Note: Descriptions are shown in the official language in which they were submitted.
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1
The invention relates to an in-pipe vehicle which can carry
out an operation within a pipeline, which pipeline may be
a gas carrying pipeline.
There have been various activities undertaken concerned
with pipeline inspection including remote cameras to enable
information on the internal condition of pipelines to be
obtained.
The present invention is concerned generally with an
arrangement which will allow operations to be undertaken
from within the pipeline, without the need for external
drives, umbilicals or other connections which restrict the
movement or utility of such arrangements.
According to one aspect of the invention there is provided
a pipeline vehicle comprising a plurality of linked modules
forming a powered train for travelling within a pipeline,
at least one of the modules being capable of carrying out
an operation on the pipeline, and wherein a module includes
clamping means for holding the vehicle at a fixed point in
the pipeline whilst rotational means are operable to rotate
part or parts of the vehicle to align the module capable of
carrying out the operation.
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2
Further, according to another aspect of the invention,
there is provided a method of effecting an operation on a
pipeline comprising passing a vehicle consisting of a train
of modules through the pipeline to detect the presence of
an item to be operated on; moving the vehicle to align a
module with the item to carry out the desired operation;
the alignment step including clamping the vehicle and
affecting axial movement of the module.
According to a further aspect of the invention, there is
provided a pipeline vehicle having a generally cylindrical
body portion and including detector means for detecting the
presence of a pipe junction in a main pipeline, means for
forming an aperture in a liner within the main pipeline,
and means for axially rotating the body portion to align
the aperture forming means with the pipe junction prior to
forming the aperture at the pipe junction prior to forming
the aperture at the pipe junction.
The abovementioned aspects of the invention are also
disclosed, and are claimed in Canadian Patent Application
No. 2,221,379, filed May 21, 1996, of which the present
application is a divisional.
Still further according to the invention there is provided
a flexible probe for indicating the proximity of an
auxiliary pipe to a device within the main pipe said probe
including means for generating a magnetic field for
detection by the device within the main pipe and indicator
means for generating a signal when the probe is adjacent to
the main pipe.
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3
The invention in its various aspects will now be described
by way of example with reference to the accompanying
drawings in which:
Figure 1 shows a main pipeline with a number of services
take-offs;
Figure 2 shows an embodiment of the self-powered pipeline
vehicle comprising a number of modules;
Figure 3 shows the control mechanism associated with a
module;
Figure 4 shows an alternative magnetic detection module.
Figure 5 shows a magnetic source probe arrangement for
insertion in a service pipe;
Figure 6 shows a transmission circuit arrangement for
Figure 5;
Figure 7 shows a detector coil configuration; and
Figure 8 shows a detector circuit arrangement for the
module.
A buried cast iron gas main pipeline 1 shown in Figure 1
carries a polyethylene pipe liner 2 which has previously
been inserted through excavation 3 as part of a
refurbishment programme.
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4
A number of exciting service pipe take-offs 4 each provide the
source of gas to individual dwellings or other premises. As part
of the refurbishment programme, there is a need to insert
a liner in each service pipe and to join this to the main
liner 2. In order to achieve this it has been necessary in
the past to make an excavation at each service connection
(e.g. a screwed pipe connector or a service tee) and
penetrate the main liner 2 through the excavation, sealing
the take off to the main using a saddle connection, having
removed part of the cast iron main in that region.
In the present invention, the need to have individual
excavations is avoided, as is the need to remove portions
of the cast iron main at such excavations. Figure 2 shows
the mechanism now employed.
The self-powered in-pipe vehicle 10 of Figure 2 includes a
plurality of dissimilar individual modules 11 - 16 linked
via similar linkage and suspension modules 17. The train
of modular elements allows flexibility of operation in that
each module provides a specific function which in this
embodiment work together to remotely connect the
polyethylene gas main to service piping inserted into old
metal piping (as described below). Other modular
configurations would allow further tasks to be effected.
The modular arrangement together with the suspension
modules allows the degree of serpentine operation needed to
negotiate bends in the pipe and to cope with the small
diameter of the pipe which can be less than 150 mm.
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5
The first module in the train is the traction module 11
which includes a motor 20 within one of the arms 22, 23
terminating in drive wheels 26 and idler wheels 25
respectively. The moveable arms 22 and 23 allow the wheels
to contact closely the inner wall of the pipe through which
it traverses and sensors within both the idler and drive
wheels detect slippage which causes the traction unit to
cause the arm to extend further to increase the traction
effect. This can be effected by a motor driven ball screw
acting on the lever arm to control the transverse load.
The motor 20 drives the wheels via gearing and feedback on
movement, direction and slippage which can be compensated
by internal control. Typically the traction unit provides
a pushing force for the train of 80 N at a speed of 30
mm/s. Power for the modules including the traction module
11 is provided by the power unit 12 which incorporates a
number of rechargeable batteries. Electrical connection to
the modules is provided via the suspension unit 17
connectors. The suspension units 17 are provided of common
construction and placed between each functional module to
give the train flexibility required for small pipes. Each
module 17 includes three spring loaded arms 30 terminating
in wheels 31. In order to avoid the use of highly
preloaded suspension springs, the three lever arms at one
end are interconnected via a slider. Thus when the
body of the suspension unit is depressed below the pipe
centre-line the wheels at the top will be pulled
away from the wall to provide no resistance to
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6
the upward centralising force. A central shaft 33 through
each suspension unit is free to rotate relative to the
body. Connectors at each end allow electrical connection
between all modules to be effected for power and
intercommunication requirements.
The manipulator module 13 includes three retractable
extenders 40 which are controlled to extend when required
beyond the manipulator's cylindrical body 41 so as to
firmly support the module as it comes wedged in the pipe.
A motor with associated gearing (e.g. ring gear) and
feedback allows the rear portion of the manipulator to
rotate relative to the front portion and as the modules are
all mechanically linked this causes modules connected to
the rear of the manipulator to axially rotate within the
pipe so that they can be aligned to a certain portion of
the pipe to effect a task when required. A 'global'
rotational manipulation for all modules has been found
effective rather than each module making adjustments
themselves, although 'local' manipulation may be required
in addition for a given module. The rotational
manipulation can provide two 210° arcs with the body clamped
against the pipe well. Electrical connection through the
rotating interface within the manipulator is provided by
use of a coiled cable to avoid slip ring interference and
reduce module length.
The sensor module 14 includes a number of magnetic sensors
50 spaced around the periphery of the module for detecting
a magnetic field from a source which is typically within the
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7
module 14. The sensors (typically 40 in number) form part
of a variable reluctance magnetic circuit. The detectors
can be of the Hall effect type.
As the vehicle moves into the region of a service pipe
junction there will be a change in the magnetic field
measurement. The hole in the offtake corresponds to the
largest loss and indicates its position.
The drill module 15 includes a motorised drill bit 60
capable of drilling a hole through the pipe, but more
typically through the pipe liner. A l6mm hole would be
suitable to access a 25mm service pipe tee.
The fusion module 16 carries a sensor 70 (e. g. a force
sensor with variable resistance when contacted by a guide
wire) for detecting the guide wire in the service pipe
liner (for reasons described below) and a heater device 71
for effecting a seal between the main liner and the service
pipe liner. The manipulator module 13 allows the rotation
by 180° of the train including module 16 to allow the
sensing and sealing functions to be affected.
A master controller circuit can be located within the power
module 12 and individual modules have localised control
circuits to effect tasks associated with their particular
devices. The master controller and the module controllers
can be formed from a common approach using a hierarchial modular
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8
organization of control and monitor process operating on
independent communicating modules. The master controller
is aware of operations being effected by individual modules
and ensures that the required tasks are carried out. Each
module control arrangement includes a control board sensor
and actuators of common hardware design with operation mode
selection under software control. Such a module control
system is shown in Figure 3.
Analogue module sensors 80 connect to a programmable
peripheral interface 81 which carries an onboard analog to
digital converter (ADC) and digital I/O lines. Digital
sensors 89 connect to the digital inputs. Information from
the interface is made available to microprocessor 82 which
includes associated data storage RAM 83 and program storage
ROM 84. A communication link 85 is also available to
communicate with other modules. The microprocessor
accesses sensor information via interface 81 (e. g. type
HD631408) and controls the loads 90, (e. g. motors or other
operational devices such as heaters) via decoder 86 and
driver circuits 87. Current monitoring feedback is
provided via line 88. Power supply regulation block 92
ensures trouble-free power supply requirements.
The microprocessor can be a T225 transputer which contains
a RISC CPU (l6bit 25MHZ) and interprocessor communications
links. Power for the devices can be high capacity nickel
cadmium rechargeable batteries of the 'pancake'
configuration.
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The system can be sufficiently intelligent to carry out the
tasks without external control although with a radio link
(e.g. 1.394GHZ) it is possible to send information on
operations being effected to an 'above ground' station
using the pipeline as a waveguide. Return signals could be
sent to override or halt tasks if they are detected as
being inappropriate. Hence automatic operation to effect
an opening in the main liner would be carried out as
follows.
The train of modules is driven by module 11 along the pipe
until detector module 14 detects a service tee through the
main liner. The aperture will typically be at the highest
point in the pipe wall but the actual position is
determined by the detectors. The train will then move on
until the drill module 15 is at the correct position
beneath the tee. The manipulator module 13 then activates
its extenders 40 to clamp the module. If the drill is not
determined to be in front of the aperture from earlier
calculations, the module then rotates in an arc to line up
the drill.
Following the drilling operation through the main liner,
the manipulator module 13 retracts its extenders and the
train moves forward until the fusion module 16 is
determined to be located beneath the service tee.
The manipulator module 13 again activates its extenders and
clamps itself to the main pipe. A rotation of the module
is effected if it is determined that this is necessary to locate
CA 02341321 2001-04-06
the detector 70 in front of the tee. The hole already
drilled in the main liner allows the service pipe liner to
be inserted through the service pipe liner to be inserted
through the service pipe using a very flexible guide wire.
The service liner has at its front end a tapered lead
component formed from cross-linked polyethylene. The
presence of the guide wire conf firms to the detector that
the correct service tee is being refurbished. Once the
lead end is located in the drilled hole, the guide wire is
removed indicating that the jointing step can be effected.
Thus the manipulator 13 rotates through 180° to locate the
heater device 71 on the fusion module 16 adjacent to the
region of the service liner end, within the main liner
hole, and electric power is applied to the heater to fuse
the joint in the liners by raising the temperature to the
crystalline melt state, causing the service liner end-piece
to expand and fuse simultaneously to the main liner.
The tasks for this service tee are now complete. The
manipulator module contracts its extenders 40 and the train
of modules moved on along the pipe until it detects the
presence of the next service pipe, when the operations can
proceed once again.
Because of the self powered, self controlled nature of the
vehicle distances of 100 metres or more can be handled even
with bends in the run.
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11
Although the magnetic source for sensor module 14 may be a
coil producing a field which is radial with respect to the
wall of the main which is detected as falling in the region
of the offtake, it is possible to use a permanent magnet
arrangement as an alternative within the module.
Figure 4 shows such an arrangement using bar magnets 100.
There is a bar magnet 100 associated with each sensor 102
(a Hall effect device having a linear output). Each sensor
102 is protected by potting compound 103.
Each sensor 102 is mounted on a sledge 104 which is
reciprocable radially and urged outwardly by two
compression springs 106, 108. Each sledge 104 is guided by
a pin 110 fixed to the sledge 104 and reciprocable in a
bore 112 in a central fixed body 114.
The body 114 is part of a module 116 equivalent to module
14 of Figure 2 which forms the train which is movable
through main 10. The upper half of Figure 4 shows a sledge
104 in its innermost position as dictated by the minimum
radius which the liner 12 presents. The lower half of
Figure 4 shows a sledge 104 in its outermost position as
dictated by the maximum radius which the line 12 presents.
Figure 4 is presented merely for information regarding the
inward and outward movement of the sledges 104. In
practice, the module 116 occupies a central position in the
main. As a result, all the sledges 104 occupy similar
radial positions with respect to the body 114.
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Each sledge 104 is retained by pins 120, 122 fixed in the
body 114 and projecting into slideways 124, 126 in the
sledge 104. Each slideway 124, 126 terminates in an
axially extending clearance hole 128, 130. Each sledge 104
can be removed from the body 114 by holding it in its
radially innermost position, as shown in the upper half of
Figure 4, and knocking the pins 120, 122 inwardly into the
clearance holes 128, 130.
Each sensor 102 has a multi-conductor lead 140 by which the
sensor 102 is connected to the detector to electronics (not
shown) housed in the housing 142 secured to one end of the
body 114.
The magnetic lines of force generated by the bar magnet
100, in each case, leave the magnet 100 at its right-hand
end and are turned radially outwardly by a block 150 of
ferromagnetic material. The lines of force pass through
the liner 12 and enter the cast iron main 10. The lines of
force travel leftward through the main 10, then turn
radially inward and pass through the liner 2, through the
sensor 102 and enter another block of ferromagnetic
material 152. The direction of the lines of magnetic lines
of force change from radially inward to horizontal in the
block 152 and then the lines of force enter the left hand
end of the magnet 100.
A block 154 of plastics material bridges the gap between
the two blocks 150, 152 of ferromagnetic material.
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Although the magnetic source has been described as within
the module, an external source could be used and can be
incorporated in a probe device as an alternative which is
now described with reference to Figure 5.
Figure 5 shows an elongate probe 160 including a head
portion 161. The head portion includes a magnetic source
coil 162 having a ferrite core and located within brass
housing 163. A plastic guide washer 164 (e. g. tri-cornered
PTFE) assists in guiding the probe through the service
pipe. To determine when the probe is in contact with the
main pipe (and more typically the main pipe liner) a switch
activator 166 is provided coupled to switch 167. The head
is connected to steel housing 170 to which is coupled a
flexible coil-like spring tube 171 which terminates in plug
172. The hollow tube 171 carries the connecting wires 173
for the switch and coil. The tube 171 is typically about
4 metres long and is sufficiently flexible to pass through
bends and other potential obstacles in the pipe.
Referring now to Figure 6, the plug 172 connects with the
transmission electronics within housing 180 via socket 181.
The electronic circuit includes a waveform generator IC,
187 (e.g. ICL 8038) connected to a battery power source 182
via switch 183. Lamps 184 and 185 (e. g. LEDs) indicate
circuit operation and when the probe contacts the main
liner. Typically the generator produces an output
frequency of about 35 KHz at 14 volts peak to peak.
When the probe reaches the main liner, the light 185 is
illuminated and the probe is in the correct position for the
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14
in pipe vehicle to detect the ac magnetic field. Once the
vehicle has detected the source, it can send a signal to
the surface to allow the probe to be partially withdrawn
while the drilling operation is being effected.
The detector module 14 of the in pipe vehicle is modified
to detect the source within the service pipe and can
include an arrangement of the form shown in Figure 7. It
could alternatively be mounted with the drill module. The
coil assembly includes a large diameter wound coil 190
which is the coarse position detector coil. A second fine
position coil 191 assembly includes two separate windings
at 90° angles to give an 'x' and 'y' co-ordinate coil 192
and 193 and associated capacitors 194, 195 and resistor
196.
The signal field information detected by the coils 190, 191
is received by the processing circuit of Figure 8. This
circuit includes amplifiers 200 and 201 and RMS to DC
converters 202, 203 and filters 204, 205. The do outputs
are converted into digital form via A to D converter 206
before handling by the vehicle computer system 207 (of the
type shown in Figure 3).
In operation, the robot is driven down the supply pipe
towards the magnetic field radiated by the source located
in the service tee. As the robot approaches the field,
the induced voltage in the coarse coil increases
and reaches a maximum as the flux cuts it at right
angles. It falls to a minimum as it passes through
the centre of the source and the axis of the
CA 02341321 2001-04-06
IS
field is in line with the coil. At this point the service
tee is adjacent to the coil but it can be at any location
around the circumference of the pipe. This coarse position
is logged by the robot vehicle Transputer (microprocessor)
and used to reposition the drill module bringing the fine
coil to the same position.
When the fine coils are in the pipe section identified by
the coarse coil, the Transputer initiates a search pattern,
to locate the centre of the source coil. This tracks the
drill module in rotational and longitudinal directions
until the output from the coils is at a minimum or null.
When the fine coils are positioned at the centre of the
source coil the drill module is rotated by 90 degrees which
brings the drill bit in line with the centre of the source
coil. The process is completed by energising the drill to
cut a hole in the PE liner to take the new PE service pipe
as described earlier.
The probe in the service pipe can be removed and replaced
with the guide wire which carries the service pipe liner,
before fusing this liner to the main pipe liner.
