG. 19A is isolated from FIG. 15C. FIG. 19B is an isometric
view of the section shown on FIG. 19A. FIGS. 19C and 19D show
aspects of camera assembly in close-up isolation, in which FIG. 19C
is shown generally on FIG. 19B, and in which FIG. 19D is the same
as FIG. 19C except with sliding door 396 illustrated as open. FIG.
19E is a plan view of FIG. 19D. FIGS. 19F and 19G are further
isometric views of aspects of camera assembly 390 in close-up
isolation, in which FIG. 19F is shown generally on FIG. 19E, and
FIG. 19G is the same as FIG. 19F except with containment cover 395
in place.
[0136] FIGS. 19A through 19G illustrate, in combination, camera
elevation plate 391, camera elevation pistons 392, cameras 393,
lights 394, containment cover 395, sliding door 396, door actuator
397, and camera actuator holes 398. Cameras 393 take samples, in
the form of pictures of the external surface of a tubular, by
shooting high-speed pictures through an opening in camera elevation
plate 391. Door actuator 397 operates on sliding door 396 over the
opening in camera elevation plate 391. It will be understood that
cameras 393 and lights 394 may need to be protected during heavy
cleaning operations. In such operations, door actuator 397 closes
sliding door 396. When camera sampling is to be done, door actuator
397 opens sliding door 396 to allow cameras 393 to "see" the
rotating tubular below through the opening in camera elevation
plate 391.
[0137] It will be appreciated with reference to FIGS. 19A through
19G that support structure and actuation linkage for cameras 393
and lights 394 has been omitted for clarity. Cameras 393 are high
speed optical cameras, per discussion above with reference to FIG.
5, and below with reference to the DAS. Lights 394 provide a highly
focused beam in the shape of a fan, advantageously overlapping the
diameter of the tubular below. The function of cameras 393 is
generally to take samples in the form of calibrated pictures of the
tubular below, in order to measure the local diameter of the
tubular at the tubular "slice" of the sample. This function is
discussed in detail below in the sections disclosing aspects and
features of the DAS.
[0138] Lights 394 on camera assembly 390 are provided to assist
with precise picture taking by cameras 393. In preferred
embodiments, camera assembly 390 provides four (4) cameras and one
set of lights, although this disclosure is not limited in these
regards. Cameras 393 are user selectable to be independently active
or "off" at any time. The embodiment of camera assembly 390
illustrated on FIGS. 19A through 19G provides for small manual
independent adjustment of cameras 393 and lights 394 via
conventional actuators and linkage omitted for clarity. Such small
adjustment includes tilting, pivoting, sliding, rotating, raising
and lowering of cameras 393 and lights 394 to get the optimum
exposure for the pictures taken by cameras 393. Other embodiments
not illustrated, may include mechanical, remote adjustment of
cameras 393 and lights 394 for optimum picture exposure. It should
be noted that operationally, cameras 393 and lights 394 are
protected by containment cover 395, as illustrated on FIG. 19G
(although also omitted for clarity on other Figures). As shown on
FIG. 19G, containment cover 395 provides actuator holes 398 for
actuators and other linkage to access cameras 393 and lights 394,
in order to enable the small adjustments described immediately
above. It will be appreciated that large adjustments of the
distance between the cameras 393 and the tubular below is provided
on-the-fly by camera pistons 392 raising and lowering camera
elevation plate 391, responsive to tubular contour, diameter and
other data regarding the tubular acquired in real time by the DAS
(as described above with reference to FIG. 14).
[0139] Although not illustrated, the scope of this disclosure
contemplates an embodiment with two independent sets of cameras
sampling the same tubular "slice". In such an embodiment, 3-D data
regarding the tubular's diameter at the "slice" could be acquired
and processed.
[0140] The electronic control systems described above (for
maintaining distance between jets 282 and external surface of
tubular) utilize real time information regarding the tubular
collected by ODS laser 222. Referring back to earlier disclosure
associated with FIGS. 5 through 9, it will be recalled that as ODS
assembly 220 travels back and forth above a rotating tubular, ODS
laser 222 scans the external surface of the tubular. It will be
further recalled that in currently preferred embodiments, ODS laser
222 includes both a laser and an optical camera to scan the
external surface of the tubular. Laser scans by ODS laser 222 may
identify contours and external surface anomalies on the tubular of
all types in real time, including surface defects (such as, for
example, scratches, gouges, divots, pitting, and laminations), as
well as larger variations in tubular diameter such as pipe joints.
Such laser scan data regarding the external surface of the tubular
is also referred to in this disclosure as "contouring data" or
"contour data", and is derived from laser data but not optical
camera data. As will be described in greater detail below, contour
data derived solely from laser scans is used for operational
cleaning purposes (including for adjusting the height of fluid jet
assembly 280, swivel brush assembly 260 and fixed brush train 240
above the tubular's surface) as well as for inspection purposes. On
the other hand, optical camera data is used in combination with
laser data from ODS laser 222, and further in combination with data
from fixed lasers 224 beneath the tubular, in order to derive
dimensional data regarding the outside diameter ("OD") of the
tubular for inspection purposes. The advantages of optical camera
data, and the use thereof in deriving OD dimensional data, are also
discussed in more detail below.
[0141] Returning now to further consideration of contour data
derived from laser scans (only) by ODS laser 222, it will be
appreciated that substantial information regarding the contours of
a tubular may be obtained. Given knowledge (1) of the absolute
position of ODS laser 222 on a tubular at a particular moment in
time, and (2) of the rotational speed of the tubular at such moment
in time, ODS laser 222 may "map" the contours over the entire
external surface of the tubular. Knowledge of the absolute position
of ODS laser 222 may be obtained via methods that include (1)
knowing when ODS laser 222 first encounters the tubular as it
begins its first pass over the tubular, and (2) establishing
relative position to the "first encounter" from sensors, such as
optical sensors, deployed in the propulsions system (such as in, or
attached to, roller pinions 292 and/or geared tracks 293 as
illustrated and described above with reference to FIGS. 6 and 10).
It will be appreciated that such optical sensors may conventionally
translate measured speed and direction of travel of ODS assembly
220 into a position relative to the "first encounter".
[0142] Further consideration will now be given to data regarding
the OD of the tubular derived for inspection purposes from both
laser and optical camera data from ODS laser 222 (on FIGS. 5
through 10), in combination with laser data from fixed lasers 224
(on FIGS. 7 through 10). Such laser and optical camera data may be
combined to obtain real time "caliper"-type measurements of the
tubular at intervals along the tubular's length. Combined and
coordinated laser data and optical camera data from ODS laser 222
and fixed lasers 224 may enable dimensional irregularities or
anomalies in the tubular (such as sag, wobble or bow in the
tubular, or areas where the tubular is out-of-round) to be
identified and location-tagged along the tubular's length. This
"caliper"-type data may be used in real time to correct (via
adjustment and compensation): (1) overall dimensional data
regarding the OD of the tubular and any point along its length, as
well as (2) contour data obtained from laser data from ODS laser
222 as described in the immediately preceding paragraphs.
[0143] It is useful to highlight some of the aspects and advantages
in combining optical camera data with laser data in obtaining
information about the OD of the tubular, or "pipe" as used in the
following optical camera discussion. Determining the outside
diameter of a drill pipe optically is a challenge. As an object
moves closer or farther from a fixed zoom lens, it grows and
shrinks respectively. For measurement purposes on pipes of varying
diameters and centerlines, simply taking a picture and determining
the size of a pipe is not practical. However, the combined use of
an optical lens with a range finding laser adds the axis of
reference necessary to account for the varying centerline distances
and calculation of diameters possible.
[0144] In order to achieve a pipe diameter measurement, an image is
taken of the pipe using a line scan camera. The line scan camera
captures a slice of the pipe. This slice contains a one dimensional
array of information, essentially containing `material` and
`non-material`. The `material` being pipe, the "non-material"
representing anything outside the pipe. The differentiation between
the two is made using threshold values on the grayscale information
contained in the array. For instance, given a grayscale color
spectrum of 8 values, non-material may be any value below 3, while
material would show 4 through 8. With the combination of a light
source and a filter on the lens, only the light reflecting off pipe
material will be allowed into the camera. This will allow for a
fine resolution between "material and "non-material" and for fast
image processing and information output.
[0145] Now, a calculation of the number of "material" pixels in the
array divided by (material+non-material) pixels will give the
percentage material in any particular slice of information. Without
a frame of reference, this number is useless. However, the
combination of this percentage with a range finding laser at each
point a slice is taken allows for accurate calculation of length
based on percentage of material.
[0146] As an example, if at 1 inch away from the lens, an image
contains 50% material and the known size of the pixel array at 1
inch away is 1 inch, the object size may be calculated to be 0.5
inches. Taking this one step further, if at 10 inches away from the
lens the pixel array is known to contain 10 inches of information,
an image containing 5% material pixels will also be 0.5 inches.
Now, using this concept in combination with a range finding laser
and careful calibrations of the pixel array size to distance ratio,
an image, or slice of a pipe, can be used to very accurately
calculate diameter based on simply the data contained in a slice
and the reference distance the lens is from the pipe, which is
provided by the range finding laser.
[0147] Using a high scan rate and high resolution camera, very
accurate calculations can be made as to the diameter of the pipe.
Combining multiple line scan cameras will multiply the accuracy.
This system will traverse the length of the pipe, taking slices of
information quickly and accurately and allow for a novel way to
determine pipe diameter information.
[0148] Returning now to consideration of contour data, it will thus
be appreciated that contour data regarding the tubular acquired by
laser scans by ODS laser 222 (and preferably corrected with
"caliper"-type data) may then be fed in real time to control
systems on other operating systems on ODS assembly 220. Such real
time contour data may then be used to make corresponding
adjustments to the operating systems. For example, and without
limitation; such real time contour data may be used to make
corresponding adjustments that include: (1) adjusting the distance
between jets 282 and the external surface of the tubular in order
to maintain a constant distance therebetween; (2) adjusting the
angle of attack of swivel brush 262 in order to obtain optimum
abrasion; (3) adjusting the general elevation of swivel brush
assembly 260 or fixed brush train 240 in order to accommodate a
large tubular diameter change such as a pipe joint; (4) adjusting
the speed or direction of rotation of swivel brush 262 or fixed
brushes 242 according to upcoming conditions; or (5) adjusting the
speed or direction of travel of ODS assembly 220 according to
upcoming conditions.
[0149] It is useful to highlight some of the advantages of
maintaining a constant distance between jets 282 and the external
surface of the tubular, notwithstanding local contour or diameter
variations in the tubular. If jets 282 are too close to the
tubular's external surface, even momentarily, then damage to the
tubular's surface (such as steel erosion and cutting) may occur,
especially during high pressure fluid blast cycles. Such damage
occurs substantially immediately if the right conditions exist. On
the other hand, if jets 282 are too far away, again even
momentarily, then fluid jet assembly 280's operations (such as
cleaning, rinsing, coating, drying, etc.) may be less than fully
effective, and possibly compromised. As distance between jets 282
and the tubular's surface increases, operating effectiveness
decreases exponentially.
[0150] It is therefore highly advantageous to maintain an optimal
distance between jets 282 and the external surface of the tubular,
so that the operating effectiveness of jets 282 is maximized
without causing damage to the tubular's surface. The electronic
control system using data that includes real time contour data
obtained by laser data from ODS laser 222, as described above, is
useful to maintain that optimal distance.
[0151] It will be further appreciated that the ODS contour data
acquisition and processing system, and related electronic control
systems, described in the preceding paragraphs, may also be
combined and coordinated in real time with concurrent data
regarding the internal surface and diameter of the tubular.
Exemplary internal data acquisition structure and technology is
described in U.S. Provisional Application Ser. No. 61/707,780 (to
which provisional application this application claims priority) and
commonly-assigned, co-pending U.S. patent application Ser. No.
13/832,340 with reference to a Multi-Lance Injector ("MLI") system
for internal inspection and cleaning of tubulars. Such concurrent
internal data may supplement ODS contour data to provide additional
information regarding the tubular in real time, including, for
example, tubular wall thickness information and further analysis of
points of interest such as apparent cracks, etc.
[0152] It may be advantageous in ODS operations to acquire ODS
contour data in a first pass over the tubular, and then return (or
go back on a second pass) for more information. Further data
regarding the OD of the tubular may be gathered in order to prepare
a summary thereof. Additionally further investigation may be
conducted on points of interest (such as cracks, pitting, gouges,
etc.) identified and location-tagged on a previous pass. Second-
(or subsequent-) pass investigations may call for the ODS to pass
by points of interest more slowly, or at a different tubular
rotation speed, than might be optimal for cleaning operations on an
previous pass.
[0153] Further advantages may also be gained by combining and
coordinating data acquisition from both the internal and external
surfaces of the tubular. The following disclosure discusses such
combined and coordinated data acquisition regarding wall thickness
measurements of tubulars.
[0154] Conventional systems are known in which the thickness of a
pipe wall is interrogated by ultrasonic methods. In such systems,
an ultrasonic transducer is deployed on (or near) the external
surface of the pipe, and the ultrasonic echoes received back are
analyzed for wall thickness information. It is known to take such
measurements while the pipe rotates about its cylindrical axis.
Significantly, during such measurements, the transducer is required
to be in good ultrasonic contact with the external surface of the
pipe, and thus there has to be a constant layer of fluid (such as
water) connecting the transducer to the external surface of the
pipe as it rotates. The pipe also has to be marked with a
circumferential reference in order to associate ultrasonic
measurements with wall thickness locations. Conventionally such
marking is done by visibly marking a longitudinal line down the
external surface of the pipe. The line can then be read by a photo
electric cell as the line passes its field of view during rotation
of the pipe.
[0155] The measurement of tubular wall thickness in the Scorpion
System is in sharp contrast to conventional systems. In preferred
embodiments, although other conventional wall thickness measurement
protocols may be used, measurement of wall thickness is preferably
by magnetic flux density analysis from the inside of the tubular to
the outside. This protocol is in distinction to ultrasonic echo
analysis from the outside only. The Scorpion System deploys a probe
generating a predetermined magnetic field on the end of an MLI
lance. The probe moves up and down the inside of the tubular as the
tubular rotates. Such a probe may be deployed, for example, on tool
heads disclosed in commonly-assigned, co-pending U.S. patent
application Ser. No. 13/832,340. One or more magnetic flux sensors
are deployed on the outside of the tubular, and may also be
moveable up and down the outside of the tubular as the tubular
rotates. Advantageously, some or all of the magnetic flux sensors
may be deployed on ODS buggy (embodiments of which are disclosed
herein). The magnetic flux sensors generate samples of measured
magnetic flux density at known points on the external surface of
the tubular as the tubular rotates. The samples thus collectively
form a helix of samples at corresponding known points on the
external surface of the tubular.
[0156] As noted, a probe generates a predetermined magnetic field
on the inside of the tubular. Each magnetic flux density sample
taken on the outside allows the degradation of the magnetic field
through the wall of the tubular to be calculated at each sample's
corresponding location on the tubular. This allows the degradation
to be mapped over the tubular. When calibrated, variations in the
nature and the amount of the degradation of the field from sample
to sample will be understood to correspond to variations in both
the density and the thickness of the tubular's wall from point to
point on the tubular's surface where the samples were taken. Thus
variations in both the density and thickness of the tubular's wall
may be mapped over the tubular.
[0157] The resulting maps of variations in the density and
thickness of the tubular's wall are very useful. Variations in
tubular wall density highlight flaws (such as cracks, pits,
de-laminations, etc) within the wall that might not otherwise be
easily detected by surface contouring data taken by laser
examination of the tubular's surface. Variations in tubular wall
thickness highlight wear on the tubular's wall from a paradigm wall
thickness.
[0158] The following sections of this disclosure now focus a
mechanical inspection data acquisition system useful in conjunction
with the ODS technology also disclosed herein. The ODS contour data
acquisition and processing system, and related electronic control
systems, described in the preceding paragraphs, dovetail into the
disclosed mechanical inspection Data Acquisition System ("DAS").
The following DAS disclosure should also be read in conjunction
with MLI disclosure in U.S. Provisional Application Ser. No.
61/707,780 (to which provisional application this application
claims priority). Note, however, that although disclosed as part of
the Scorpion System, the DAS technology could be used independently
in many tubular processing operations. It is not limited to
deployment on a tubular cleaning system.
[0159] Conventional technology calls for pipe joints and other
tubulars to receive regular EMI (Electro-Magnetic Inspection or
equivalent nomenclature) analysis to check the integrity of the
joint. EMI analysis provides data, ideally in a graph format,
interpretable to see, for example, if the tubular's wall thickness
has fallen below a certain acceptable thickness at any point, or if
the tubular has any unacceptable defects such as pits or
cracks.
[0160] EMI is conventionally provided by passing electromagnetic
sensors over a stationary tubular, such as a joint of drill pipe.
Alternatively, the tubular can be conventionally passed over a
stationary electromagnetic sensor apparatus. This operation can be
done in the shop or in the field. If an anomaly is found, the EMI
sweep operation has to stop in order to pinpoint the anomaly.
Further analysis is then done manually at the site of the anomaly
(usually sonic analysis) to determine whether the pipe joint is in
or out of specification. In some embodiments of the ODS, an EMI
sweep operation may be configured by deploying an EM "donut" ring
on ODS assembly 220 as shown on FIGS. 5 though 10. The donut ring
may sweep the tubular as ODS assembly 220 moves up and back above
the rotating tubular.
[0161] The Scorpion System's DAS is an optional add-on to the other
aspects of the Scorpion System disclosed elsewhere in this
disclosure. The DAS provides sensors at suitable locations (such
as, without limitation, on drift tooling or dedicated sensor lances
on the MLI, or on the insides of shrouds or on a dedicated probe
head on some embodiments of the ODS according to FIGS. 1 through 4,
or as recorded by laser(s) and optical camera(s) onboard ODS laser
222 and by fixed lasers 224 on other embodiments of the ODS
according to FIGS. 5 through 10). These sensors are provided to
analyze the state of the rotating tubular. A further particularly
advantageous sensor placement (without limitation) would be to
locate a resistivity tool in an internal drift.
[0162] The DAS sensors may be of any suitable type for inspecting
the tubular. The DAS sensors may be, for example, electromagnetic
sensors, sonic sensors, lasers, cameras (still or video, optical or
otherwise) accelerometers, or any other type of sensor, and the DAS
is expressly not limited in this regard. Examination of the tubular
by the sensors may be done at the same time that cleaning
operations are done, or alternatively during separate inspection
passes of the MLI or the ODS along the tubular.
[0163] It will be appreciated that the DAS may be enabled by any
suitable data acquisition system capable of taking multiple sensor
readings at high sampling rates, and then converting those readings
into human-interpretable qualitative and quantitative data
regarding the sampled specimen. Such data acquisition systems are
well known in the art. The software also compares the sampled data
with stored data, again in real time. As will be described in
further detail below, the stored data may include, for example,
earlier inspections of the same specimen, or paradigms such as
theoretical scans of a specimen that meets applicable performance
specifications.
[0164] A primary principle of the DAS is to acquire, in real time,
sufficient data regarding the state of a tubular to have generated
a unique and highly-individualized data "signature" of the tubular
representing its current state as sampled. The signature represents
any recorded and repeatable combination of sampled information
points regarding the state of the tubular. Such sampled information
points may include, by way of example and without limitation,
qualitative and quantitative data regarding: [0165] (a) location,
shape and nature of anomalies on interior and/or exterior walls of
tubular (such as scratches, scars, pits, gouges, repairs or cuts
from prior service, or manufacturing defects of a similar nature);
[0166] (b) location and nature of variations in wall thickness of
tubular; [0167] (c) location and nature of variations in
cross-sectional shape of the tubular; or [0168] (d) location and
nature of cracks or other points of weakness within the
tubular.
[0169] The foregoing data is advantageously in high resolution. The
more sampled information points regarding a tubular are combined
into a signature, the more unique and highly-individualized the
signature is likely to be. It will be appreciated that the
"sample-richness" or "granularity" of the DAS signature of a
tubular may be further enhanced by combining synchronous sampling
of the exterior and interior of the tubular. One option for data
acquisition in an illustrated embodiment of the Scorpion System is
for an MU lance with data acquisition capability and the ODS probe
head or laser (as described elsewhere in this disclosure) to be run
synchronously down the tubular with all such sensors (internal and
external) being in data communication with each other. In this way,
the DAS may acquire real time data regarding the tubular in which
the data quality is enhanced by concurrent and substantially
co-located sampling from both sides of the wall of the tubular. The
DAS software and hardware is configured to allow a user to zoom in
on points of interest on a graphical display in order to classify
and measure anomalies.
[0170] A further feature in preferred embodiments of the DAS is a
"stop/start curtain" that may be provided on embodiments of the
ODS. The stop/start curtain is particularly advantageous in
embodiments of the Scorpion System where "synchronous" examination
(as described above) of the interior and exterior of the tubular is
available. However, the curtain feature is not limited to such
embodiments. The curtain feature refers to one or more sensors
placed on each end of the ODS, and may use the optical range to be
in the form of a "light" curtain. These sensors detect when the
tubular is present underneath, and when it is not. The sensors may
be lasers or lights (hence the colloquial reference to a "curtain")
or any other sensor capable of such detection. As the ODS moves
toward the tubular to commence operations, the curtain at the near
end of the ODS detects the end of the tubular and
synchronizes/coordinates DAS processing to this event. As the ODS
nears completion of its travel over the tubular, the curtain at the
near end of the ODS detects the end of the tubular and warns the
DAS of this event. The curtain at the far end of the DAS eventually
detects the end of the tubular and notifies that DAS that a full
sweep of the tubular has been completed. It will be appreciated
that the curtain feature may then be operated in reverse for a pass
of the ODS along the tubular in the opposite direction.
[0171] Once acquired, the signature of the tubular may then be
compared with the expected corresponding signature of a paradigm.
The paradigm may be anything from the expected signature of a brand
new, perfectly-manufactured tubular (the "perfect pipe"), to the
expected signature of a tubular that meets all applicable
performance specifications for the tubular when in service (for
example, minimum wall thickness over a certain percentage of the
tubular and no more than a certain number of pits, cracks or other
anomalies above a certain size or depth). A summary report may then
be produced that may summarize and highlight key points of interest
in the comparison, including anomalies in OD measurements. In
addition, the Scorpion System may generate "One-Way Tracking Tags"
that may be affixed to each length of tubular processed by the
System. Each tag advantageously includes serial number information
(which may be in the form of bar codes) that ties the tubular to
any corresponding cleaning and inspection information collected or
generated by the Scorpion System.
[0172] It will be appreciated that with regard to comparison to the
expected signature of a tubular that meets all applicable
performance specifications, the DAS provides an advantageous
substitute to conventional EMI analysis. Information regarding the
condition of the tubular may be obtained concurrently with cleaning
operations, potentially obviating the need for additional, separate
EMI analysis after cleaning.
[0173] The current signature of the tubular may also be compared
with earlier corresponding signatures of the same tubular to
identify specific changes in the tubular since the previous
inspection. Alternatively, the current signature of the tubular may
be compared against stored data sets or other known signatures
where such a comparison will be expected to identify areas of
interest in the tubular such as deterioration of wall integrity, or
other wear or damage. Such stored data sets or known signatures
might include, for example, "perfect pipe" in one type of
comparison, or tubulars with known defects or wear and tear in
another type of comparison.
[0174] In the currently preferred embodiment, the signature of the
tubular appears as a series of graphs and other visual media. This
makes comparison with paradigms or previous signature of the
tubular relatively straightforward. Nothing in this disclosure
should be interpreted, however, to limit the DAS or the Scorpion
System in this regard.
[0175] One advantage of the DAS is that it is operable on a
rotating tubular specimen. It will be appreciated that sensors
scanning or sampling a rotating tubular are able to discern
characteristics of the tubular that would either be undetectable or
poorly detectable on a stationary tubular. For example, without
limitation, the following characteristics are detectable (or better
detectable) when the tubular is rotating: [0176] (a) Vibrational
frequency and amplitude; [0177] (b) Harmonic response
characteristics; [0178] (c) Torsional displacement in response to
torsional load; or [0179] (d) Responses to sonic, optical or
magnetic radiation
[0180] It will be further appreciated that by rotating the tubular
during sensing or sampling, logs over the tubular become available
that enable high resolution in pinpointing an item of interest,
such as a defect or an anomaly, or a tubular identification or
tracking tag. The sensing and sampling then goes well beyond
accurate pinpointing, enabling real time qualitative analysis of
the item of interest. As noted above, the DAS may obviate current
manual electromagnetic and sonic analysis of lengths of tubulars,
one-by-one.
[0181] Sensors on the DAS are connected to the processing unit by
conventional telemetry, such as hard wire cables, wireless
telemetry or optical cables. The telemetry selected will depend on
environmental conditions such as distance over which telemetry is
required, bandwidth and signal interference levels.
[0182] As disclosed earlier, the DAS may be embodied on any
conventional data acquisition system whose performance matches the
needs of the Scorpion System for obtaining, processing, comparing
and displaying sensor readings and samples in real time. In a
currently preferred embodiment of the DAS, however, the applicable
software is advantageously customized to the Scorpion System via
conventional programming to achieve the following operational goals
and advantages:
[0183] (1) Receive and process a high sampling rate from many
sensors, so as to effectively sample the tubular in real time with
high resolution. Such high resolution comes not only from a high
sample rate at each sensor, but also from concurrently processing
samples from a high number of sensors.
[0184] (2) Display the output in easily-readable graphical formats,
with the capability to "drill down" or "magnify" on areas of
specific interest. The resolution level is able to support such
magnification.
[0185] (3) Display the output against user selected paradigm(s) so
that differences can be easily identified and characterized. The
paradigms have the same resolution as the real time data so that
magnification of areas of interest supports a true, full comparison
with the paradigm.
[0186] (4) Display the output remotely, allowing review of data and
comparisons away from the machine. Such remote review may be
enabled by transmission of local data to remote terminals, or by
linking remote terminals to local terminals via conventional
terminal-sharing applications such as GoToMeeting by Citrix.
[0187] A paradigm for optimal Scorpion System operating efficiency
includes being able to program the ODS to run automatically. That
is, to repeat a cycle of tubular exterior processing operations
(including cleaning and data acquisition operations) as a series of
tubulars are automatically and synchronously: (1) placed into
position at the beginning of the cycle, (2) ejected at the end of
the cycle, and then (3) replaced to start the next cycle. It may
also be advantageous in some embodiments (although the Scorpion
System is not limited in this regard) to synchronize ODS and MU
operations. Specifically, embodiments of the electronic control
system of the Scorpion System allow users to select a "Dirtiness
Factor" for a tubular (or series thereof). The Dirtiness Factor
reflects a weighted estimate including an assessment of the
severity of the tubular's contamination and the level of clean
required by the Scorpion System. All speeds, pressures, distances
and other relevant factors for cleaning operations are then
automatically generated according to the Dirtiness Factor and fed
into the cleaning systems of the Scorpion System. The goal by
applying and following the Dirtiness Factor regimen is to clean the
tubular 100% to the level selected before cleaning in one pass,
without having to return and re-clean. As a result, the Scorpion
System's cleaning efficiency with respect to time and quality will
be maximized, while still giving the desired level of clean.
Similarly, the consumption of consumables such as brushes, liquids,
fluids, etc., used in the cleaning process will be minimized, while
still giving the desired level of clean.
[0188] In automatic mode on the ODS, the user may specify the
sequence of ODS operations in a cycle on each tubular. The cycle of
ODS operations will then be enabled and controlled automatically,
including causing the ODS buggy to travel up and down above a
tubular, with corresponding repositioning of ODS buggy (if
required) with respect to the tubular. If applicable, the cycle may
also include coordinating ODS operations in a cycle with concurrent
MLI operations. The cycle may be repeated in automatic mode, as
tubulars are sequentially placed into position. In semi-automatic
mode, the operation may be less than fully automatic in some way.
For example, a cycle may be user-specified to only run once, so
that tubulars may be manually replaced between cycles. In manual
mode, the user may dictate each ODS operation individually, and the
ODS may then pause and wait for further user instruction.
[0189] For the avoidance of doubt, a "cycle" as described
immediately above may comprise one pass or multiple passes of (1)
the ODS, and/or of (2) user-selected lances in the MLI through each
tubular, all in order to enable a user-selected sequence of
operations. Nothing in this disclosure should be interpreted to
limit the Scorpion System in this regard. Further, again for the
avoidance of doubt, in a currently preferred embodiment of the
Scorpion System, the ODS may run synchronously or asynchronously
with some or all of the lances on the MLI, all according to user
selection.
[0190] The Scorpion System as described in this disclosure is
designed to achieve the following operational goals and
advantages:
[0191] Versatility.
[0192] The Scorpion System as disclosed herein has been described
with respect to currently preferred embodiments. However, as has
been noted repeatedly in this disclosure, such currently preferred
embodiments are exemplary only, and many of the features, aspects
and capabilities of the Scorpion System are customizable to user
requirements. As a result the Scorpion System is operable on many
diameters of tubular in numerous alternative configurations. Some
embodiments may be deployed onto a U.S. Department of Transport
standard semi-trailer for mobile service.
[0193] Substantially Lower Footprint of Cleaning Apparatus.
[0194] As noted above, conventionally, the cleaning of range 3
drill pipe requires a building at least 120 feet long. Certain
configurations of the Scorpion System can, for example, clean range
3 pipe in a building of about half that length. Similar footprint
savings are available for rig site deployments. As also noted
above, a mobile embodiment of the Scorpion System is designed
within U.S. Department of Transportation regulations to be mounted
on an 18-wheel tractor-trailer unit and be transported on public
roads in everyday fashion, without requirements for any special
permits.
[0195] Dramatically Increased Production Rate in Cleaning.
[0196] An operational goal of the Scorpion System is to
substantially reduce conventional cleaning time. Further, the
integrated yet independently-controllable design of each phase of
cleaning operations allows a very small operator staff (one person,
if need be) to clean numerous tubulars consecutively in one
session, with no other operator involvement needed unless
parameters such as tubular size or cleaning requirements change. It
will be further understood that in order to optimize productivity,
consistency, safety and quality throughout all tubular operations,
the systems enabling each phase or aspect of such operations are
designed to run independently, and each in independently-selectable
modes of automatic, semi-automatic or manual operation. When
operator intervention is required, all adjustments to change, for
example, modes of operation or tubular size being cleaned, such
adjustments are advantageously enabled by hydraulically-powered
actuators controlled by system software.
[0197] Improved Quality of Clean.
[0198] It is anticipated that the Scorpion System will open up the
pores of the metal tubular much better than in conventional
cleaning, allowing for a more thorough clean. In addition, the high
rotational speed of the tubular during cleaning operations allows
for a thorough clean without a spiral effect even though cleaning
may optionally be done in one pass.
[0199] Throughout this disclosure, reference has been made to
software-driven electronic control systems and data
acquisition/processing systems. It will be understood that such
systems may be embodied on software executable on conventional
computers, networks, peripherals and other data processing
hardware.
[0200] Also, throughout this disclosure, conventional control,
power and hydraulic/pneumatic actuating systems for features and
aspects of the disclosed technology have been omitted for clarity.
Likewise, conventional support structure for features and aspects
of the disclosed technology, such as structural steel, has been
omitted for clarity.
[0201] Although the present invention and its advantages have been
described in detail, it should be understood that various changes,
substitutions and alternations can be made herein without departing
from the spirit and scope of the invention as defined by the
appended claims.
* * * * *