Method and apparatus to detect faults in conduits

Abstract

Conduit integrity monitors enable the detection of defects or faults in conduits. One type of the conduit integrity monitor measures the bending stiffness of the conduit. A load cell device is used to detect a force applied by a bent conduit. Defective or damaged portions may cause an increase or decrease in bending stiffness that can be detected by the conduit integrity monitor. Another type of the conduit integrity monitor includes proximity sensors each measuring its distance to a predetermined layer of the conduit, such as a metallic reinforcement layer. Defects or damage in the conduit may cause the conduit to change shape, which can be detected by the proximity sensors.

What is claimed is:  
     
         1 . An integrity monitor for use with a conduit, comprising: 
 a receiving mechanism adapted to receive the conduit, the receiving mechanism adapted to further bend the conduit by a predetermined amount; and    a detector device adapted to measure a force applied by the bent conduit.    
     
     
         2 . The integrity monitor of  claim 1 , wherein the measured force represents a bending stiffness of the conduit to indicate physical integrity of the conduit.  
     
     
         3 . The integrity monitor of  claim 1 , wherein the receiving mechanism is adapted to receive a hose, the flexible conduit comprising the hose.  
     
     
         4 . The integrity monitor of  claim 1 , wherein the receiving mechanism is adapted to receive a composite coiled tubing, the flexible conduit comprising the composite coiled tubing.  
     
     
         5 . The integrity monitor of  claim 1 , wherein the receiving mechanism is adapted to receive a flexible conduit formed at least in part of a flexible material.  
     
     
         6 . The integrity monitor of  claim 1 , wherein the receiving mechanism comprises a plurality of rollers arranged to bend the conduit.  
     
     
         7 . The integrity monitor of  claim 1 , wherein the detector device comprises a load cell.  
     
     
         8 . The integrity monitor of  claim 1 , further comprising a positioning device adapted to position the conduit.  
     
     
         9 . The integrity monitor of  claim 1 , wherein the detector device is adapted to measure a force applied by the bent conduit when a relatively high internal pressure is applied in the conduit.  
     
     
         10 . A system to determine integrity of a conduit, comprising: 
 a plurality of integrity monitors, each integrity monitor comprising: 
 a receiving mechanism adapted to receive a portion of the conduit, the receiving mechanism adapted to further bend the portion of the conduit by a predetermined amount; and  
 a detector device adapted to measure a bending stiffness of the bent portion of the conduit,  
   wherein the plurality of integrity monitors are spaced apart along a length of the conduit and angularly offset from each other.    
     
     
         11 . The system of  claim 10 , wherein a first integrity monitor is positioned to detect bending stiffness along a first cross-sectional axis of the conduit, and a second integrity monitor is positioned to detect bending stiffness along a second cross-sectional axis of the conduit.  
     
     
         12 . The system of  claim 11 , wherein the first and second axes are substantially perpendicular to each other.  
     
     
         13 . The system of  claim 10 , further comprising a positioning device adapted to detect a position of the conduit.  
     
     
         14 . The system of  claim 10 , wherein the receiving mechanism comprises a plurality of rollers arranged to bend the conduit.  
     
     
         15 . The system of  claim 14 , wherein the receiving mechanism further comprises a retainer, at least one of the rollers being rotatably mounted on the retainer.  
     
     
         16 . The system of  claim 15 , wherein the detector device is in contact with the retainer.  
     
     
         17 . The system of  claim 16 , wherein the detector device comprises a load cell.  
     
     
         18 . The system of  claim 17 , wherein the load cell has a loading surface, and wherein the retainer is in contact with the loading surface.  
     
     
         19 . A method of determining integrity of a conduit, comprising: 
 passing the conduit through an integrity monitor;    bending a portion of the conduit by a predetermined amount in the integrity monitor; and    measuring a bending stiffness of the conduit portion.    
     
     
         20 . The method of  claim 19 , further comprising determining if the conduit portion is faulty based on the measured bending stiffness.  
     
     
         21 . The method of  claim 19 , further comprising: 
 mounting the conduit on a reel assembly; and    unwinding the reel assembly to release the conduit.    
     
     
         22 . An apparatus for use with a conduit, comprising: 
 a plurality of proximity sensors positioned proximal the conduit, the conduit having plural layers, the plural layers comprising a structural layer;    each proximity sensor adapted to sense a distance to the structural layer,    the plurality of proximity sensors adapted to detect a shape of the conduit.    
     
     
         23 . The apparatus of  claim 22 , wherein the proximity sensors comprise inductive proximity sensors.  
     
     
         24 . The apparatus of  claim 22 , wherein the proximity sensors are arranged circumferentially around a portion of the conduit.  
     
     
         25 . The apparatus of  claim 24 , wherein the proximity sensors are arranged in pairs, each pair of proximity sensor adapted to detect a diameter of one section of the conduit.  
     
     
         26 . The apparatus of  claim 25 , wherein the proximity sensors are arranged in plural sets spaced apart along a longitudinal axis of the conduit.  
     
     
         27 . The apparatus of  claim 24 , wherein the proximity sensors are arranged at at least the following positions around the conduit: 0°, 30°, 60°, 90°, 120°, 150°, 180°, 210°, 240°, 270°, 300°, and 330°.  
     
     
         28 . The apparatus of  claim 22 , wherein the structural layer comprises metal, each proximity sensor adapted to interact with the metal to sense the distance.  
     
     
         29 . The apparatus of  claim 22 , wherein the plural layers comprise an outer layer formed of a non-electrically conductive layer, each proximity sensor adapted to sense the distance to the structural layer through the non-electrically conductive layer.  
     
     
         30 . A method of determining integrity of a conduit, comprising: 
 providing a plurality of proximity sensors;    measuring a distance of each proximity sensor to one of plural layers of the conduit, the one of plural layers comprising a structural layer; and    determining a shape of the conduit based on the distance measurements, the shape indicating the integrity of the conduit.    
     
     
         31 . The method of  claim 30 , wherein providing the plurality of proximity sensors comprises providing a plurality of sets of proximity sensors, the method further comprising spacing the sets apart along a longitudinal axis of the conduit.  
     
     
         32 . An apparatus for determining integrity of a conduit having an inner liner formed of a predetermined material, comprising: 
 a housing defining a bore;    a retainer mechanism arranged inside the housing; and    a test liner retained by the retainer mechanism and in communication with the bore, the retainer mechanism adapted to be removed from the housing to enable removal of the test liner for visual inspection of wear.    
     
     
         33 . The apparatus of  claim 32 , wherein the retainer mechanism comprises first and second sleeves removably connected to each other.  
     
     
         34 . The apparatus of  claim 32 , wherein the test liner is formed of a material that is the same as the material of the conduit liner.  
     
     
         35 . The apparatus of  claim 32 , further comprising a connection assembly adapted to be connected to the conduit.  
     
     
         36 . A method of detecting wear of a liner in a conduit, comprising: 
 providing a test structure having an inner bore and a test liner in communication with the inner bore;    flowing a fluid through the inner bore; and    inspecting the test liner to determine wear of the conduit liner.    
     
     
         37 . The method of  claim 36 , further comprising flowing the same fluid through a bore of the conduit.  
     
     
         38 . A method for use with a connector assembly for a conduit, comprising: 
 connecting the conduit to the connector assembly;    placing a first mark on a portion of the connector assembly adjacent the conduit;    marking a second mark on a portion of the conduit adjacent the connector assembly; and    inspecting for a gap between the first and second marks to detect for possible failure of a connection between the conduit and the connector assembly.