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.

Description

TECHNICAL FIELD

[0001] The invention relates to methods and apparatus to detect faults in conduits, such as hoses and the like.

BACKGROUND

[0002] To operate a well, various operations are performed. For example, after a wellbore has been drilled, casing can be installed in the wellbore by cementing the casing to the walls of the wellbore. To perform the cementing operation, cement slurry is pumped into the wellbore to fill the annulus between the casing and the wellbore. Mixing and pumping equipment, which can be carried on a truck, is brought out to the well site for performing cement mixing and for pumping cement slurry into the wellbore. The common way for delivering cement slurry from the cement mixer to the well site is by use of treating iron. However, treating iron, which is typically made of a metal such as steel, is relatively heavy. As a result, equipment used to deploy treating iron is often large and unwieldy. Thus, it may be desirable to use flexible conduits formed of materials that are lighter weight than metal tubing. One example of a flexible conduit is a multi-layered hose with rubber layers and reinforcement metal wires.

[0003] Conduits can also be used to pump other types of fluids into a wellbore, such as gravel packing fluids, fracturing fluids, clean-up fluids, and so forth. For enhanced flexibility and ease of use, conduits are mounted on a reel, with the reel rotated to deploy and retrieve the conduit. After the well operation has been completed, the reel can be rewound to reload the conduit. However, after multiple uses of the conduit, deterioration of the conduit and other damage may occur. A damaged conduit may fail and cause injury to well site personnel, as well as damage to the well. If a damaged conduit is encountered at a well site, then operations at the well site may have to be halted until a replacement conduit can be found and brought to the well site, which may cause substantial delays. Delays in well operations can result in substantial costs to the well operator.

SUMMARY

[0004] In general, according to one embodiment, an integrity monitor for use with a conduit comprises a receiving mechanism adapted to receive the conduit. The receiving mechanism is adapted to further bend the conduit by a predetermined amount. A detector device is adapted to measure a force applied by the bent conduit.

[0005] Other features and embodiments will become apparent from the following description, from the drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 illustrates an embodiment of equipment used to deploy a conduit into a wellbore.

[0007] FIG. 2 is a cross-sectional view of an example conduit.

[0008] FIGS. 3A-3G illustrate various possible defects in the conduit of FIG. 2.

[0009] FIG. 4A is a rear-view of a truck carrying a reel assembly and a conduit integrity monitor, in accordance with one embodiment, to detect defects in the conduit of FIG. 1.

[0010] FIG. 4B is a schematic view of the conduit integrity monitor.

[0011] FIG. 5 illustrates a bending stiffness detector that is part of the conduit integrity monitor of FIG. 4B.

[0012] FIG. 6 illustrates an example load cell for use in the bending stiffness detector of FIG. 5.

[0013] FIG. 7 illustrates a conduit axial position detection device that is part of the conduit integrity monitor of FIG. 4B.

[0014] FIG. 8 is a graph that illustrates the bending stiffness of a conduit, with some portions of the conduit having defects.

[0015] FIG. 9 illustrates a conduit integrity monitor according to another embodiment.

[0016] FIGS. 10A-10C illustrate, respectively, positions of three sets of inductive sensors in the conduit integrity monitor of FIG. 9.

[0017] FIG. 10D illustrates the collective positions of the inductive sensors of FIGS. 10A-10C.

[0018] FIG. 11A is a graph representing the minimum and maximum diameters of a conduit along its length as measured by the conduit integrity monitor of FIG. 9.

[0019] FIG. 11B is a graph representing the ovality of a conduit along its length as measured by the conduit integrity monitor of FIG. 9.

[0020] FIGS. 12A-12B are graphs showing changes in the shape of a conduit in response to a pressure test.

[0021] FIG. 13 is a vertical sectional view of a connection assembly for connecting to a conduit.

[0022] FIGS. 14A-14B are a vertical sectional view of a liner wear detector, in accordance with an embodiment.

[0023] FIG. 15 illustrates a mechanism to detect separation of a conduit from a connection assembly.

DETAILED DESCRIPTION

[0024] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.

[0025] As used here, the terms “up” and “down”; “upward” and “downward”; “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the invention. However, when applied to equipment and methods that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.

[0026] Referring to FIG. 1, in accordance with one example embodiment, a truck 12 carrying equipment including a reel assembly 14 is located at a well site that includes a well 10 and wellhead equipment 16. Although not shown, the truck 12 also includes pump equipment and mixing equipment (e.g., cement mixer). The reel assembly 14 carries a conduit 20 that can be unreeled from the reel assembly 14 for connection to the wellhead equipment 16. A cement head 24 and manifold 22 are connected at the upper portion of wellhead equipment 16, with the hose 20 connected to the manifold 22. In other embodiments, other arrangements for connecting the hose 20 to the wellhead equipment can be employed.

[0027] In accordance with some embodiments of the invention, the conduit 20 is a flexible hose that is formed of various layers. As shown in the cross-sectional view of FIG. 2, the conduit 20 includes an inner liner 102, a reinforcement layer 104, another layer 106, and an outer jacket 108. The conduit 20 defines an inner bore 100 through which fluids can flow. In one example embodiment, the liner 102 and the layer 106 can be formed of a flexible material such as rubber. The outer jacket 108 is formed of a durable or wear-tolerant material, such as high-density polyethylene. The reinforcement layer 104 can be formed of metal wires arranged at different angles to provide support for the conduit 20. In other embodiments, the conduit 20 can have other arrangements (whether single-layered or multi-layered) and can be formed of other materials. The conduit 20 is designed to withstand high pressures (e.g., greater than about 1,000 psi) during operation when a fluid or slurry is pumped through the conduit 20. Also, the reinforcement layer 104 provides relatively high tensile strength for the conduit 20. More generally, the reinforcement layer 104 is considered a “structural layer” of the conduit, since it provides the structural strength of the conduit 20.

[0028] The conduit 20 can be subjected to various types of deterioration and damage over time. This occurs when the conduit 20 is repeatedly reeled and unreeled from the reel assembly 14 and connected to the wellhead equipment 16 Also, handling by personnel at the well site may also cause damage, such as when the conduit 20 collides with other equipment, is run over by vehicles, and so forth.

[0029] Alternatively, instead of a flexible hose, the conduit 20 can be a composite coiled tubing. Typically, a composite coiled tubing includes an inner liner (which can be formed of a thermoplastic material in one example) and one or more structural reinforcement layers (made of graphite fiber or fiberglass, as examples). Other example composite coiled tubings are described in U.S. Pat. No. 5,828,003. Composite coiled tubing is deployed into the wellbore 10 through wellhead equipment 16, rather than to an attachment as in the case of the flexible hose.

[0030] FIGS. 3A-3G illustrate examples of deterioration or damage that may be experienced by the conduit 20. FIG. 3A shows the conduit 20 being flattened so that deformation occurs at portions 200 and 202. The effect is a substantially non-circular conduit. FIG. 3B shows a conduit 20 in which corrosion 204 has removed or weakened a portion of the layers of the conduit 20. FIG. 3C shows a kink 206 in the conduit 20, where one part along the circumference of the conduit 20 has been deformed. Generally, bending stiffness is lowered at the kinked portion 206, and bending stiffness may increase at other portions of the conduit in the same cross-section, making it hard to bend in a different direction.

[0031] FIG. 3D shows wear of the inner liner 102, as indicated by 208. When fluids are run through the bore 100 of the conduit 20, such fluids can wear away the liner 102 of the conduit 20 over time.

[0032] FIG. 3E shows external damage at a portion 210 of the conduit 20. FIG. 3F shows a manufacturing defect at location 212, where the metal reinforcement layer 104 is not properly formed. FIG. 3G illustrates damage to an inner part of the reinforcement layer 104 due to an over-pressure condition within the bore 100 of the conduit 20.

[0033] Except for the liner defect shown in FIG. 3D, the other defects shown in FIGS. 3A-3C and 3E-3G affect the bending stiffness of the conduit at various portions. In accordance with some embodiments of the invention, a conduit integrity monitor is used to monitor the bending stiffness of the conduit along its length so that the presence of such defects can be identified. Because the conduit 20 is relatively flexible, the shape of the conduit 20 is changed when pressure is increased in the conduit 20. In another embodiment, a proximity sensor can be used to detect for changes in the shape of the conduit, with and without pressure within the conduit 20. Both these devices are explained in greater detail below.

[0034] FIG. 4A illustrates a rear view of the truck 12 and reel assembly 14 of FIG. 1. A conduit integrity monitor 300 is mounted on the truck 12, with the conduit 20 run through the integrity monitor 300. As the conduit 20 is unreeled, the conduit 20 extends through the integrity monitor 300 so that the integrity of the conduit 20 is monitored along its length. While the conduit 20 is being run through the integrity monitor 300, one or more characteristics of the conduit 20 along the length of the conduit can be detected by the integrity monitor 300. This can be communicated to an operator console that is located either on the truck 12 itself or at some other location.

[0035] As represented in FIG. 4B, the integrity monitor 300 includes a conduit axial positioning device 304 and first and second bending stiffness detectors 302 and 304 positioned on either side of the positioning device 304. In other embodiments, other arrangements of positioning device(s) and bending stiffness detector(s) can be employed. The bending stiffness detector 302 is mounted to detect bending stiffness along an X axis (FIG. 2), which corresponds to the 0° cross-sectional axis of the conduit 20. The second bending stiffness detector 306 is mounted generally perpendicularly to the first bending stiffness detector 302, and is capable of detecting bending stiffness of the conduit 20 along a Y axis (FIG. 2), which corresponds to the 90° cross-sectional axis of the conduit 20. Thus, the integrity monitor 300 is capable of detecting bending stiffness along two different cross-sectional axes. In other embodiments, only one bending stiffness detector or more than two bending stiffness detectors can be used.

[0036] Referring to FIG. 5, the bending stiffness detector 302 or 306 is illustrated in greater detail. In one embodiment, the bending stiffness detector includes three rollers 402, 404, and 406 (which can be knurled rollers). The roller 402 includes a portion 408 that is shaped to receive the generally tubular conduit 20. The rollers 404 and 406 similarly include corresponding receiving portions 410 and 412. The rollers 402 and 406 are generally at a first level while the roller 404 is positioned at another level below the first level. The rollers 402, 404 and 406 are arranged to bend the conduit 20 by a predetermined bending radius. For example, for a conduit having a diameter of about 2.8 inches, the bending radius can be selected to be greater than the minimum specified bend radius of the conduit 20 (e.g., about 30 inches).

[0037] First and second alignment clasps 414 and 416 are used to position the rollers 402 and 406. The adjustment to achieve the desired bending radius of the conduit 20 passing through the bending stiffness detector is through the position of the roller-load cell assembly 404, 420.

[0038] The roller 404 is mounted on a load cell device 420 that measures a downwardly vertical force applied by the roller 420 due to interaction of the conduit 20 and the rollers 402, 404, and 406. The roller 404 is rotatably mounted in a retainer 430 having a bottom plate 432 that is in contact with the load cell device 420.

[0039] Referring to FIG. 6, the load cell device 420 according to one example embodiment has a loading surface 450 and circuitry (not shown) that is capable of detecting a force applied along the direction L. The loading surface 450 is in contact with the bottom plate 432 of the retainer 430. An electrical connector 452 is attached to the side of the load cell device 420 to enable the load cell device 420 to be electrically connected to another component, which receives signals generated by the load cell device 420 indicating the force applied due to bending of the conduit 20, from which the bending stiffness of the conduit 20 at different portions can be derived. In one embodiment, the load cell device 420 is a pancake load cell from Futek Advanced Sensor Technology, Inc. In other embodiments, other devices for detecting forces applied by the conduit 20 subjected to predetermined bending can also be employed.

[0040] The arrangement in FIG. 5 shows a first orientation of the bending stiffness detector with respect to the conduit 20. In the arrangement shown in FIG. 5, the bending stiffness detector is positioned to measure the bending stiffness of the conduit 20 along the Y direction (FIG. 2). However, if the bending stiffness detector is rotated about 90° with respect to the conduit 20, then the bending stiffness detector is positioned to measure the bending stiffness of the conduit 20 along the X direction, which is perpendicular to the Y direction (FIG. 2).

[0041] Referring to FIG. 7, the conduit axial positioning device 302 is illustrated. The axial positioning device 302 includes a first roller 502 that is rotatably mounted to a housing 504 of the axial positioning device 302. The axial positioning device 302 also includes a second roller 506 that is rotatably mounted to a spring-loaded retainer 508. The roller 502 is generally fixed in position with respect to the housing 504, but the spring-loaded retainer 508 allows up and down movement of the roller 506 to enable positioning of the conduit 20. The rollers 502 and 506 include respective receiving portions 503 and 507 to receive the conduit 20.

[0042] The roller 502 is mounted on a pin (not shown) that is rotatably attached to the housing 504. The pin is also operably coupled to a counter 510 that counts the number of times that the roller 502 rotates. This enables the operator of the reel assembly 14 to determine the position of the conduit 20 with respect to the conduit integrity monitor 300. Thus, if damage is detected, the operator can determine where along the conduit 20 the damage has occurred.

[0043] Referring to FIG. 8, a graph shows the bending stiffness of the conduit 20 along its axial position as measured by the conduit integrity monitor 300. Curves 602 and 604 represent the bending stiffness of the conduit (along the X and Y directions) before first use of the conduit (job 0). Curves 606 and 608 represent the bending stiffness of the conduit 20 along its axial position in the X and Y directions after a predetermined number of uses (e.g., 500 jobs). Bumps in the curves 606 and 608 proximal position P1 of the conduit 20 represent the change in bending stiffness due to a kink (such as that shown in FIG. 3C). Because of the kink, the bending stiffness along one direction (X or Y) increases while the bending stiffness along the perpendicular direction decreases. Further along the conduit 20, a over-pressure defect in the conduit 20 causes the bending stiffness along both the X and Y directions to be decreased.

[0044] As shown in FIG. 8, a curve 610 represents an acceptable minimum bending stiffness of the conduit 20. As bending stiffness drops, other important physical properties of the conduit are affected, such as the burst pressure of the conduit. Thus, bending stiffness is a key indicator of wear and physical damage. In the example of FIG. 8, the kink and over-pressure defects are not enough to cause the bending stiffness to fall below the acceptable level. However, this may not always be true, since with further uses, the kink and over-pressure defects may deteriorate to a point that the bending stiffness along one of the X and Y directions would fall below the acceptable level. If that occurs, then some type of a warning may be issued to the operator of the reel assembly 14 so that use of the conduit 20 can be stopped. Alternatively, before a reel assembly 14 is delivered to a job site, the operator of the reel assembly can check the bending stiffness of the conduit to ensure that the conduit is not close to failure. If so, then the operator can choose another reel assembly to take to the job site.

[0045] In accordance with another embodiment, instead of using a conduit integrity monitor system that monitors the bending stiffness of the conduit 20, a proximity monitoring system 700 uses analog inductive proximity sensors 702, as shown in FIG. 9. Each inductive proximity sensor 702 is designed to detect its proximity with an electrically conductive layer (in this case the metal reinforcement layer 104) in the conduit 20. The inductive proximity sensor 702 detects for induced magnetic fields in the electrically conductive layer, and based on the strength of the induced magnetic fields, is able to determine a distance between the inductive proximity sensor and the electrically conductive layer. The inductive proximity sensor is able to measure the distance through non-electrically conductive layers (108 and 106) of the conduit 20. Calibration data is stored in a memory module on each sensor, with the calibration data used to enable an accurate measurement of the distance. The calibration data calibrates for individual sensor distance response as well as for variations of the response with temperature. Optionally, temperature in the vicinity of the sensors can be measured, with the measured temperature used to select the appropriate calibration data to use.

[0046] Multiple sensors 702 are arranged along the circumference of the conduit 20. Thus, if the conduit 20 is not damaged, the conduit will be substantially circular, and the inductive proximity sensor 702 will detect a distance between the sensor and the reinforcement layer 104 of the conduit 20 that is within a predetermined range. However, if any portion of the conduit 20 is damaged, then that portion may be substantially further away or closer to one or more of the inductive proximity sensors than the other sensors. Further, when internal pressure is applied in the conduit 20, substantial shifts are seen in the distances to the sensors (due to deformation of the conduit) when compared to an undamaged conduit. The substantial shifts in detected distances are used to identify damaged locations of the conduits. Thus, going back to the defect shown in FIG. 3A, the conduit 20 at locations 200 and 202 will be closer to the proximity sensors positioned proximal those locations, and a substantial shift in detected distances will occur under internal pressure. This is also the case for defects shown in FIGS. 3B, 3C, 3E, 3F, and 3G; however, the proximity sensor may not be able to pick up defects shown in FIG. 3D, which is a non-structural defect that does not affect the overall shape of the conduit 20.

[0047] The proximity monitoring system 700 includes a first set 704 of positioning rollers 706 and 708 and a second set 710 of positioning rollers 712 and 714. The first set 704 of rollers 706 and 708 are arranged generally along direction 750 to center the conduit 20 along that direction, while the second set 710 of rollers 712 and 714 are arranged generally along direction 752 to center the conduit 20 along that direction. The conduit 20 is passed through an opening formed in a “scraper” 718. The scraper 718 has a housing in which the inductive proximity sensors 702 are mounted around the conduit 20.

[0048] There are three sets of inductive proximity sensors: a first set 702A, a second set 702B, and a third set 702C. In one embodiment, as illustrated, the three sets of inductive proximity sensors 702 are offset longitudinally along the conduit 20. This offsetting enables more inductive proximity sensors 702 to be arranged around the conduit 20 without affecting the accuracy of the detection of distances.

[0049] Referring to FIGS. 10A-10C, the positions of the three sets of proximity sensors referenced to the conduit 20 are illustrated. In FIG. 10A, the first set of proximity sensors 702A are arranged at 0°, 90°, 180°, and 270°. The second set of proximity sensors 702B are arranged at 30°, 120°, 210°, and 300°. As shown in FIG. 8C, the third set of proximity sensors 702C are positioned at 60°, 150°, 240°, and 330°. The collection of all three sets of proximity sensors 702A, 702B, and 702C are illustrated in FIG. 8D. The proximity sensors work in pairs (about 180° apart) to enable measurement of the diameter of the conduit between each pair of sensors.

[0050] FIGS. 11A-11B illustrate how the proximity monitoring system 700 can be used to monitor the integrity of the conduit 20. FIG. 11A is a graph that plots the maximum and minimum diameters of the conduit 20 (as detected by each of the six pairs of proximity sensors 702) along the axial length of the conduit 20. A first curve 800 represents the maximum acceptable diameter, and a second curve 802 represents the minimum acceptable diameter. A curve 804 represents the maximum diameter among the diameters detected by the twelve sensors at each point along the conduit 20. A curve 806 represents the minimum diameter among the diameters detected by the twelve proximity sensors. A first upward spike 808 on the curve 804 represents an increase in diameter at a first position of the conduit 20, and a first downward spike 810 on the curve 806 represents a decrease in diameter at a second position of the conduit 20. A second downward spike 812 occurs at a later position along the conduit 20. In the illustrated example, the tip of the first downward spike 810 reaches the minimum acceptable diameter, while the tip of the second downward spike 812 falls below the minimum acceptable diameter, which indicates that the conduit 20 has experienced a substantial change in shape. Thus, the conduit 20 in the example of FIG. 11A would be unacceptable for use.

[0051] The curves are shown to an operator (on a display, such as one on the truck 14) when the hose 20 is reeled out at the beginning of a job, and also when the hose 20 is reeled back in at the end of a job.

[0052] FIG. 11B illustrates a graph that plots ratio of the minimum diameter to the maximum diameter (Dmin/Dmax) along the axial axis of the conduit 20. The graph represents the ovality at each point along the conduit 20. A curve 820 represents the minimum acceptable ovality. A curve 822 represents the ovality along the length of the conduit before the first job, while a curve 824 represents the ovality of the conduit 20 after 500 jobs. The downward spikes in each of the curves 822 and 824 show where defects cause the ovality to drop. In the example, after 500 jobs, the ovality of the conduit 20 is unacceptable at two locations, a first location corresponding to downward spike 826 and a second location corresponding to downward spike 828.

[0053] Referring to FIGS. 12A-12B, in conjunction with use of the proximity monitoring system 700 of FIG. 9, a pressure test can be performed to determine the integrity of the conduit 20. Pressure is built up in the bore 100 of the conduit 20 to a predetermined level, with the idea that portions of the conduit that are defective would change their shapes more than other portions of the conduit 20. In FIG. 12A, the change in shape at each position along the conduit 20 due to the pressure test is plotted before first use of the conduit 20. The curve 850 represents no change in response to the pressure test. The curve 852 represents the maximum change detected by one of the twelve proximity sensors, while the curve 854 represents the minimum change detected by another one of the twelve proximity sensors.

[0054] FIG. 12B illustrates the change in shape of the conduit 20 in response to the pressure test after the conduit has been used in 500 jobs. The curve 852A represents the maximum change in shape detected by one proximity sensor (an increase in distance from the sensor), while the curve 854A represents the minimum change in shape detected by another proximity sensor (a reduction in distance from the sensor). As shown in FIG. 12B, the portions of the conduit 20 that are defective experience the greatest shape change, as evidenced by spikes 860 and 862 on curve 852A and spike 864 on curve 854A.

[0055] Thus, in accordance with some embodiments of the invention, conduit integrity monitors are provided to detect for certain types of faults, defects, or damage. One conduit integrity monitor monitors the bending stiffness of the conduit, while another integrity monitor detects the change in shape of the structural layer of the conduit. Shape changes (e.g., a conduit becoming more oval or other shape changes as discussed above) indicate a reduction in physical strength of the conduit at the cross-section, which may cause the conduit to fail at an unacceptably low internal pressure or in response to other forces. By detecting for faults in the conduit, defective or damaged conduits can be replaced before they are brought to the well site, where conduit failure may cause substantial delays in well operation and add substantial costs. Also, conduits that fail suddenly and unexpectedly may pose serious safety concerns to well personnel.

[0056] Another concern associated with connecting a flexible conduit, such as the multi-layered composite conduit 20 shown in FIG. 2, to another structure is the integrity of the connection mechanism. If an unreliable connection mechanism is used, then it is likely that the conduit 20 will separate from a connector during operation.

[0057] Referring to FIG. 13, a connection mechanism 1100 in accordance with one embodiment for connecting the conduit 20 to a connector 1102 is illustrated. The conduit 20 has multiple layers, with the external layer 108 and the internal liner 102. To achieve a more reliable connection between the conduit 20 and the connector 1102, an insert 1104 and a crimp are used to more securely engage the flexible conduit 20. One end of the insert 1104 has a flange 1106 that sits on a connector ring 1108. The other end of the insert 1104 has an outer sawtooth profile 1110 for engaging the inner surface of the liner 102. Also, the crimp 1112 is provided around the outside of the insert 1104, with the crimp 1112 having inner protrusions 1114 that engage the outer surface of the external conduit layer 108. A first end of the crimp 1112 has an engagement member 1116 that fits into a groove 1118 formed on the outer surface of the insert 1104. The inner diameter of the inner protrusions 1114 of the crimp 1112 progressively increases the further they are from the first end of the crimp 1112. This enables easier engagement of the conduit 20 into an annular space between the sawtooth profile 1110 of the insert 1104 and the inner protrusions of the crimp 1112. The crimp 1112 is compressed onto the conduit 20 while the crimp 1112 is on the insert 1104.

[0058] Referring to FIG. 15, once the conduit 20 is connected to the connection mechanism 1100, one portion of the connection mechanism 1100 and the adjacent end portion of the conduit 20 can be painted with some predetermined color or otherwise marked. Thus, a first mark 1122 is provided on a portion of the connection mechanism 1100 adjacent the conduit, and a second mark 1124 is provided on a portion of the conduit 20 adjacent the connection mechanism 1100. If slippage occurs between the conduit 20 and the connection mechanism 1100, a gap 1120 will develop between the marked portion 1124 of the conduit 20 and the marked portion 1122 of the connection mechanism 1100. This gap provides a visual indication to the operator that the connection of the conduit 20 is about to fail. Such a slippage detection mechanism and method can be applied to a flexible hose. Alternatively, the slippage detection mechanism and method according to other embodiments can be applied to a composite coiled tubing.

[0059] Another issue associated with use of the conduit 20 is that the liner is prone to wear after repeated use. However, it is usually difficult to determine when the liner 102 has been damaged to a level that makes it unsafe or unreliable to use. As noted above, wear of the liner 102 is difficult to detect with the bending stiffness detector (FIG. 5) or the proximity integrity monitor (FIG. 9). To enable detection of liner wear, a liner wear detector device 1200 in accordance with some embodiments is used, as shown in FIGS. 14A-14B. One end of the conduit 20 is connected by a connection mechanism 1202 that is similar to the connection mechanism 1100 of FIG. 13. The connection mechanism 1202 is in turn connected by a connector mandrel 1204 to another connection mechanism 1206 that is part of the wear detector device 1200. The wear detector device 1200 has a housing 1208 that is threadably connected to the connection mechanism 1206. Inside the housing 1208 is arranged a first sleeve 1210 that is threadably connected to a second sleeve 1212. The first sleeve 1210 has a narrowed portion 1214 that ends at a shoulder 1216. The second sleeve 1212 similarly has a narrowed portion 1218 that ends in a shoulder 1220. In accordance with some embodiments, a liner insert 1222 can be placed between the shoulders 1216 and 1220. The liner insert 1222 is formed of the same material as the liner 102 in the conduit 20. The first and second sleeves 1210 and 1212 form part of a retainer mechanism for the liner insert 1222 (also referred to as a “test liner”).

[0060] The wear detector device 1200 can be periodically detached from the connection mechanism 1202 so that the sleeves 1210 and 1212 can be pulled out of the wear detector device 1200. The sleeves 1210 and 1212 can then be unscrewed so that the liner 1222 can be pulled out for examination. Wear in the liner insert 1222 can be visually detected. If the liner insert 1222 is deteriorated, then it can be assumed that the liner 102 in the conduit 20 may also be similarly deteriorated since the same fluid flows through at the same rate. When that occurs, the conduit 20 is replaced with a new conduit. A test liner can be used with either a conduit system containing a flexible hose or a composite coiled tubing. For use with a composite coiled tubing, the wear detector device 1200 is modified to connect to the composite coiled tubing.

[0061] While the invention has been disclosed with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover such modifications and variations as fall within the true spirit and scope of the invention.

Claims

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.