Ultrasonic thickness gage for pipe

Abstract

The invention is a compact ultrasonic tester involving rotating sensors The processor rotates with the sensors so that the output signal of the processor goes through the slip rings, rather than the output signal of the sensors. A spraying system is incorporated in conjunction with rollers. The rollers take the applied spray on the pipe surface and paint a film on the outer pipe surface to allow a good contact for meaningful results. A floating shoe is provided for holding each sensor against the pipe wall. The sensors are biased into contact with the pipe surface and the machine can handle different diameters of pipe. By controlling the pipe speed of advance and the rotational speed or the sensors, 100 percent coverage of the pipe wall is assured. The machine is compact and can be installed behind existing electromagnetic/gamma testers without major modifications to pipe-testing facilities.

I claim: 
     
       1. An apparatus for testing tubular goods, comprising: (a) a frame;   (b) sensing means mounted to said frame for detecting flaws in a tubular and for sending an output signal, said sensing means comprising at least one ultrasonic sensor, a movably mounted holder for said ultrasonic sensor, and a shoe mounted to said holder;   (c) computing means on said frame hardwired to said sensing means to process said output signal of said sensing means and deliver a second output signal;   (d) means for rotating said sensing means and computing means in tandem on said frame;   (e) means on said frame for allowing a takeoff of said second signal and for supplying power as said sensing means and computing means are rotated, said means for allowing a takeoff of said second signal and for supplying power comprising a slip ring assembly;   (f) a tubular to be inspected, said tubular being centrally located on said frame such that said means for rotating can rotate said sensing means and said computing means around the outer surface of said tubular;   (g) at least one fluid outlet directed at the outer surface of said tubular; and   (h) a lead roller mounted to said holder.   
     
     
       2. The apparatus of claim 1, wherein said lead roller has a tapered end adapted to engage the tubular for displacement or said roller and sad holder.   
     
     
       3. The apparatus of claim 2, further comprising: (a) a biasing means mounted on said frame capable of driving said shoe toward the tubular; and   (b) a tail roller mounted to said holder on the opposite side of said shoe from said lead roller, said tail roller having an oppositely oriented tapered surface to said lead roller.   
     
     
       4. The apparatus of claim 3, further comprising: (a) drying means for displacing fluid applied by said outlet, off the tubular; and   (b) collection means for gathering . .any.!. fluid displaced by said drying means off the tubular.   
     
     
       5. The apparatus of claim 4, wherein: said drying means comprises at least one gas nozzle; and   said collection means comprises a drain pan under the tubular to catch liquid blown off the tubular by said gas nozzle.   
     
     
       6. The apparatus of claim 5, wherein: said means for rotating drives said sensor at a speed sufficient to obtain at least 100 percent coverage of the outer surface of the tubular.   
     
     
       7. An apparatus for testing tubular goods, comprising: (a) a frame;   (b) a shoe floatingly mounted on said frame;   (c) a support drum mounted on said frame;   (d) at least one sensor mounted to said shoe;   (e) a computing means hardwired to said sensor for processing a signal from said sensor, said computing means and sensor means mounted to said frame for tandem movement; and   (f) a tubular to be inspected, insertable through the center of said support drum such that said computing means and sensor can rotate in tandem around the outer surface of said tubular;   (g) at least one fluid outlet directed at the tubular,   (h) applicator means to spread fluid deposited . .in.!. .Iadd.on .Iaddend.the tubular by said outlet; and   (i) a lead roller mounted to said shoe.   
     
     
       8. The apparatus of claim 7, wherein said lead roller has a tapered end adapted to engage the tubular for displacement of said roller and said holder.   
     
     
       9. The apparatus of claim 8, further comprising: (a) a biasing means mounted on said frame capable of driving said shoe toward the tubular; and   (b) a tail roller mounted to said holder on the opposite side of said shoe from said lead roller, said tail roller having an oppositely oriented tapered surface to said lead roller.   
     
     
       10. The apparatus of claim 9, further comprising: (a) drying means for displacing fluid applied by said outlet, off the tubular; and   (b) collection means for gathering . .any.!. liquid displaced by said drying means off the tubular.   
     
     
       11. The apparatus of claim 10, wherein: said drying means comprises at least one gas nozzle; and   said collection means comprises a drain pan under the tubular to catch liquid blown off the tubular by said gas nozzle.   
     
     
       12. An apparatus for testing tubular goods, comprising: (a) a frame;   (b) at least one ultrasonic sensor mounted to said frame;   (c) a computing means hardwired to said sensor for processing a signal from said sensor;   (d) a movably mounted holder housing said ultrasonic sensor;   (e) a shoe floatingly mounted on said holder;   (f) means for rotating said ultrasonic sensor and said computing means in tandem on said frame;   (g) means on said frame to allow a takeoff of the signal from said computing means and to supply power as said sensor and computing means are rotated;   (h) coating means on said frame, . .further comprising:.!. .Iadd.including .Iaddend.   . .(i).!. at least one fluid outlet directed at a tubular. .;.!. and .Iadd.at least one lead roller mounted to said holder and having a tapered end, the lead roller spreading .Iaddend.   . .(j) applicator means to spread.!. fluid deposited on a tubular by said .Iadd.at least one .Iaddend.outlet . .said applicator means comprising at least one lead roller mounted to said holder, said lead roller having a tapered end.!.. .Iadd.13. Apparatus for inspecting a plurality of elongate tubulars, comprising:   an inspection machine frame;   a drum spaced radially outward from a respective tubular, the drum being rotatable about a central axis with respect to the frame;   a motor for rotating the drum;   a plurality of sensors each mounted circumferentially about the rotatable drum for detecting flaws in each tubular and for outputting electrical sensed signals;   an electronic processor fixedly mounted on the drum at a position axially opposite the plurality of sensors with respect to a slip ring assembly and electrically interconnected with each of the plurality of sensors to process the electrical sensed signals from each of the plurality of sensors and for delivering processed signals representing flaws in the tubular;   the slip ring assembly secured to the frame for transmitting the processed signals from the electronic processor;   a liquid outlet directed at an outer surface of the tubular for wetting a radial spacing between each of the plurality of sensors and the tubular; and   a housing at least substantially enclosing the electronic processor for protecting the processor from the liquid discharged from the liquid outlet. .Iaddend..Iadd.14. The apparatus as defined in claim 13, further comprising:   a liquid storage supply for supplying liquid to the liquid outlet; and   the liquid outlet being spaced axially opposite the electronic processor with respect to the slip ring assembly and including at least one nozzle for selectively discharging the liquid onto the surface of the tubular. .Iaddend..Iadd.15. The apparatus as defined in claim 14, further comprising:   a hood for at least partially containing the liquid discharged from the at least one nozzle onto the tubular; and   a drain pan positioned below the drum to catch the liquid discharged from the at least one nozzle onto the tubular. .Iaddend..Iadd.16. The apparatus as defined in claim 14, further comprising:   at least one gas nozzle for discharging a drying gas onto the tubular.   
     
     
        .Iaddend..Iadd.17.  The apparatus as defined in claim 13, further comprising: an access door within the housing for selectively accessing the processor. .Iaddend..Iadd.18. The apparatus as defined in claim 13, further comprising:   a curved underside concave planar surface adjacent each of the plurality of sensors and rotatable therewith with respect to the frame, each curved underside planar surface geometrically conforming substantially to an exterior cylindrical surface of the tubular for coating a radial spacing between the respective sensor and the tubular with the discharged liquid. .Iaddend..Iadd.19. The apparatus as defined in claim 18, further comprising:   each of the plurality of sensors is an ultrasonic sensor; and   a plurality of biasing members each for biasing at least one of the plurality of ultrasonic sensors toward the tubular. .Iaddend..Iadd.20. The apparatus as defined in claim 13, wherein each of the plurality of sensors is hardwired to the electronic processor. .Iaddend..Iadd.21. The apparatus as defined in claim 13, further comprising:   a plurality of sensor supports each for movably mounting a respective sensor on the drum. .Iaddend..Iadd.22. The apparatus as defined in claim 13, further comprising:   the plurality of sensors include at least four ultrasonic spaced circumferentially about the rotatable drum; and   the motor rotates the drum at a speed such that the at least four ultrasonic sensors obtain at least 100% coverage at an outer surface of   
     
     
        the tubular. .Iaddend..Iadd.23.  The apparatus as defined in claim 13, further comprising: a displacement mechanism for moving each of the plurality of sensors radially with respect to varying diameters of the plurality of elongate tubulars. .Iaddend..Iadd.24. Apparatus for inspecting a plurality of elongate tubulars, comprising:   an inspection machine;   a drum spaced radially outward from a respective tubular, the drum being rotatable about a central axis with respect to the frame;   a motor for rotating the drum;   a plurality of ultrasonic sensors each mounted circumferentially about the rotatable drum for detecting flaws in the supported tubular and for outputting sensed signals;   a slip ring assembly secured to the frame for transmitting radially outward therethrough indications of the sensed signals;   a liquid storage supply for supplying liquid;   at least one nozzle selectively positioned at a stationery location with respect to said frame for discharging the liquid onto the surface of the tubular at a position spaced axially from the plurality of sensors for wetting a radial spacing between each of the plurality of sensors and the tubular; and   a curved underside concave planar surface adjacent each of the plurality of sensors and rotatable therewith with respect to the frame, each curved underside planar surface geometrically conforming substantially to an exterior cylindrical surface of the tubular for coating a radial spacing between a respective sensor and the tubular with the discharged liquid. .Iaddend..Iadd.25. The apparatus as defined in claim 24, further comprising:   a hood for at least partially containing the liquid discharged from the at least one nozzle onto the tubular; and   a drain pan positioned below the drum to catch the liquid discharged from   
     
     
        the at least one nozzle onto the tubular. .Iaddend..Iadd.26.  The apparatus as defined in claim 24, further comprising: at least one gas nozzle for discharging a drying gas onto the tubular. .Iaddend..Iadd.27. The apparatus as defined in claim 24, further comprising:   an electronic processor mounted on the drum at a preselected circumferential location and electrically interconnected with each of the plurality of sensors to process the sensed signals from each of the plurality of sensors and for delivering processed signals representing flaws in the tubular;   a housing for at least substantially enclosing the electronic processor to protect the processor from the discharged liquid; and   an access door within the housing for selectively accessing the processor. .Iaddend..Iadd.28. The apparatus as defined in claim 25, further comprising:   each of the plurality of sensors is an ultrasonic sensor;   a plurality of biasing members each for biasing at least one of the plurality of ultrasonic sensors toward the tubular; and   a plurality of sensor supports each for movably mounting a respective ultrasonic sensor on the drum. .Iaddend..Iadd.29. The apparatus as defined in claim 25, further comprising:   the plurality of sensors includes at least four ultrasonic sensors spaced circumferentially about the rotatable drum; and   the motor rotates the drum at a speed such that the at least four ultrasonic sensors obtain at least 100% coverage at an outer surface of   
     
     
        the tubular. .Iaddend..Iadd.30.  A method of inspecting a plurality of elongate tubulars, comprising: successively supporting each of the plurality of elongate tubulars relative to an inspection machine frame;   positioning each supported tubular within a drum spaced radially outward from the supported tubular;   mounting a plurality of sensors circumferentially about the drum;   securing a slip ring assembly to the frame to receive electrical signals from the plurality of sensors;   mounting an electronic processor on the drum at a position axially opposite the plurality of sensors with respect to the slip ring assembly;   electrically interconnecting each of the plurality of sensors to the electronic processor to process the sensed signals from each of the plurality of sensors and deliver processed signals representing flaws in the supported tubular;   rotating the drum with respect to the frame and the supported tubular;   directing a liquid from a location stationary with respect to the frame onto an outer surface of the supported tubular spaced axially from the plurality of sensors for wetting a spacing between each of the plurality of sensors and the supported tubular;   transmitting the processed signals from the electronic processor through the slip ring assembly secured to the frame; and   detecting flaws in the supported tubular based on the transmitted signals. .Iaddend..Iadd.31. The method as defined in claim 30, further comprising:   containing the liquid discharged from the at least one nozzle onto the supported tubular with a hood; and   positioning a drain pan below the drum to catch the liquid discharged from the at least one nozzle onto the supported tubular. .Iaddend..Iadd.32. The method as defined in claim 30, further comprising:   discharging a drying gas onto the supported tubular. .Iaddend..Iadd.33. The method as defined in claim 30, further comprising:   at least substantially enclosing the electronic processor with a housing to protect the processor from the discharged liquid; and   selectively accessing the processor through an access door within the   
     
     
        housing. .Iaddend..Iadd.34.  The method as defined in claim 30, further comprising: biasing each of the plurality of sensors toward the supported tubular; and   displaying the transmitted signals to detect flaws in each of the supported tubulars. .Iaddend..Iadd.35. The method as defined in claim 30, further comprising:   movably mounting each of the plurality of sensors on the rotatable drum. .Iaddend..Iadd.36. A method of inspecting a plurality of elongate tubulars,   successively supporting each of the plurality of elongate tubulars relative to an inspection machine frame;   positioning each supported tubular within a drum spaced radially outward from the supported tubular;   mounting a plurality of sensors circumferentially about the drum;   rotating the drum with respect to the frame and the supported tubular;   directing a liquid from a location stationary with respect to the frame onto an outer surface of the supported tubular spaced axially from the plurality of sensors for wetting a spacing between each of the plurality of sensors and the supported tubular;   providing a curved underside concave planar surface adjacent each of the plurality of sensors and rotatable therewith for geometrically conforming substantially to an exterior cylindrical surface of the supported tubular and coating a radial spacing between the respective sensor and the supported tubular with the discharged liquid;   transmitting the processed signals from the rotating drum to a receiver secured to the frame; and   using the transmitted signals to detect flaws in the supported tubular. .Iaddend..Iadd.37. The method as defined in claim 36, further comprising:   partially containing the liquid discharged from the at least one nozzle onto the supported tubular with a hood; and   positioning a drain pan below the drum to catch the liquid discharged from   
     
     
        the at least one nozzle onto the supported tubular. .Iaddend..Iadd.38. The method as defined in claim 36, further comprising: discharging a drying gas onto the supported tubular. .Iaddend..Iadd.39. The method as defined in claim 36, further comprising:   securing a slip ring assembly for the frame to receive electrical signals from the plurality of sensors. .Iaddend..Iadd.40. The method as defined in claim 39, further comprising:   mounting an electronic processor on the drum at a preselected circumferential location; and   electrically interconnecting each of the plurality of sensors to the electronic processor to process the sensed signals from each of the plurality of sensors and delivering processed signals representing flaws in the supported tubular. .Iaddend..Iadd.41. The method as defined in claim 40, further comprising:   at least substantially enclosing the electronic processor in a housing to protect the processor from the discharged liquid; and   selectively accessing the processor through an access floor within the housing. .Iaddend..Iadd.42. The method as defined in claim 36, further comprising:   biasing each of the plurality of sensors toward the supported tubular. .Iaddend..Iadd.43. The method as defined in claim 36, further comprising:   movably mounting each of the plurality of sensors on the drum. .Iaddend.