Method and apparatus for special end area inspection

A magnetic inspection system to inspect tubular member ends and tubular couplers, the magnetic inspection system comprising:

• a longitudinal flaw detection assembly (LFDA) that generates a magnetic field that passes circumferentially through the end of the tubular member;
• a transverse flaw detection assembly (TFDA) that generates a magnetic field that passes longitudinally through the end of the tubular member;
• an inspection station frame assembly positioned on a substantially planar horizontal surface, the LFDA and the TFDA mounted to the inspection station frame assembly so that the LFDA and the TFDA are spaced-apart from the substantially planar horizontal surface, the LFDA and the TFDA positioned on the inspection station frame assembly so that the end of the tubular member is positioned in both the LFDA and the TFDA;
• a magnetic particle inspection (MPI) insertion apparatus adapted to coat the tubular member in an MPI fluid, the MPI fluid having a plurality of ferromagnetic particles suspended therein, the ferromagnetic particles appearing fluorescent when exposed to an ultraviolet light;
• an ultraviolet light assembly adapted to expose an exterior surface of the tubular member to ultraviolet light and an interior surface of the tubular member to ultraviolet light;
• a tubular member clamping apparatus positioned closely adjacent to and separate from the inspection station frame assembly, the tubular member clamping apparatus adapted to support the tubular member within the LFDA and the TFDA, rotate the tubular member within the LFDA and the TFDA about an axis of the tubular member that is substantially parallel to the substantially planar horizontal surface, the tubular member clamping apparatus exerts a compensating force on the tubular member that resists the magnetic forces of the LFDA exerted on the tubular member during inspection of the tubular member;
• and
• the tubular member clamping apparatus including:
• a vertical support beam mounted to the substantially horizontal surface;
• a first and second compensating piston assembly each having lower ends mounted to opposite sides of the vertical support beam;
• pivotable rollers mounted on ends of the respective compensating piston assemblies opposite the vertical support beam, the pivotable rollers supporting the tubular member;
• a clamping piston assembly coupled to a motorized roller to clamp the tubular member between the pivotable rollers and the clamping piston while rotating the tubular member;
• and
• wherein when the LFDA exerts a magnetic force on the tubular member pulling the tubular member toward a pole of the LFDA, the compensating pistons exert reactive forces on the tubular member to push one or more of the pivotable rollers into tighter contact with the tubular member.

A method for inspecting tubular members comprising:

• (a) inserting a tubular member into a longitudinal flaw detection apparatus (LFDA) and a transverse flaw detection apparatus (TFDA), the tubular member supported by a clamping apparatus adapted to rotate the tubular member on an axis of the tubular member;
• (b) rotating the tubular member with a motorized roller of the clamping apparatus;
• (c) passing a magnetic field generated by the LFDA circumferentially through the tubular member while spraying the interior and exterior of the tubular member with a magnetic particle inspection (MPI) fluid having a plurality of ferromagnetic particles that appear fluorescent when exposed to ultraviolet light;
• (d) exposing the interior and exterior of the tubular member to ultraviolet light and identifying areas of congregated MPI in response to the circumferential passage of the magnetic field;
• (e) passing a magnetic field generated by the TFDA longitudinally through the tubular member while spraying the interior and exterior of the tubular member with the MPI fluid;
• (f) exposing the interior and exterior of the tubular member to ultraviolet light and identifying areas of congregated MPI in response to the longitudinal passage of the magnetic field;
• and
• (g) in response to generation of magnetic forces by the magnetic fields, exerting a counteracting force on the tubular member with the clamping apparatus, preventing contact between the tubular member and the LFDA and the TFDA.