RESUMO
Pipeline inspection gauges (PIGs) carry out automatic pipeline inspection with nondestructive testing (NDT) technologies like ultrasound, magnetic flux leakage, and eddy current. The ultrasonic straight beam allows technicians to determine the wall thickness of the pipeline through the time of flight diffraction (TOFD), providing the pipeline reconstruction and allowing the detection of several defects like dents or corrosion. If the pipeline is of a long distance, then the inspection process is automatic, and the fluid pressure pushes the PIG through the pipeline system. In this case, the PIG velocity and its axial alignment with the pipeline cannot be controlled. The PIG geometry, the pipeline deformations, and the girth welds cause a continuous chattering when the PIG is running, removing the transducers perpendicularity with the inspection points, which means that some echoes cannot be received. To reduce this problem, we propose a novel method to design a sensor carrier that takes into account the angularity and distance effects to acquire the straight beam echoes. The main advantage of our sensor carrier is that it can be used in concave and convex pipeline sections through geometric adjustments, which ensure that it is in contact with the inner pipe wall. Our improvement of the method is the characterization of the misalignment between the internal wall of the pipeline and the transducer. Later, we analyzed the conditions of the automatic pipeline inspection, the existing recommendations in state-of-the-art technology, and the different mechanical scenarios that may occur. For the mechanical design, we developed all the equations and rules. At the signal processing level, we set a fixed gain in the filtering step to obtain the echoes in a defined distance range without saturating the acquisition channels. For the validation, we compared through the mean squared error (MSE) our sensor carrier in a straight pipe section and a pipe elbow of steel versus other sensor carrier configurations. Finally, we present the design parameters for the development of the sensor carrier for different pipeline diameters.
RESUMO
This paper presents the improvement of an ultrasonic pulse generator for a pipeline inspection gauge (PIG), which uses 64 transducers for inspecting distances up to 100 km with an axial resolution fixed at 3 mm and variable speeds between 0 and 2 m/s. An ultrasonic pulse generator is composed of a high-voltage (HV) MOSFETs, driver logic and an HV power supply. We used a DC-HV DC converter device as the HV power supply because it reduces the size of the ultrasound system considerably. However, pipeline geometry and inspection effects such as hammer and shock cause a variable pulse repetition frequency (PRF), producing voltage drops, poor quality of the HV pulse generated, failures in the dimensioning of defects and damage to devices by over-voltage. Our improvement is to implement a control scheme to maintain the high quality of the HV regardless of the variable PRF. To achieve this, we characterized three transfer functions of the DC-HV DC converter, varying the connected load to 10%, 45% and 80%. For the characterization, we used the least squares technique, considering an autoregressive exogenous (ARX) model. Later, we compared three control schemes: (1) proportional-integral-derivative (PID) tuned by simultaneous optimization of several responses (SOSR), (2) PID tuned by a neural network (NN) and (3) PI tuned by the analytical design method (ADM). The metrics used to compare the control schemes were the recovery time, the maximum over-voltage and the excess energy when the shock and hammer effects happen to occur. Finally, to verify the improvement of the HV pulser, we compared the ultrasonic pulses generated for various frequencies and amplitudes using the pulse generator with and without the control scheme.