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.

We claim: 
     
         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.