Claims:WE CLAIM:

1) An adaptable magnetizer device for inline inspection, comprising:
- a magnetizer section having
• a shaft assembly;
• a plurality of magnetic bar assembly (6);
• a plurality of flapper assembly (17);
• a plurality of connectors and linkage arms; and
- a CPU section for storing data; and
- a battery section;
wherein, the plurality of magnetic bar assembly (6) is centrally arranged around the shaft assembly;
the plurality of flapper assembly (17) is arranged on the magnetic bar assembly (6) at the central portion and a plurality of strong magnets (12) are arranged on either side of the flapper assembly (17); and
the diameter of the adaptable magnetizer is adjustable upto 20% to allow contact with the pipeline at site of fluctuation. .

2) The adaptable magnetizer device as claimed in claim 1, wherein the shaft assembly comprises:
a. a central shaft (1);
b. a front shaft (2); and
c. rear shaft (3)
wherein; the front and rear shafts are coaxially arranged at the anterior and posterior ends of the central shaft (1).

3) The adaptable magnetizer device as claimed in claim 1, wherein the plurality of magnetic bar assembly (6) comprises:
a. an anchor block (7) having an anterior protruding end (8) and a posterior protruding end (9);
b. a plurality of magnets (12) arranged at anterior and posterior section of the anchor block enclosed in a plurality of bumpers and wear plates;
c. a plurality of flapper assembly (17) arranged in the central portion of the anchor block (7).

4) The adaptable magnetizer device as claimed in claim 1, wherein the plurality of magnates (12) is encased in bumper plate (15, 16) and wear plate (14, 13) at the front and rear ends.

5) The adaptable magnetizer device as claimed in claim 1, wherein the plurality of magnates are located between anchor block front (8) and mount magnet front (10) at the anterior end and between anchor block rear (9) and mount magnet rear (11) at the posterior end.

6) The adaptable magnetizer device as claimed in claim 1, wherein the plurality of flapper assembly (17) are housed on the outer surface of the magnetizer.

7) The adaptable magnetizer device as claimed in claim 1, wherein the flapper assembly (17) consist of a plurality of flappers (18), mounted with a plurality of hall- effect sensors (19) and a plurality of proximity sensors (20).

8) The adaptable magnetizer device as claimed in claim 1, wherein the plurality of flappers (18) are controlled by a single microcontroller.

9) The adaptable magnetizer device as claimed in claim 1, wherein the magnet core is shielded by hardened steel to achieve wear resistant functioning.

10) The adaptable magnetizer device as claimed in claim 1, wherein the magnetic bar assembly (6) is arranged on the magnetic shaft by a plurality of magnetic caps (5) and linkage arms (4).

11) The method for inline inspection by an adaptable magnetizer, comprising:
- launching adaptable magnetizer device in the pipeline;
- detecting flux leakage by means of plurality of sensors;
- sending data captured by the plurality of sensors to a plurality of microcontrollers in the CPU section;
- storing data in the storing unit to capture and store output data;
wherein,
the diameter of the adaptable magnetizer is adjustable upto 20% to allow contact with the pipeline at site of fluctuation;
each microcontroller is connected to a plurality of flapper assembly; and
the output data gets analyzed and stored at the CPU section of the device and yields comprehensive information which is not limited to valve bends, welds, anomalies present in the pipeline.
, Description:FIELD OF THE INVENTION

[001] The present invention generally relates to a system capable of leakage inspection in the pipelines. The present invention particularly relates to an adaptable magnetizer device capable of detecting inline cracks in the pipeline system.

BACKGROUND OF THE INVENTION

[002] Presently, pipelines prove to be a significant mode for transportation of gases, water, fuel oils, and so forth in different fields. However, there can be transportation misfortune as a result of aging, corrosion, obstacles, crack or mechanical faults within the pipeline. Thus, numerous functional methods are presently being developed for inspecting damages on the surface of pipes. In this way, the lifetime of pipeline can be extended by normal assessment of pipeline and perceiving the breaks, harms and faults in the pipeline and guaranteeing legitimate support of deficiencies.

[003] The pipeline inspection apparatus as disclosed in US3483466 detects longitudinal defects by producing unidirectional magnetic flux that flows in a circumferential path. A plurality of flux leakage detector to search for flux leakage around the tubular member; said flux producing means and said flux leakage detector means being fixed relative to each other and being adapted to have a relative motion that is substantially only longitudinal with respect to the central axis of said tubular member. The apparatus propel through the pipeline in one axial movement through a given section of pipe. Further, the movement of the flux is only longitudinal and the flux leakage detector means is fixed against rotary motion which includes plurality of coils made up of elongated rectangular shape.

[004] The invention US5359939 relates to an inline pipe inspection device that comprises a spring-loaded arrangement. The spring-loaded arrangement provides an adequate pressure between the supporting brushes of the device and the interior pipe wall. This arrangement results in an effective magnetic inspection within the pipes of variable internal diameters. This device can provide a supplemental force when it passes from a relatively small to a relatively large diameter pipe to rapidly and effectively position a magnetizing section of the device within the larger diameter pipe.

[005] Traditional leakage detecting apparatus as disclosed in US9285290 includes a carrier disposed for motion along the pipe and a detector connected to move with the carrier in an axial direction. The detector comprises a drum mounted for rotation, a flexible material and at least two sensors responsive for drum rotation. The flexible material will be drawn into contact with a wall of the pipe at a leak location, thereby producing a torque on the drum, causing the drum to rotate, and the at least two sensors to generate signals from which leak location is determined.

[006] The pipeline inspection tool as disclosed in US8319494B2 includes two pole magnets oriented at an oblique angle relative to the central longitudinal axis of the tool body. The tool comprises an array of sensor coil set located between opposing edges of the two pole magnets and oriented perpendicular to the central longitudinal axis. Because the line of sensor coils is rotated relative to the magnetic bias field, the receiver coils are in-line with, and have the same angular orientation as, the transmitter coil. The tool provides improved sensitivity to small defects, substantial decrease in RF pulser power requirements, full circumferential coverage, self-calibration of the transmitted signals, and less interference between transmitter coils caused by acoustic ring around.

[007] Further, an acoustic system for leak detection is disclosed in US20120285221. The system includes a disk-shaped probe for insertion into fluid flowing within a pipe. The probe has a convex front surface facing in direction of flow. The probe further includes wheels to engage a pipe wall to maintain the probe's orientation within the pipe. At least one pressure sensor is embedded in the probe and is responsive to pressure changes resulting from a leak in the pipe wall. Data collection circuitry is disposed in the probe to receive probe location data and to receive an acoustic signal from the pressure sensor from which the pressure and location of a leak may be determined.

[008] However, none of the earlier approaches discusses implementing an adaptable magnetizer device capable of detecting and measuring defects with accuracy and precision nor does they discuss about storing of cracks/ defects either within or on the surface of the pipeline in an efficient and precise manner. Further, none of the prior art devices detect 100% leakage and capability to adjust according to thickness of the pipeline and to remain in contact with pipeline in spite of any discontinuity because of crack or bent in pipe.

OBJECTIVE OF THE INVENTION

[009] An object of the present invention is to provide an adaptable system for detecting cracks and leakages in a pipeline carrying fluids.

[0010] Another object of the present invention is to enable an adaptable magnetizer device to detect and inspect cracks and leakages inside and outside the surface of the pipeline by .

[0011] Another object of the present invention is to enable circumferential detection and/ or inspection of cracks and defects through magnetic flux leakage detection.

[0012] Yet another object of the invention is to provide an adaptable device which is capable of adjusting itself according to the circumference of the pipelines to ensure 100% leakage detection.

[0013] Another object of the present invention is to provide a movable adaptable magnetizer device which can propagate to long distances within the oil/gas pipeline system.

[0014] Another object of the present invention is to store leakage data in the movable magnetic device while propagating within the oil/gas pipeline system.

[0015] Yet, another object of the present invention is to store leakage data within the data storage section of the magnetizer device.

[0016] Other objects and advantages of the present invention will become apparent from the following description, taken in conjunction with the appending claims, illustrations and examples to disclose the aspects of the present invention.

SUMMARY OF INVENTION

[0017] The present invention relates to a device capable of inspecting cracks and detecting leakage through inline inspection. The device is capable of moving and adjusting itself within the oil/ gas pipeline to inspect any defect/ crack or leakage either inside or outside of the pipeline. The device detects defects within the pipeline by detecting magnetic flux leakage with the help of a strong permanent magnet.

[0018] The present invention proposes a device comprising an adaptable magnetizer capable of performing circumferential crack detection through magnetic flux leakage. The adaptable magnetizer is mounted with a plurality of hall-effect sensors and proximity sensors located on a plurality of flappers of the adaptable magnetizer. The hall-effect sensors are capable of measuring magnetic flux leakage. The plurality of flappers of the adaptable magnetizer may be controlled by a single microcontroller. The data sensed by the hall- effect sensor gets monitored and stored in data storage section of the adaptable magnetizer device and the output data may be used for further analysis and detection of leakages either inside or outside of the surface of the oil/ gas pipeline.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when taken in conjunction with the detailed description thereof and in which:

[0020] Fig. 1(a) shows the magnetizer section of the adaptable magnetizer and Fig. 1(b) shows the linkage of the adaptable magnetizer with the CPU section and battery section.

[0021] Fig. 2 illustrates exploded view of the adaptable magnetizer comprising a plurality of magnetic bar assembly.

[0022] Fig. 3 is diagrammatically representing a single magnetic bar assembly.

[0023] Fig. 4 illustrates the exploded view of the magnetic bar assembly comprising flapper assembly.

[0024] Fig. 5 depicts an exploded view of the flapper assembly with proximity sensor and hall effect sensors mounted on the flapper assembly;

[0025] Fig.6 shows the (a) isometric view; (b) Front view and (c) side view of the storage unit attached to the magnetizer section; and

[0026] Fig.7 shows the process and components involved in the form of a flow diagram.

DETAILED DESCRIPTION OF THE INVENTION

[0027] The following presents a simplified description of the invention in order to provide a basic understanding of some aspects of the invention. This description is not an extensive overview of the present invention. It is not intended to identify the key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concept of the invention in a simplified form.

[0028] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0029] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

[0030] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention.

[0031] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0032] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. The equations used in the specification are only for computation purpose.

[0033] The present invention discloses a magnetizer device for detecting magnetic flux leakage in an oil/ gas pipeline. The magnetizer device comprises a magnetizer section for leakage detection and a data storing unit placed adjacent to the metal housing of the adaptable magnetizer for storing the detected leakage information. The data storing unit comprises of a plurality of microcontrollers placed in the CPU/ MCU section of the adaptable magnetizer device. A battery section is also attached adjacent to the CPU section of the magnetizer device as shown in Fig 1(b).

[0034] The magnetizer section disclosed in the present invention is an adaptable magnetizer that may be capable of moving within the pipeline and detecting leakage inside or on the surface of the pipeline by measuring the magnetic flux leakage. The magnetizer is so designed that it can easily pass through pigging condition. The flexibility of the adaptable magnetizer ensures that it remains in continuous contact with the pipeline and provides significant reduction in vibrations and results in improved life of magnetizer. The magnetizer is capable of changing its own circumference so as to adjust according to the fluctuations in the diameter of the pipeline. Such fluctuations in diameter of the pipeline may be due to cracks or bends in the pipeline. The degree in fluctuation in diameter of the pipeline may be upto 20% for which the magnetizer is capable to adjust itself to have maximum contact with the inner surface of the pipeline

[0035] In accordance with the present invention, Fig. 1a shows the magnetizer section of the movable adaptable magnetizer device. The diameter of the magnetizer section is greater than the inner diameter of the pipeline to be inspected. The adaptable magnetizer section has the capability to adjust as per the spatial requirements. The magnetizer section comprises a plurality of magnetic bar assembly arranged around a central shaft assembly. The movement of the magnetic bars is flexible for adapting to variation in inner diameter of the pipeline.

[0036] As an embodiment, Figure 1b shows arrangement of the adaptable magnetizer. When the magnetizer device is launched in the fluid pipeline, the adaptable magnetizer adjusts itself with the inner diameter of pipeline and a constant magnetic flux gets detected by hall sensors. The magnetic flux of the pipeline gets disturbed and fluctuates from normal on encountering any defect in the pipeline material. These flux leakages are subsequently detected by hall sensors arranged on magnetizer assembly.

[0037] Fig. 2 of the present invention shows an exploded view of the magnetizer section wherein a plurality of magnetic bar assembly (6) is configured around a shaft assembly in a circular arrangement. In an embodiment, 6 magnetic bars are mounted on the shaft assembly through linkage bars.

[0038] The shaft assembly comprises a central shaft (1) and a pair of shafts coaxially arranged at the anterior and posterior ends of the central shaft (1) i.e. front shaft (2) and rear shaft (3). The anterior end of the shaft i.e. the front shaft (2) is removably connected to the central shaft (1) by means of a plurality of magnetic caps (5) and a plurality of linkage arms (4). The linkage arms (4) provide connectivity and hold together the magnetic bar assembly (6) with the front shaft (2) of the shaft assembly. The posterior end of the shaft i.e. the rear or end shaft (3) binds together the magnetic bar assembly (6) with the posterior end of the shaft assembly.

[0039] Fig. 3 and Fig. 4 of the present invention depict a magnetic bar assembly in its singular and exploded arrangement (6). The magnetic bar assembly (6) as disclosed in Fig. 3 and Fig. 4 comprises an anchor block (7) made up of a strong metal having an anterior protruding end (8) and a posterior protruding end (9) configured with bolt assembly to engage bumpers (15, 16) and wear plates (13, 14). The central portion of the anchor block is configured to mount a plurality of flapper assembly (17) in between a plurality of mounting arrangements (10) and (11). In a specific embodiment, a total of 24 flappers are mounted through spring steel on the magnetic bar assembly.

[0040] A plurality of strong permanent magnets (12) are located on the either side of the plurality of flapper assembly (17) i.e. between the flapper assembly (17) and the ends of the shaft assembly. The magnets (12) are located on both the front and rear end of the magnetic bar assembly (6) and covered by the bumper, wherein the front bumper (15) is engaged with the anterior end of the anchor block (8) and rear bumper (16) is engaged with the posterior end of the anchor block (9). The bumpers (15, 16) in turn are encased within the wear plates (14, 13) at front and rear ends of the anchor block. Thus, front bumper (15) and front wear plate (14) are fixed to the anchor block front (8) and the rear bumper (16) and rear wear plate (13) are both fixed to the anchor block rear (9).

[0041] In an embodiment, the magnets used herein may be selected from super strong magnets which can generate an axial magnetic flux of at least 1 Tesla. The super strong magnets include but not limited to magnets of the formula Nd2Fe14B (neodymium magnet), SmCo (Samarium cobalt magnets) etc. Nd2Fe14B is an alloy of neodymium, iron and boron, and preferably used because of its high strength. In a preferred embodiment, the magnet is Neodymium N52, which is a super strong permanent magnet that may achieve the axial magnetic flux of 1.43 Tesla (T)/ magnet.

[0042] The strong permanent magnets of the front magnetic bar assembly are encased in between the anchor block front (8) and mount magnet front (10) and is placed within the wear plate front (14) and in turn by the bumper front (15). In a similar embodiment, the strong permanent magnets are kept intact at the rear side/ end of the magnetic bar assembly. The permanent magnets at the rear ends are placed in between the anchor block rear (9) and mount magnet rear (11) and is encased within the wear plate rear (13) and in the bumper rear (16). A plurality of flapper assembly is placed in between the mount magnet front (10) and mount magnet rear (11).

[0043] A plurality of flapper assembly (17) is housed on the outer surface of the adaptable magnetizer. The plurality of flapper assembly (17) is mounted on the magnetic bar through spring steel. Fig. 5 of the present invention depicts an exploded view of the flapper assembly (17). The flapper assembly (17) comprises, but is not limited to, a plurality of flappers enclosing a plurality of proximity sensors (19) and a plurality of hall- effect sensors (20). The plurality of hall- effect sensors (20) are placed on magnet-plate-casing assembly. The hall- effect sensors (20) detect and/ or inspect the magnetic flux leakage. The proximity sensors (19) identify the placement of defects on the inner or outer surface of the pipeline. These sensors keep sensing the field and the data is continuously processed and stored through the use of microcontrollers placed in the CPU section of the adaptable magnetizer which is placed at the back side of the metal housing. In a specific embodiment, 24 flappers embody 96 hall sensors and 24 proximity sensors. Four flappers are clubbed through a single microcontroller unit (MCU).

[0044] Fig. 6 depicts the CPU section / storage unit attached to the adaptable magnetizer device. and Fig. 7 illustrates arrangement of the components of the adaptable magnetizer device assembly.

[0045] A plurality of microcontrollers (MCU) is placed in the CPU section of the magnetizer device at back side of the metal housing for storing leakage data. Each MCU supports a set of flappers. This helps in reducing the risks of losing data in case of any damage caused to any flapper. The microcontrollers remain safe and secure with data being captured by the controllers and not the flappers. In previous inventions the flappers are loaded with microcontroller and in case of any physical damage, the data collection and processing get hampered. This method also allows reducing the number of wires being used for data collection.

[0046] A total of 6 MCUs capture the overall flux leakage across the diameter of pipeline. The data captured by the MCUs is sent to central processing unit (CPU) for further processing and storage in a flash drive through various connectors and cables. These connectors are used for processing of leakage information. The power supply to magnetizer, MCUs, and CPU is provided through a separate unit called battery section. A plurality of other devices that need controlling can also be attached to CPU section which includes but are not limited to Odometer, Transmitter etc.

[0047] The plurality of magnetic bars capable of adapting to the variation in the inner diameter of the pipes to avoid tool stucking in the pipeline by implementing a retractable multiple bar mechanism. The magnetic core may further be shielded by a hardened steel and enables to achieve wear- resistant functioning of the pipeline.

[0048] The adaptable magnetizer device used for inline inspection of pipeline can move axially inside the pipeline and can detect the leakage, cracks and/or deformities generated inside inner as well as outer surface of the pipeline. A magnetic field is created across outer surface of the magnetizer section by the adaptable magnetizer device. The flux leakage is measured by a data sensing unit. The data sensing unit comprises of a plurality of proximity sensors (19) to identify the placement of defects on the inner or outer surface of the pipeline and a plurality of hall-effect sensors to detect magnetic flux generated. The data analysis unit analyses the flux leakage information and the data storing unit captures and store output data; wherein, the output data gets stored at the CPU section of the device and yields comprehensive information which is not limited to valve bends, welds, anomalies present in the pipeline. The output generated gets stored in CPU section of the adaptable magnetizer at 1500 sample/ second/ sensor.

[0049] The present invention also discloses a process for inline inspection by an adaptable magnetizer. The adaptable magnetizer moves axially inside the pipeline carrying fluids/gas, while adapting to the inner variation of the pipeline to avoid being obstructed by any crack or bend inside the pipeline. The flexible movement of the adaptable magnetizer is achieved through bars for adjusting to variation in inner diameter of the pipeline. When commissioned in pipeline due to differential pressure of the fluid, the tool starts moving in the direction of flow. To accommodate for the space requirement, the linkage arms rotate, and the magnetic bar turns in such a manner that the dimension of the adaptable magnetizer is just fit and make regular contact with the inner surface of the pipeline.

[0050] As the tool passes through the pipeline, a strong magnetic field is induced into the pipe wall by magnets of the inspection tool. The magnetic flux is created by the super strong magnet inside the magnetizer section which is detected by the sensors placed in the flappers. Defects in the pipeline are present in the form of discontinuities that will cause redistribution of the magnetic flux around itself (the defect) and thus, some of the magnetic flux lines leak out into the surrounding surfaces. This deviation in the flux leakage field are then detected by the sensors installed in the flappers.

[0051] The flexibility of the device used in our invention also ensures easy identification and measurement of defects within the pipeline surface and aids the proximity sensors to detect the flaws or abnormalities with precision. The data generated by the sensors of the adaptable magnetizer are capable of providing high repeatability of the flaws and defect detection.

[0052] The data generated is then stored simultaneously in the adjacent section . A plurality of flappers sends data to the microcontrollers in the CPU section of the device and yields comprehensive information relating to valve bends, welds, cracks and other anomalies present in the pipeline.

[0053] ADVANTAGES OF ADAPTABLE MAGNETIZER:
The adaptable magnetizer of the present invention when employed in the pipeline offers a number of advantages:
a. Flexibility: As the arms of the agnetizer can rotate, the Magnetic bars can adjust with the variation in the thickness of the pipeline.
b. Pass through 1.5 D Bend: The adaptable magnetizer is designed in such a way that it can easily pass through a 1.5D bend which is a necessary condition for pigging.
c. Continuous contact with Pipeline: The flexibility of this Magnetizer ensure that it remains in continuous contact with the pipeline. Which is required for the flappers to be in continuous contact.
d. Ease in defect Measurement & Identification: With the above conditions of continuous contact, the defect identification and measurement of the defects is quite easy. This aids the proximity sensors to detect the flaws or abnormalities present in the pipeline with good precision.
e. High Data Rate: The data generated by the sensors of this adaptable magnetizer can be transferred up to 1500 data points per seconds, which gives the high repeatability of the flaws and defect detection.
f. Reduction in Vibrations: Due to the flexibility, there is significant reduction in the vibrations which results in improved life of the Magnetizer and high accuracy.

[0054] While the present invention has been described with reference to one or more preferred aspects, which aspects have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, such aspects are merely exemplary and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the invention. The scope of the invention, therefore, shall be defined solely by the following claims. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the invention.