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SYSTEMS AND METHODS FOR USE IN WELDING PIPE SEGMENTS OF A
PIPELINE
BACKGROUND
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of PCT/US2015/047603, filed
August 28,
2015, which claims priority to U.S. Provisional Application No. 62/043,757,
filed August 29,
2014. This application is also a continuation-in-part of PCT/U52015/022665,
filed on March
26, 2015, and U.S. Patent Application No. 14/228,708, filed on March 28, 2014.
PCT/U52015/022665 claims the benefit of U.S. Patent Application No.
14/228,708. This
application is also a continuation-in-part of PCT/U52014/039148, filed on May
22, 2014, and
U.S. Patent Application No. 14/272,914, filed on May 8, 2014, both of which
claim priority
to U.S. Provisional Application No. 61/826,628, filed on May 23, 2013.
PCT/U52014/039148 claims the benefit of U.S. Patent Application No.
14/272,914. This
application also claims priority to U.S. Provisional Application No.
62/175,201, filed on June
12, 2015, and U.S. Provisional Application No. 62/189,716, filed on July 7,
2015. The
contents of all of these applications are incorporated herein by reference in
their entirety.
Field
[0002] The present patent application relates to various field systems and
methods that are
used for the purpose of welding pipe segments of a pipeline.
[0003] Pipeline systems, which can include long stretches of pipe sections or
segments
(e.g., miles of pipe segments) comprising steel, stainless steel or other
types of metal, are
used to transport fluids such as water, oil, and natural gas between two
locations (e.g., from a
source of origin that may be land or water based to a suitable storage
location). Construction
of pipeline systems typically involves connection of pipe segments of suitable
diameter and
lengthwise dimensions together via weld joints, for example, capable of
providing a liquid
tight seal for the connected pipe segments.
[0004] During formation of a weld joint between two pipe segments (e.g., two
pipe
segments having the same or similar transverse cross-sectional dimensions), an
end of one
pipe section or segment is brought into close proximity or contact with an end
of a second
pipe section or segment. The pipe segments are held in relation to each other
and a weld joint
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is formed to connect the two ends of the pipe segments using a suitable
welding process.
After the weld is complete and cleaned, the weld may be inspected. After
inspection, it may
be desirable to apply external protective coatings to the weld joint.
[0005] Conventional internal welders frequently include internal alignment
mechanisms
that expand radially outward to contact the interior of the pipe. Alignment of
the two pipe
segments is accomplished from inside when extension members of a central
member contact
the interior of the pipe relatively close to the pipe segment joint faces on
either side of the
joint as shown in U.S. Patent No. 3,461,264; 3,009,048; 3,551,636; 3,612,808
and GB
1261814 (which is each incorporated herein by reference in its entirety). In
order to weld the
joint, the structure of the expander should be configured to allow sufficient
space to
accommodate a rotating torch. It would therefore be advantageous to provide
internal
alignment that allows sufficient space for a rotating or articulating torch or
to align the pipe
segments externally so as to eliminate the need for an internal expander which
may create
significant internal clutter.
[0006] In addition, the conventional process of internal welding usually
involves internal
or external alignment and an insertion of the internal welder so that torches
align with the
face joint. In this process it is sometimes difficult to assess the accuracy
of positioning of the
internal welder in general and the torch in particular. It is even more
difficult to assess the
accuracy of the position of the torch as the torch traverses the inside of the
pipe along its
orbital path during welding. It would therefore be advantageous to provide a
system of
tracking the structure of or positioning of pipe edges at the pipe interface
in order to control
the torch by use of the tracked condition of the interface. Specifically, it
would be
advantageous to first track a profile of the interface with a laser before
sending a signal to an
electronic controller to direct the position and orientation of the welding
torch relative to the
tracked pipe interface profile.
[0007] Furthermore, conventional pipeline welding systems that employ external
alignment mechanisms typically support two segments on rollers and manipulate
the position
and orientation of the segments until alignment is satisfactory. Whether an
alignment is
satisfactory typically will depend, for example, on industry acceptable high-
low gauges that
are fairly accurate but are manually operated and positioned at discrete
locations and not over
the entire pipe interface. In any case, the profile or structure of the
interface as observed
from the inside of the pipe is not typically a consideration for quality of
alignment. It would
therefore be advantageous to provide an alignment system in which information
about the
interface profile as read by the laser is used as an input parameter during
the external
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alignment process. Specifically, it would be advantageous to provide the
information from
the torch controlling laser to the controller which would utilize the
information in controlling
external alignment mechanisms.
[0008] Moreover, conventional pipeline systems for welding pipe segments will
typically
lack a capability to visually inspect the weld applied by the torch. It
therefore would be
advantageous to provide a camera that followed the torch weld application and
a display for
showing an image of the weld in order for an operator to visually inspect the
quality of the
weld. Other advantages of the present disclosure will be apparent by review of
this disclosure.
Patentable advantages are not limited to those highlighted in this section. In
addition, the
advantages addressed herein should be considered independent of one another
and not reliant
on one another unless specifically noted herein. Additional advantages are
also described in
the claims provided in this application.
[0009] In a welding operation, the pipes are typically preheated to a suitable
temperature
prior to welding, and a significant amount of heat is also generated during
the welding
process.
[0010] Sometime after the weld is complete and cleaned, the weld may be
inspected. It is
desirable to inspect the weld at a temperature closer to the pipe operating
temperature than to
the raised weld temperature. Therefore, cooling after the welding process may
be desired
before inspection. After inspection, it may be desirable to apply external
protective coatings
to the joint. To facilitate this coating, heat may be added to the pipe in
order to raise the pipe
temperature required for application of certain external coatings (e.g.,
polypropylene).
[0011] After such heating, the pipe connection is ideally be allowed to cool
to a suitable
temperature before further processing steps are performed occur (e.g., before
spooling of the
connected piping sections or handling /placement of the piping sections in
water or at some
other suitable location on land).
[0012] During
some pipe fabrication steps (e.g., after welding and before inspection),
external portions of the joined pipe are readily accessible and cooling at the
external surface
is an option. However, during some portions in the process (e.g., after
certain materials have
been externally applied to the outside surface of the pipe) the external
surface is not available
on which to conduct a pipe cooling process.
[0013]
Internal cooling could be useful during certain portions of the fabrication
process
(i.e., even when external cooling is available). Internal cooling within the
pipes can be
challenging due to the size of the pipes and the difficulty of accessibility
to the interior
portion of the piping section that is located at or near the weld joint. It
would therefore be
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especially desirable to provide internal cooling so that during portions of
the process where
external surfaces of the pipe are inaccessible, cooling can be implemented to
more quickly
condition the pipe for future steps that require lower temperatures (e.g.,
spooling).
[0014]
Existing pipeline weld inspection processes such as ultrasonic testing and x-
ray
radiography can be challenging. For example, some processes may require a
large team (e.g.
4, or more personnel) of highly trained personnel to travel to remote
locations where the
pipeline is being constructed; may require a ruggedized computer to be
transported by
dedicated truck to and used in remote locations with harsh environments;
provide; use
inspection equipment which is tethered by network wires ("tethered") to a
dedicated
ruggedized computer equipment and truck; may be inefficient because each
member of the
team may only be needed for certain steps of the process; require a highly
trained technician
on site to interpret the results of the test; and require that desired
analysis be completed and
the results written on the pipe before the team can move to inspect a next
weld. Of course
these are generalities, and not all of these issues are present in all
systems.
[0015] Currently pipe joining technology remains an art relying on the
avoidance of error
by a worker applying a weld. Some welding technologies require adequate data
management,
work control and supervision of activities. As a result of such challenges,
welding quality,
completion time, and economics can also be challenging
[0016] The present patent application provides improvements over prior art
field systems
and methods.
SUMMARY
[0017] The present application relates to a field system and methods that can
be deployed
in the application of pipe welding. The field system provides many embodiments
relating to
pipe welding systems and methods, that can be used in combination with one
another, or
individually. Such welding systems and methods, include, for example, internal
welding
systems and methods, tie-in welding system and methods, pipe inspection
systems and
methods, pipe handling systems and methods, internal pipe cooling systems and
methods,
non-destructive testing systems and methods, as well as remote interface and
database
systems and methods (uLog), to name a few. The application further relates to
welded pipes
that result from some or all of such processes.
[0018] One aspect of the present patent application provides a field system
for welding
two pipes. The field system includes a first pipe engagement structure; a
second pipe
engagement structure; an inspection detector; a motor; one or more processors;
and a weld
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torch. The first pipe engagement structure is configured to engage the
interior surface of a
first pipe to enable the first pipe engagement structure to be fixed relative
to the first pipe.
The second pipe engagement structure is configured to engage the interior
surface of a second
pipe to enable the second pipe engagement structure to be fixed relative to
the second pipe.
The inspection detector is positioned between the first pipe engagement
structure and the
second pipe engagement structure, the inspection detector configured to emit
an inspection
beam of radiation. The motor is operatively associated with the inspection
detector to direct
the inspection beam of radiation along an interface region between the pipes.
The one or
more processors are operatively associated with the inspection detector to
determine a profile
of the interface region between the pipes. The weld torch is configured to
create a weld
between the pipes based on the profile of the interface region between the
pipes.
[0019] Another aspect of the present patent application provides a field
system for welding
two pipes. The field system includes a first pipe engagement structure; a
second pipe
engagement structure; an inspection detector; one or more orientation motors;
one or more
processors; and a weld torch assembly. The first pipe engagement structure is
configured to
engage the interior surface of a first pipe to enable the first pipe
engagement structure to be
fixed relative to the first pipe. The second pipe engagement structure is
configured to engage
the interior surface of a second pipe to enable the second pipe engagement
structure to be
fixed relative to the second pipe. The inspection detector is positioned
axially between the
first pipe engagement structure and the second pipe engagement structure, the
inspection
detector configured to inspect an interface region between the pipes and
generate profile data
based thereon. The one or more orientation motors are operatively associated
with the
inspection detector to direct the inspection beam of radiation along the
interface region
between the pipes. The one or more processors are operatively associated with
the inspection
detector and configured to receive the profile data from the inspection
detector to determine
one or more characteristics of the interface region between the pipes. The
weld torch
assembly includes a weld torch and at least one weld torch motor, the weld
torch and the at
least one weld torch motor being actuated by the one or more processors to
create a weld
between the pipes based on the one or more characteristics of the interface
region between
the pipes.
[0020] Yet another aspect of the present patent application provides a field
system for
welding two pipes is provided. The field system includes a frame configured to
be placed
within the pipes; a plurality of rollers configured to rotatably support the
frame; a drive motor
that drives the rollers to move the frame within the pipes; a brake system
that secures the
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frame from movement at a desired location within the pipes; an inspection
detector carried by
the frame, the inspection detector configured to detect a characteristic of an
interface region
between the pipes; a weld torch carried by the frame; one or more battery
cells carried by the
frame, the one or more battery cells configured to power the drive motor, the
inspection
detector and the weld torch; and one or more processor operatively connected
with the drive
motor, the inspection detector and the weld torch.
[0021] Yet another aspect of the present patent application provides a method
for welding
a pair of insulated pipes to one another. Each pipe includes a metal pipe
interior surrounded
by an insulator material. End portions of the pipes to be welded have the
metal pipe interior
exposed. The method includes aligning the exposed metal pipe ends to be
welded, welding
the exposed metal pipe ends to one another, heating the exposed end portions
of the welded
pipes, applying an insulator to the heated exposed end portions of the welded
pipes such that
the insulator is adhered to an exterior surface of the metal pipe interior,
thus insulating the
formerly exposed end portions of the pipes, and applying cooling energy from
within the
pipes to an interior surface of the metal pipes.
[0022] Yet another aspect of the present patent application provides a system
for welding a
pair of insulated pipes to one another. Each pipe comprises a metal pipe
interior surrounded
by an insulator material. End portions of the pipes to be welded have the
metal pipe interior
exposed. The system includes a weld torch configured to weld the exposed metal
pipe ends to
one another; a heater configured to heat the exposed end portions of the
welded pipes; an
insulator supply configured to apply insulator material to the heated exposed
end portions of
the welded pipes such that the insulator is adhered to an exterior surface of
the metal pipe
interior, thus insulating the formerly exposed end portions of the pipes; and
a cooler system
configured to be positioned within the pipes, the cooler system applying
cooling energy to an
interior surface of the metal pipes to facilitate cooling of the metal pipes
after the insulator
material is applied.
[0023] Yet another aspect of the present patent application provides a method
for welding
a pair of insulated pipes to one another. Each pipe includes a metal pipe
interior surrounded
by an insulator material. End portions of the pipes to be welded have the
metal pipe interior
exposed. The method includes aligning the exposed metal pipe ends to be
welded, welding
the exposed metal pipe ends to one another, heating the exposed end portions
of the welded
pipes, applying an insulator to the heated exposed end portions of the welded
pipes such that
the insulator is adhered to an exterior surface of the metal pipe interior,
thus insulating the
formerly exposed end portions of the pipes, and applying cooling energy from
within the
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pipes to an interior surface of the metal pipes after applying the insulator;
and performing a
pipeline deployment procedure. Applying the cooling energy reduces a wait time
between
applying the insulator and performing the pipeline deployment procedure.
[0024] Yet another aspect of the present patent application provides a welded
pipe
assembly. The welded pipe assembly includes a first metal pipe having a length
of at least 30'
and an exterior diameter of less than 24"; a second metal pipe having a length
of at least 30'
and an exterior diameter of less than 24"; weld material connecting the first
pipe with the
second pipe, the weld material comprising a plurality of weld pass layers, the
plurality of
weld pass layers including a root pass layer and a hot pass layer disposed on
top of the root
pass layer, wherein the hot pass layer is positioned closer to an interior
longitudinal axis of
the welded first and second pipes than the root pass layer.
[0025] Yet another aspect of the present patent application provides a welded
pipe
assembly. The assembly includes a first metal pipe having a length of at least
30' and an
exterior diameter of less than 24"; a second metal pipe having a length of at
least 30' and an
exterior diameter of less than 24"; a welded joint connecting the first metal
pipe and the
second metal pipe, the welded joint comprising a first internal bevel formed
in the first metal
pipe and a second internal bevel formed in the second metal pipe, and a root
pass layer of
weld material disposed in a region defined by the first internal bevel and the
second internal
bevel.
[0026] Yet another aspect of the present patent application provides a pipe
cooling system.
The pipe cooling system includes a frame, a plurality of rollers, a drive
motor, a brake system,
a cooler, and one or more processors. The frame is configured to be placed
within welded
pipes. The plurality of rollers is configured to rotatably support the frame.
The drive motor
drives the rollers to move the frame within the pipes. The brake system
secures the frame
from movement at a desired location within the pipes. The cooler is cooler
carried by the
frame, the cooler applying cooling energy to an interior surface of the metal
pipes to facilitate
cooling of the welded metal pipes. The one or more processors are operatively
connected
with the drive motor, the brake system and the cooler. The one or more
processors operating
the cooler to reduce the temperature of the welded pipes to a predetermined
level.
[0027] Yet another aspect of the present patent application provides a welded
pipe
assembly. The welded pipe assembly includes a first metal pipe; a second metal
pipe and
weld material connecting the first metal pipe with the second metal pipe. The
first metal pipe
has a length of at least 30 feet and an exterior diameter of less than 24
inches. The second
metal pipe has a length of at least 30 feet and an exterior diameter of less
than 24 inches. The
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weld material includes a plurality of weld pass layers. The plurality of weld
pass layers
including a root pass layer and a hot pass layer disposed on top of the root
pass layer. The hot
pass layer is positioned closer to an interior longitudinal axis of the welded
first and second
pipes than the root pass layer.
[0028] Yet another aspect of the present patent application provides a welded
pipe
assembly. The welded pipe assembly includes a first metal pipe, a second metal
pipe and a
welded joint connecting the first metal pipe and the second metal pipe. The
first metal pipe
has a length of at least 30 feet and an exterior diameter of less than 24
inches. The second
metal pipe has a length of at least 30 feet and an exterior diameter of less
than 24 inches. The
welded joint includes a first internal bevel formed in the first metal pipe
and a second internal
bevel formed in the second metal pipe, and a root pass layer of weld material
disposed in a
region defined by the first internal bevel and the second internal bevel.
[0029] Yet another aspect of the present patent application provides a field
system for
welding two pipes. The field system includes a first pipe engagement structure
configured to
engage the interior surface of a first pipe to enable the first pipe
engagement structure to be
fixed relative to the first pipe; a second pipe engagement structure
configured to engage the
interior surface of a second pipe to enable the second pipe engagement
structure to be fixed
relative to the second pipe; one or more weld torches configured to be
positioned within the
pipes to create an internal weld at an interface region between the pipes; a
motor operatively
associated with the one or more weld torches to rotate the one or more weld
torch along the
interface region between the pipes; and one or more processors that control
the motor and the
one or more weld torches, the one or more processors operating the motor and
the one or
more weld torches to generate a complete circumferential weld along the
interface region by
rotating the one or more weld torches along the interface region in a single
rotational
direction until the complete circumferential weld is completed.
[0030] Yet another aspect of the present patent application provides an
inspection system
for pre-inspecting an interface region between two pipes to be welded end-to-
end. The system
includes a frame configured to be placed within the pipes; a plurality of
rollers configured to
rotatably support the frame; a drive motor that drives the rollers to move the
frame within the
pipes; a brake system that secures the frame from movement at a desired
location within the
pipes; a sensor movable with the frame that detects the interface region
between the pipes; an
inspection detector configured to generate signals based upon a profile of the
interface region
between the pipes; a motor that rotationally moves the inspection detector
along the interface
region; and one or more processors operatively associated with the drive
motor, the sensor,
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the inspection detector and the motor, the one or more processors operating
the drive motor to
move the frame through at least one of the pipes until the sensor detects the
interface region,
the one or more processors operating the brake system to secure the frame from
movement at
a location within the pipes that positions the inspection detector in relation
to the interface
region to enable the inspection detector to detect the profile of the
interface region between
the pipes; the one or more processors operating the inspection detector and
the motor to scan
the interface region between the pipes, and in response to detecting one or
more undesirable
characteristics of the interface region, the one or more processors sending
instructions based
thereon.
[0031] Yet another aspect of the present patent application provides a field
system for pre-
inspecting an interface region between two pipes to be welded end-to-end. The
system
includes a frame configured to be placed within the pipes; a plurality of
rollers configured to
rotatably support the frame; a drive motor that drives the rollers to move the
frame within the
pipes; a brake system that secures the frame from movement at a desired
location within the
pipes; an inspection detector configured to generate signals based upon a
profile of the
interface region between the pipes; one or more orientation motors that
rotationally moves
the inspection detector along the interface region; and one or more processors
operatively
associated with the drive motor, the inspection detector and the motor, the
one or more
processors operating the brake system to secure the frame from movement at a
location
within the pipes that positions the inspection detector in relation to the
interface region to
enable the inspection detector to detect the profile of the interface region
between the pipes;
the one or more processors operating the inspection detector and the motor to
scan the
interface region between the pipes to generate pre-weld profile data, and in
response to
detecting one or more undesirable characteristics of the pre-weld profile
data, the one or more
processors sending instructions based thereon.
[0032] Yet another aspect of the present patent application provides a method
for pre-
inspecting an interface region between two pipes to be welded end-to-end. The
method
includes moving a frame within at least one of the pipes to be welded;
detecting the interface
region between the pipes; securing the frame from movement at the interface
region
between the pipes; detecting a profile of the interface region between the
pipes; and in
response to detecting one or more undesirable characteristics of the interface
region between
the pipes, generating instructions based thereon.
[0033] Yet another aspect of the present patent application provides a pipe
cooling system.
The pipe cooling system includes a frame configured to be placed within welded
pipes; a
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plurality of rollers configured to rotatably support the frame; a drive motor
that drives the
rollers to move the frame within the pipes; a brake system that secures the
frame from
movement at a desired location within the pipes; a cooler carried by the
frame, the cooler
applying cooling energy to an interior surface of the metal pipes to
facilitate cooling of the
welded metal pipes; and one or more processor operatively connected with the
drive motor,
the brake system and the cooler, the one or more processors operating the
cooler to reduce the
temperature of the welded pipes to a predetermined level.
[0034] One aspect of the present patent application provides a method of
welding two
pipes. The method includes internally clamping a first pipe with a first
clamp; internally
clamping a second pipe with a second clamp, the first and second pipes being
clamped so that
they are disposed in end-to-end adjacent relationship, with an interface
region therebetween;
scanning the interface region from a location within the pipes and between the
clamps to
obtain profile data from the interface region; welding the two pipes in end-to-
end relationship
based on the profile data; and internally inspecting the welded pipes from a
location within
the pipes and between the clamps
[0035] One aspect of the present patent application provides a welding
processing system
for facilitating pipe welding remote from a field system for performing pipe
weld operations
between a first pipe and a second pipe. As an example, the remote field system
comprises an
inspection detector configured to emit an inspection beam of radiation to scan
a profile of an
interface region between the first and second pipes and a weld torch
configured to create a
weld between the first and second pipes based on the profile of the interface
region between
the first and second pipes. The welding processing system comprises: a
receiver configured
to receive, from the remote weld system, profile data determined from the scan
of the
interface region between the pipes by the inspection detector; one or more
processors
configured to compare one or more characteristics of the profile data of the
scan of the
interface region with one or more characteristics of predefined profile data
of predetermined
interface regions and configured to determine control operation data for the
remote field
system based on the comparison; and a transmitter configured to transmit the
control
operation data to the remote field system. The control operation data is
configured to cause
the weld torch to perform one or more welding operations on the interface
region between the
pipes.
[0036] One aspect of the present application provides a method for welding
pipes. The
method comprises: aligning ends of the two pipes to be welded, the pipes
comprising a metal
pipe interior surrounded by an insulator material, the metal pipe interior
being exposed at
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portions of the pipes adjacent the ends of the pipes to be welded; welding the
aligned ends of
the pipes to one another from within the pipes to form a weld joint;
generating weld data
during the welding of the aligned ends, the weld data corresponding to welding
parameters
associated with the welding; inspecting the welded joint with an inspection
laser from within
the welded pipes to derive internal weld inspection data; inspecting the
welded joint with an
inspection radiation source to derive radiation inspection data; transmitting
the weld data, the
internal weld inspection data, and the radiation inspection data to a remote
computer system
to derive additional weld data; and receiving the derived additional weld
data. The additional
weld data is derived from the transmitted data and additional inspection data
received by the
remote system from inspection of other pipes.
[0037] One
aspect of the present patent application provides a field system for
facilitating
field testing and physical operations based thereon. The field system
comprises: a field
device configured to perform an operation that physically affects an object;
an inspection
device configured to scan the object; and one or more processors
communicatively connected
to the inspection device and configured to receive inspection data associated
with the scan of
the object from the inspection device. The one or more processors are
communicatively
connected to a remote computer system and configured to transmit the
inspection data to the
remote computer system. The one or more processors are configured to receive
data related
to performing the operation from the remote computer system responsive to
transmitting the
inspection data, and cause, based on the operation-related data, the field
device to perform the
operation that physically affects the object. The operation-related data is
derived from the
inspection data and other inspection data associated with a separate scan of
another object.
[0038] One
aspect of the present patent application provides a method for facilitating
field
testing and physical operations based thereon. The method comprises: scanning,
by an
inspection device of a field system, an object to provide inspection data
associated with the
scan of the object to one or more processors; transmitting, by one or more
processors of the
field system, the inspection data to a remote computer system; receiving, by
the one or more
processors, data related to performing an operation that physically affects an
object from the
remote computer system responsive to transmitting the inspection data; and
causing, by the
one or more processors, based on the operation-related data, a field device of
the field system
to perform the operation that physically affects the object. The operation-
related data is
derived from the inspection data and other inspection data associated with a
separate scan of
another object.
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[0039] One aspect of the present patent application provides a computer system
for
facilitating field testing and physical operations based thereon remotely from
a field system at
which the field testing and physical operations occurs. The remote field
system comprises an
inspection device configured to scan the object and a field device configured
to perform an
operation that physically affects the object. The computer system comprises: a
receiver
configured to receive, from the remote field system, inspection data
associated with the scan
of the object by the inspection device; one or more processors configured to
process the
inspection data to generate data related to performing the operation that
physically affects the
object; and a transmitter configured to transmit the operation-related data to
the remote field
system to cause the remote field system to perform the operation that
physically affects the
object, wherein the operation is performed based on the operation-related
data.
[0040] One
aspect of the present patent application provides a method for facilitating
field
testing and physical operations based thereon remotely from a field system at
which the field
testing and physical operations occurs. The remote field system comprises an
inspection
device configured to scan the object and a field device configured to perform
an operation
that physically affects the object. The method comprises: receiving, by a
receiver, from the
remote field system, inspection data associated with the scan of the object by
the inspection
device; processing, by one or more processors, the inspection data to generate
data related to
performing the operation that physically affects the object; and transmitting,
by a transmitter,
the operation-related data to the remote field system to cause the remote
field system to
perform the operation that physically affects the object, wherein the
operation is performed
based on the operation-related data.
[0041] One aspect of the present patent application provides a computer system
for
facilitating field testing at a field system and physical operations based
thereon. The field
system comprises an inspection device configured to scan the object and one or
more field
devices configured to perform one or more operations that physically affect an
object. The
computer system comprises a receiver configured to receive, from the field
system,
inspection data associated with the scan of the object by the inspection
device. The scan of
the object by the inspection device is subsequent to a performance of the one
or more
operations by the one or more field devices that physically affected the
object. The one or
more operations are performed using a first set of input parameters. The
computer system
also comprises one or more processors configured to: detect, based on the
inspection data, a
defect related to the object; generate, an operation protocol associated with
at least one
operation type of the one or more operations responsive to the defect
detection, wherein the
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operation protocol comprises a second set of input parameters having at least
one input
parameter different from the first set of input parameters; select the
operation protocol for
performing a subsequent operation similar to at least one of the one or more
operations; and
generate, based on at least one input parameter of the operation protocol,
data related to
performing the subsequent operation. The computer system further comprises a
transmitter
configured to transmit the operation-related data to one or more field systems
to cause the
one or more field systems to perform the subsequent operation. The subsequent
operation is
performed based on the operation-related data.
[0042] One
aspect of the present patent application provides method for facilitating
field
testing at a field system and physical operations based thereon. The field
system comprises
an inspection device configured to scan the object and one or more field
devices configured
to perform one or more operations that physically affects an object. The
method comprises
receiving, by a receiver, from the field system, inspection data associated
with the scan of the
object by the inspection device. The scan of the object by the inspection
device is subsequent
to a performance of the one or more operations by the one or more field
devices that
physically affected the object. The one or more operations are performed using
a first set of
input parameters. The method also comprises: detecting, by one or more
processors, based
on the inspection data, a defect related to the object; generating, by the one
or more
processorsõ an operation protocol associated with at least one operation type
of the one or
more operations responsive to the defect detection, wherein the operation
protocol comprises
a second set of input parameters having at least one input parameter different
from the first
set of input parameters; selecting, by the one or more processors, the
operation protocol for
performing a subsequent operation similar to at least one of the one or more
operations;
generating, by the one or more processors, based on at least one input
parameter of the
operation protocol, data related to performing the subsequent operation; and
transmitting, by
a transmitter, the operation-related data to one or more field systems to
cause the one or more
field systems to perform the subsequent operation. The subsequent operation is
performed
based on the operation-related data.
[0043] One aspect of the present patent application provides a computer system
for
facilitating field testing at a field system and physical operations based
thereon. The field
system comprises an inspection device configured to scan the object and one or
more field
devices configured to perform one or more operation that physically affects
the object. The
computer system comprises a receiver configured to receive, from the field
system,
inspection data associated with the scan of the object. The scan of the object
is subsequent to
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a performance of the one or more operations that physically affected the
object. The one or
more operations are performed using a first set of input parameters. The
computer system
also comprises one or more processors configured to: determine, based on the
inspection data,
whether a quality of one or more aspects of the object resulting from the one
or more
operations exceeds a quality standard indicated by a predefined quality
profile; generate an
operation protocol associated with at least one operation type of the one or
more operations,
wherein the operation protocol is generated to comprise one or more of the set
of input
parameters responsive to the quality of the one or more aspects of the object
exceeding the
quality standard indicated by the predefined quality profile; select the
operation protocol for
performing a subsequent operation similar to at least one of the one or more
operations; and
generate, based on at least one input parameter of the operation protocol,
data related to
performing the subsequent operation. The computer system further comprises a
transmitter
configured to transmit the operation-related data to one or more field systems
to cause the
one or more field systems to perform the subsequent operation. The subsequent
operation is
performed based on the operation-related data.
[0044] One aspect of the present patent application provides a method for
facilitating field
testing at a field system and physical operations based thereon. The field
system comprises
an inspection device configured to scan the object and one or more field
devices configured
to perform one or more operation that physically affects the object. The
method comprises
receiving, by a receiver, from the field system, inspection data associated
with the scan of the
object. The scan of the object is subsequent to a performance of the one or
more operations
that physically affected the object. The one or more operations are performed
using a first set
of input parameters. The method also comprise: determining, by one or more
processorsõ
based on the inspection data, whether a quality of one or more aspects of the
object resulting
from the one or more operations exceeds a quality standard indicated by a
predefined quality
profile; generating, by the one or more processors, an operation protocol
associated with at
least one operation type of the one or more operations, wherein the operation
protocol is
generated to comprise one or more of the set of input parameters responsive to
the quality of
the one or more aspects of the object exceeding the quality standard indicated
by the
predefined quality profile; selecting, by the one or more processors, the
operation protocol for
performing a subsequent operation similar to at least one of the one or more
operations;
generating, by the one or more processors, based on at least one input
parameter of the
operation protocol, data related to performing the subsequent operation; and
transmitting, by
the one or more processors, the operation-related data to one or more field
systems to cause
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the one or more field systems to perform the subsequent operation. The
subsequent operation
is performed based on the operation-related data.
[0045] One aspect of the present patent application provides a computer system
for
facilitating field testing and physical operations based thereon. The computer
system
comprises one or more processors configured to: obtain, from one or more field
systems, data
related to observations of one or more operations performed on a plurality of
objects. The
plurality of objects comprises (i) one or more objects determined to have a
defect resulting
from the one or more observed operations and (ii) one or more objects without
the defect.
The one or more processors are also configured to: compare, based on the
observation-related
data, a first set of observations of an operation performed on an object
determined to have the
defect with one or more other sets of observations of the operation performed
on one or more
other objects without the defect; determine, based on the comparison, a common
difference
that the first set of observations has with the one or more other sets of
observations; and
cause, based on the common difference, an operation trigger to be implemented
such that a
field system is caused to perform an operation associated with the operation
trigger when a
circumstance corresponding to the common difference occurs during a subsequent
operation
that physically affects one or more additional objects.
[0046] One
aspect of the present patent application provides a method for facilitating
field
testing and physical operations based thereon. The method comprises obtaining,
by one or
more processors, from one or more field systems, data related to observations
of one or more
operations performed on a plurality of objects. The plurality of objects
comprises (i) one or
more objects determined to have a defect resulting from the one or more
observed operations
and (ii) one or more objects without the defect. The method also comprises:
comparing, by
the one or more processors, based on the observation-related data, a first set
of observations
of an operation performed on an object determined to have the defect with one
or more other
sets of observations of the operation performed on one or more other objects
without the
defect; determining, by the one or more processors, based on the comparison, a
common
difference that the first set of observations has with the one or more other
sets of observations;
and causing, by the one or more processors, based on the common difference, an
operation
trigger to be implemented such that a field system is caused to perform an
operation
associated with the operation trigger when a circumstance corresponding to the
common
difference occurs during a subsequent operation that physically affects one or
more additional
objects.
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[0047] One aspect of the present patent application provides a system for
aligning and
welding together two segments of a pipe. The system includes a welding
mechanism for
applying a weld to a face joint of the two segments, the welding mechanism
including an
articulating torch, a laser sensor for reading a profile of the face joint,
and an electronic
controller for receiving information signals from the laser sensor to control
the position
and/or orientation of the torch; an alignment mechanism for manipulating the
orientation of
the longitudinal axis of at least one of the segments relative to the other;
and wherein the
welding mechanism further includes a carriage for securing a position of the
welding
mechanism in the pipe and a welding portion capable of rotating relative to
the supporting
portion within the pipe; and wherein the torch and the laser sensor are
rotatably supported by
the welding portion such that during welding, the torch follows the laser
sensor along the face
joint.
[0048] One aspect of the present patent application provides a method of
aligning and
welding together two segments of a pipe. The method includes the steps of:
placing a first
pipe segment on an alignment device; inserting an internal welding machine
having a laser
and a weld torch into the first pipe segment; generally aligning a second pipe
segment with
the first pipe segment and internal welding machine; griping an external
portion of the first
and second pipe segments to adjusting an axial position of the internal
welding machine so as
to generally line up with a face joint of the first and second pipe segments;
adjusting a
relative alignment of the first and second pipe segments via the alignment
device based on a
signal from the internal welder; beginning a root weld cycle in which the
laser scans the face
joint, the torch follows the laser, and the output from the laser is used to
control the position
of articulated torch, where the position and orientation of the torch with
respect to the face
joint is controlled to produce a quality weld; determining a face joint
profile from the laser;
releasing the alignment device and removing internal welding machine from an
open pipe
segment end; and repositioning a next sequential pipe segment on the external
alignment
mechanism in preparation for welding of a next joint.
[0049] One aspect of the present patent application provides an internal heat
exchanger
(IHEX) for pipeline welding. The internal heat exchanger includes a drive
system configured
to move the IHEX into a position within at least one pipe section near a weld
joint location
with another pipe section; a cooling section including cooling structure
configured to
selectively cool one or more interior surface portions of the at least one
pipe section; and a
controller in communication with the cooling structure and configured to
activate the cooling
section when the IHEX is at the position within the at least one pipe section.
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[0050] One aspect of the present patent application provides a welding system.
The
welding system includes a plurality of welding stations, each welding station
including a
weld station computer and weld system in communication with the weld station
computer,
each welding station including one or more sensors, the one or more sensors
configured to
measure weld data including lead wire speed data; a plurality of wireless
devices in
communication with the one or more of the welding station computers to receive
the weld
data including the measured lead wire speed data; and a cloud server in
communication with
the wireless devices, the cloud server being configured to process the weld
data including the
lead wire speed data, and configured to determine an amount of consumable
welding material
used by the plurality of welding stations for a given period of time, wherein
the cloud server
is configured to communicate the amount of consumable welding material used to
one or
more of the wireless devices.
[0051] One aspect of the present patent application provides welding system.
The welding
system includes a welding station, the welding station including a weld
station computer and
a weld system in communication with the weld station computer, the weld system
including a
supply of weld material, a welding device, and a weld supply motor assembly
that moves the
weld material to the welder device; a weighting device operatively connected
with the weld
station computer and configured to measure a weight of the supply of weld
material and to
communicate the weight of the supply of weld material to the weld station
computer in the
form of weight data; and a sensor operatively connected with the weld supply
motor
assembly and the weld station computer so as to communicate the speed of the
weld supply
motor assembly to the weld station computer in the form of speed data; wherein
the weld
station computer is operatively connected to the weld supply motor assembly
and is
configured to control the speed of the motor assembly based on the weight
data.
[0052] One aspect of the present patent application provides a method of
controlling
welding. The method includes measuring, using a weight measuring device, a
first weight of
a supply of weld material at a first time; measuring, using the weight
measuring device, a
second weight of the supply of weld material at a second time subsequent to
the first time;
calculating, using a computer, a difference in measured weight between the
first weight and
the second weight, the difference in measured weight corresponding to measured
used weld
material; calculating, using the computer, a theoretical weight of used weld
material based on
a speed of a motor assembly feeding the weld material to a welding device;
comparing, by
the computer, the theoretical weight of used weld material to the measured
weight of used
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weld material; and adjusting, by the computer, the speed of the motor assembly
so as to
correct a slippage of the motor assembly.
[0053] One aspect of the present patent application provides a welding system.
The
welding system includes a plurality of welding stations, each welding station
including a
weld station computer and weld system in communication with the weld station
computer,
each welding station including one or more sensors, the one or more sensors
configured to
measure weld data including lead wire speed data; a plurality of wireless
devices in
communication with the one or more of the welding station computers to receive
the weld
data including the measured lead wire speed data; and each weld station
computer being
configured to process the weld data, including the lead wire speed data, for
the weld system
in communication therewith, the weld station computer configured to determine
an amount of
consumable welding material used by the weld system for a given period of time
and
generating consumption data based thereon.
[0054] One
aspect of the present patent application provides a system for pipeline
testing.
The system includes a testing device adapted to generate nondestructive test
data regarding at
least a portion of a weld; said testing device communicating said
nondestructive test data to a
second device which is adapted to receive said nondestructive test data; and
said testing
device adapted to operate remotely from a means of analyzing said
nondestructive test data.
[0055] One aspect of the present patent application provides a system for
nondestructive
pipeline testing. The system includes an imaging equipment adapted to generate
nondestructive test data regarding a portion of a welded pipe; a remote
processing device
adapted to receive and process inspection data regarding said portion of said
welded pipe.
[0056] One aspect of the present patent application provides a method of
nondestructive
pipeline testing. The method includes the steps of: providing an imaging
equipment;
generating a nondestructive test data; providing a means to provide said
nondestructive test
data for analysis; and said nondestructive test data provided for analysis at
a location remote
from the tested portion of a pipe and the equipment proximate to the tested
portion of a pipe.
[0057] One aspect of the present patent application provides a system for
pipeline
construction. The system includes a system for real-time logging of weld data;
and said weld
data is provided for analysis by computerized means and/or by subject experts.
[0058] One aspect of the present patent application provides a computer
program product
for welding support. The computer program product includes a computer readable
program
code means which provides to a computer memory a welding data; a computer
readable
program code means which provides to said memory a data from a data set
comprising a
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pipeline data; a computer readable program code means which processes said
welding data
and said pipeline data to provide a record output.
[0059] One aspect of the present patent application provides a method of data
management
executed on a computer. The method includes the steps of: communicating a
first data from a
first device to a second device, said first data which is a data regarding a
pipeline
construction; processing said first data by a cloud-based network means.
[0060] One aspect of the present patent application provides a computer
system. The
system includes a first device having a processor which processes a pipeline
construction
data, said first device communicating said pipeline construction data to a
cloud-based
memory, said pipeline construction data processed by a cloud-based processor.
[0061] These and other aspects of the present patent application, as well as
the methods of
operation and functions of the related elements of structure and the
combination of parts and
economies of manufacture, will become more apparent upon consideration of the
following
description and the appended claims with reference to the accompanying
drawings, all of
which form a part of this specification, wherein like reference numerals
designate
corresponding parts in the various figures. In one embodiment of the present
patent
application, the structural components illustrated herein are drawn to scale.
It is to be
expressly understood, however, that the drawings are for the purpose of
illustration and
description only and are not intended as a definition of the limits of the
present patent
application. It shall also be appreciated that the features of one embodiment
disclosed herein
can be used in other embodiments disclosed herein. As used in the
specification and in the
claims, the singular form of "a", "an", and "the" include plural referents
unless the context
clearly dictates otherwise. In addition, as used in the specification and the
claims, the term
"or" means "and/or" unless the context clearly dictates otherwise. It should
also be
appreciated that some of the components and features discussed herein may be
discussed in
connection with only one (singular) of such components, and that additional
like components
which may be disclosed herein may not be discussed in detail for the sake of
reducing
redundancy. Just for example, where a single weld torch head is described, the
same
configuration can be used for additional weld torch heads provided in the same
system (e.g.,
in an internal welding system), and can also be used in other welding systems
(such as the tie-
in internal welders) described herein. Similarly, various components such as
the clamps, seals,
brakes, weld consumption detection systems, or other components described
herein, can be
used with various embodiments described herein. For example, the braking
system, motors,
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clamps seals, as described in one embodiment can be applied to other
embodiments described
herein, as will be appreciated by those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0062] FIGS. lA and 1B show block diagrams of a method for welding pipe
segments,
wherein FIG. lA shows a high level block diagram of the method and FIG. 1B
shows a more
detailed block diagram of the method, in accordance with an embodiment of the
present
patent application;
[0063] FIG. 2 shows a cross-sectional view of a welded joint connecting a
first pipe and a
second pipe in accordance with an embodiment of the present patent
application;
[0064] FIGS. 2A and 2B show bevel details for a single pipe segment and for a
joint (prior
to welding) between two pipe segments in accordance with an embodiment of the
present
patent application;
[0065] FIGS. 2C-2F show a front view, a perspective view, a side view and a
detailed view
of a bevel gage used to gage the pipe bevel in accordance with an embodiment
of the present
patent application;
[0066] FIGS. 2G-2I show cross-sectional views of pipelines with weld joints
formed
between their pipes, where FIG. 2G shows a weld joint in which root pass and
hot pass weld
layers are formed by an internal weld system and the fill and cap pass weld
layers are formed
by an external weld system, FIG. 2H shows a weld joint in which a root pass
weld layer is
formed by an internal weld system and the hot, fill and cap pass weld layers
are formed by an
external weld system and FIG. 21 shows a weld joint formed by an external weld
system in
accordance with an embodiment of the present patent application;
[0067] FIGS. 3-7 show block diagrams of the methods for welding pipe segments
for
different weld situations in accordance with an embodiment of the present
patent application;
[0068] FIGS. 7A and 7B show views of an external clamp being used to clamp
pipes
together from the outside in accordance with an embodiment of the present
patent application;
[0069] FIG. 8 shows a perspective view of a system for welding two pipe
segments in
accordance with an embodiment of the present patent application;
[0070] FIG. 9 shows an enlarged view of a pipe interface of two pipe segments
to be
welded using the system of FIG. 8 in accordance with an embodiment of the
present patent
application;
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100711 FIG. 9A shows a partial cross-sectional view of the pipeline in which
an ideal
alignment of a weld torch to an internal bevel (along longitudinal axes of the
pipes) in
accordance with an embodiment of the present patent application;
[0072] FIG. 10-1 shows the system of FIG. 8 in which an internal weld system
is inserted
into a first pipe segment in accordance with an embodiment of the present
patent application;
[0073] FIGS. 10-2 and 10-3 show the system of FIG. 8 in which the internal
weld system
is inserted into the first pipe segment and a second pipe segment is being
aligned with the
first pipe segment in accordance with an embodiment of the present patent
application;
[0074] FIGS. 10A and 10B show views of the internal weld system being
constructed and
arranged to be positioned in pipes having an external diameter of 26 to 28
inches external
diameter and in pipes having an external diameter of less than 24 inches,
respectively in
accordance with an embodiment of the present patent application;
[0075] FIGS. 10C and 10D show a left side perspective view and a bottom
perspective
view of a cradle for carrying and moving the first pipe and the second pipe in
accordance
with an embodiment of the present patent application;
[0076] FIGS. 10E and 1OF show two pipe alignment errors, while FIG. 10E shows
an
angular pipe alignment error and FIG. 1OF shows a position pipe alignment
error;
[0077] FIG. 11 shows the internal weld system for welding two pipe segments in
accordance with an embodiment of the present patent application;
[0078] FIG. 11A shows a view of an umbilical operatively connected to the
internal weld
system in accordance with an embodiment of the present patent application;
[0079] FIG. 12 shows a detailed view of a forward-most section of the internal
weld
system in accordance with an embodiment of the present patent application;
[0080] FIGS. 13-22 show views of various components of the forward-most
section of the
internal weld system in accordance with an embodiment of the present patent
application;
[0081] FIG. 22A shows an exemplary weld wire spool in accordance with an
embodiment
of the present patent application;
[0082] FIG. 22B shows an exemplary weld feed assembly in accordance with an
embodiment of the present patent application;
[0083] FIGS. 23 and 24 show a front view and a cross-sectional view of a
center section of
the internal weld system in accordance with an embodiment of the present
patent application;
[0084] FIGS. 25-31 show views of various components of the center section of
the internal
weld system in accordance with an embodiment of the present patent
application;
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[0085] FIGS. 32A and 32B show side and top views of a drive section of the
internal weld
system in accordance with an embodiment of the present patent application;
[0086] FIG. 33 shows a view of the center section of the internal weld system
being
positioned inside the pipe segments, where both clamps and seals are engaging
the inner
surfaces of the pipes, and where some components of the center section are not
shown for
sake of clarity, in accordance with an embodiment of the present patent
application;
[0087] FIG. 34 shows a cross-sectional view of the center section of the
internal weld
system being positioned inside the pipe segments, where some components of the
center
section are not shown for sake of clarity, in accordance with an embodiment of
the present
patent application;
[0088] FIG. 35 shows a view of the center section of the internal weld system
being
positioned inside the pipe segments, where only clamps are engaging the inner
surfaces of the
pipes and where some components of the center section are not shown for sake
of clarity, in
accordance with an embodiment of the present patent application;
[0089] FIGS. 35A and 35B show cross-sectional views of the center section of
the internal
weld system, where the clamps are in their extended and retracted positions,
respectively and
where some components of the center section are not shown for sake of clarity,
in accordance
with an embodiment of the present patent application;
[0090] FIG. 35C shows a side (head-on) view of the internal weld system in
accordance
with an embodiment of the present patent application;
[0091] FIG. 36 shows a view of a clamp shoe of the internal weld system in
accordance
with an embodiment of the present patent application;
[0092] FIG. 37 shows a view of a spider member of an clamp of the internal
weld system
in accordance with an embodiment of the present patent application;
[0093] FIG. 38 shows a view of a clamp shoe pin member of the internal weld
system in
accordance with an embodiment of the present patent application;
[0094] FIGS. 39 and 40 show views of a hub of the clamp of the internal weld
system with
the clamp shoe pin member and the link member connected thereto in accordance
with an
embodiment of the present patent application;
[0095] FIGS. 41 and 42 show front perspective and rear perspective views of a
weld head
assembly of the internal weld system in accordance with an embodiment of the
present patent
application;
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[0096] FIG. 43 shows another rear perspective view of the weld head assembly
of the
internal weld system, wherein a weld torch of the weld head assembly has been
raised to a
desired welding position, in accordance with an embodiment of the present
patent application;
[0097] FIGS. 44-46 show a left side perspective view, a perspective view and a
cross-
sectional view of the weld head assembly, where some components of the weld
head
assembly are not shown for sake of clarity, in accordance with an embodiment
of the present
patent application;
[0098] FIGS. 47, 48 and 49 show perspective views of the weld head assembly,
where the
weld torch is positioned, by an axial positioning system, in its centered
axial position in FIG.
47, and the weld torch is positioned, by the axial positioning system, in the
right and left axial
positions in FIGS. 48 and 49, respectively, in accordance with an embodiment
of the present
patent application;
[0099] FIGS. 50 and 51 show a left side perspective view and an exploded view
of the
weld head assembly, where some components of the weld head assembly are not
shown for
sake of clarity, in accordance with an embodiment of the present patent
application;
[00100] FIG. 52 shows a bottom perspective view of a top positioning member of
the weld
head assembly in accordance with an embodiment of the present patent
application;
[00101] FIG. 53 shows a top elevational view of the weld head assembly, where
some
components of the weld head assembly are not shown for sake of clarity, in
accordance with
an embodiment of the present patent application;
[00102] FIG. 54 shows a cross-sectional view of the weld head assembly wherein
the weld
torch is positioned in a normal, non-tilted position in accordance with an
embodiment of the
present patent application;
[00103] FIGS. 55 and 56 show a rear perspective view and a cross-sectional
view of the
weld head assembly, respectively, wherein the weld torch is positioned by a
tilt positioning
system to +50 of angular tilt in accordance with an embodiment of the present
patent
application;
[00104] FIG. 56A shows a cross-sectional view of the weld head assembly in
accordance
with an embodiment of the present patent application
[00105] FIGS. 57 and 58 show a rear perspective view and a cross-sectional
view of the
weld head assembly, respectively, wherein the weld torch is positioned by a
tilt positioning
system to -5 of angular tilt in accordance with an embodiment of the present
patent
application;
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[00106] FIG. 59 shows an exploded view of the weld head assembly, where some
components of the weld head assembly are not shown for sake of clarity, in
accordance with
an embodiment of the present patent application;
[00107] FIGS. 60A-63 show schematic views of the internal weld system with one
weld
torch, an inspection camera and two inspection detectors in accordance with an
embodiment
of the present patent application;
[00108] FIGS. 64-69 show schematic views of the internal weld system with two
weld
torches, an inspection camera and an inspection detector in accordance with an
embodiment
of the present patent application;
[00109] FIG. 70 shows a schematic diagram showing the flow of compressed air
through
the internal weld system in accordance with an embodiment of the present
patent application;
[00110] FIG. 71 shows a schematic diagram showing the flow of power, including
weld
power, communication data, and controls data through the internal weld system
in accordance
with an embodiment of the present patent application;
[00111] FIG. 72 shows a schematic diagram showing the flow of shield gas
through the
internal weld system in accordance with an embodiment of the present patent
application;
[00112] FIGS. 72A, 72B and 72C show close-up views of an internal weld torch
used in a
prior art system and the internal weld system, respectively, where the pipes
have a gap and
radial offset (Hi-Lo) alignment;
[00113] FIG. 72D shows exemplary weld parameters that are used for uphill and
downhill
weld procedures in accordance with an embodiment of the present patent
application;
[00114] FIG. 73 shows a perspective view of a system for welding two
externally aligned
pipe segments supported on alignment mechanisms in accordance with an
embodiment of the
present patent application;
[00115] FIG. 74 shows an enlarged, external view of a pipe interface of two
pipe segments
to be welded using the system of FIG. 73 in accordance with an embodiment of
the present
patent application;
[00116] FIG. 75 shows the system in which a weld system is inserted into a
pipe segment in
accordance with an embodiment of the present patent application, wherein one
of the pipe
segments is not shown for the sake of clarity;
[00117] FIG. 76 shows an enlarged view of a section of FIG. 75 showing a weld
portion of
the weld system positioned for welding in a pipe segment in accordance with an
embodiment
of the present patent application, wherein one of the pipe segments is not
shown for the sake
of clarity.
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[00118] FIG. 77 shows a cross-sectional view of FIG. 76 taken along the axis B-
B showing
the arrangement of various weld portion elements in accordance with an
embodiment of the
present patent application;
[00119] FIGS. 78 and 79 show side views of the weld system of FIG. 75, where
the pipe
segment is not shown for sake of clarity, in accordance with an embodiment of
the present
patent application;
[00120] FIG. 80 shows a perspective view of the system of FIG. 73 in a
configuration
showing a first procedure in which a pipe segment is placed on an external
alignment
mechanism in accordance with an embodiment of the present patent application;
[00121] FIG. 81 shows a perspective view the system of FIG. 73 in a
configuration showing
a procedure subsequent to FIG. 80 in which the weld system is inserted into a
pipe segment in
accordance with an embodiment of the present patent application;
[00122] FIG. 82 shows a side view of the weld portion of the system of FIG. 73
in
accordance with an embodiment of the present patent application;
[00123] FIG. 83 shows an enlarged perspective view of a section of the weld
portion of the
system of FIG. 73 in accordance with an embodiment of the present patent
application;
[00124] FIG. 84 shows another enlarged perspective view of a section of the
weld portion
of the system of FIG. 73 in accordance with an embodiment of the present
patent application;
[00125] FIG. 85 shows an enlarged perspective view of a rotary mechanism of
the system
of FIG. 73 in accordance with an embodiment of the present patent application;
[00126] FIG. 86 shows a purge and inspection system in accordance with an
embodiment of
the present patent application;
[00127] FIG. 87 shows a detailed view of a forward-most section of the purge
and
inspection system in accordance with an embodiment of the present patent
application;
[00128] FIG. 88 shows a purge assembly of the purge and inspection system in
accordance
with an embodiment of the present patent application;
[00129] FIGS. 89 and 90 show a front view and a cross-sectional view of a
center section of
the purge and inspection system in accordance with an embodiment of the
present patent
application;
[00130] FIG. 91 shows purge seals of the purge and inspection system in
accordance with
an embodiment of the present patent application;
[00131] FIG. 92 shows of the rotatable hub of the purge and inspection system
in
accordance with an embodiment of the present patent application;
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[00132] FIG. 93 shows a detailed view of a drive section of the purge and
inspection system
in accordance with an embodiment of the present patent application;
[00133] FIG. 94 shows a schematic diagram showing the flow of purge gas
through the
purge and inspection system in accordance with an embodiment of the present
patent
application;
[00134] FIG. 95 shows a schematic diagram showing the flow of compressed air
through
the purge and inspection system in accordance with an embodiment of the
present patent
application;
[00135] FIG. 96 shows a schematic diagram showing the flow of purge gas
through the
purge and inspection system in accordance with another embodiment of the
present patent
application;
[00136] FIG. 97 shows a partial view of the purge and inspection system in
accordance with
an embodiment of the present patent application;
[00137] FIG. 98 shows a close-up view of an external weld torch of an external
weld system
used in the purge and inspection system in accordance with an embodiment of
the present
patent application;
[00138] FIGS. 99 and 100 show close-up views of the external weld torch of the
external
weld system used in a prior art system and the purge and inspection system,
respectively,
where the pipes have a gap and radial offset (Hi-Lo) alignment;
[00139] FIG. 101 shows a tie-in internal weld system in accordance with an
embodiment of
the present patent application;
[00140] FIG. 102 shows a detailed view of a power section of the tie-in
internal weld
system in accordance with an embodiment of the present patent application;
[00141] FIG. 103 shows a schematic diagram showing the flow of power including
weld
power, communication data, and controls data through the tie-in internal weld
system in
accordance with an embodiment of the present patent application;
[00142] FIG. 103A shows a cross-sectional view of the center section of the
tie-in internal
weld system, where the clamps are in their retracted positions, and where some
components
of the center section are not shown for sake of clarity, in accordance with an
embodiment of
the present patent application;
[00143] FIG. 103B shows a method for aligning two pipes, pre-inspecting an
interface
region between the two pipes to be welded end-to-end, welding the two pipes,
post-weld
inspecting the weld joint formed between the two pipes in accordance with an
embodiment of
the present patent application;
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[00144] FIG. 103C shows a side view of a tie-in internal weld system in
accordance with
another embodiment of the present patent application;
[00145] FIG. 103D shows a perspective view of the tie-in internal weld system
in
accordance with another embodiment of the present patent application;
[00146] FIG. 103E shows a perspective view of weld head assemblies of the tie-
in internal
weld system in accordance with another embodiment of the present patent
application;
[00147] FIG. 103F shows a front view of the weld head assemblies of the tie-in
internal
weld system in accordance with another embodiment of the present patent
application;
[00148] FIGS. 103G-103J show a procedure in which one or more weld head
assemblies are
operated in clockwise and counterclockwise directions to perform a welding
operation in the
tie-in internal weld system in accordance with another embodiment of the
present patent
application;
[00149] FIG. 104 shows a perspective view of an exemplary internal cooling
system for use
in pipeline welding in accordance with an embodiment of the present patent
application;
[00150] FIG. 105 shows a perspective view of the internal cooling system of
FIG. 104
immediately prior to insertion within an end of a pipe section in accordance
with an
embodiment of the present patent application;
[00151] FIG. 106 shows a perspective view of the internal cooling system of
FIG. 104
located within a first pipe section that is secured via a weld joint to a
second pipe section in
accordance with an embodiment of the present patent application;
[00152] FIG. 107 shows another view of FIG. 106 in which the internal cooling
system is
located within the first and second pipe segments at a suitable location in
relation to the weld
joint to facilitate internal cooling at the weld joint in accordance with an
embodiment of the
present patent application;
[00153] FIG. 108 shows a perspective view of the internal cooling system of
FIG. 104
connected with a tie-in clamp in accordance with an embodiment of the present
patent
application;
[00154] FIG. 109 shows a perspective view of the internal cooling system of
FIG. 104
connected with a tie-in clamp in accordance with another embodiment of the
present patent
application;
[00155] FIGS. 110A and 110B show perspective and partial perspective views,
respectively,
of the internal cooling system for use in pipeline welding in accordance with
another
embodiment of the present patent application;
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[00156] FIGS. 111A and 111B show partial perspective views of portions of the
internal
cooling system for use in pipeline welding in accordance with another
embodiment of the
present patent application, in which the portion of the internal heat
exchanger is within two
pipe segments secured to each other via a weld joint, and a water pump is
provided at an end
of a portion of a pipe section;
[00157] FIGS. 112A and 112B show partial perspective views of portions of the
internal
cooling system for use in pipeline welding in accordance with another
embodiment of the
present patent application, in which the portion of the internal heat
exchanger is within two
pipe segments secured to each other via a weld joint, and a water pump is
provided at an end
of a portion of a pipe section;
[00158] FIG.113 shows a cross-sectional view of the pipes with their exposed
metal pipe
ends aligned in accordance with an embodiment of the present patent
application;
[00159] FIG. 114 shows a cross-sectional view of the pipes with the weld joint
formed
between their exposed metal pipe ends in accordance with an embodiment of the
present
patent application;
[00160] FIGS. 115A and 115B show a cross-sectional view and a perspective view
of the
pipes with the weld joint formed between their exposed metal pipe ends and a
heater
positioned on the pipes to heat the exposed end portions of the welded pipes,
respectively in
accordance with an embodiment of the present patent application;
[00161] FIGS. 116A and 116B show a cross-sectional view and a perspective view
of the
pipes with the weld joint formed between their exposed metal pipe ends and an
insulator
supply positioned on the pipes to apply an insulator material to the heated
the exposed end
portions of the welded pipes, respectively in accordance with an embodiment of
the present
patent application;
[00162] FIGS. 117A and 117B show a cross-sectional view and a perspective view
of the
pipes with the weld joint formed between their exposed metal pipe ends and an
insulator
supply positioned on the pipes to apply an insulator material to the heated
exposed end
portions of the welded pipes in accordance with an embodiment of the present
patent
application;
[00163] FIG. 118 shows a cross-sectional view of the pipes with the weld joint
formed
between their exposed metal pipe ends and an insulator adhered to the exterior
surface of the
metal pipe interior, thus insulating the formerly exposed end portions of the
pipes in
accordance with an embodiment of the present patent application;
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[00164] FIG. 119 shows a perspective view of a cooler system configured to
apply cooling
energy to an interior surface of the pipes to facilitate cooling of the pipes
after the insulator
material is applied in accordance with an embodiment of the present patent
application;
[00165] FIG. 120 shows a partial, cross-sectional view of the cooler system
being
positioned within the pipes in accordance with an embodiment of the present
patent
application;
[00166] FIGS. 121 and 122 show partial, cross-sectional views of the cooler
system being
positioned within the pipes, where FIG. 121 shows a heat exchanger of the
cooler system
positioned in contact with the interior surface of the welded pipes to remove
heat from the
welded pipes and FIG. 122 shows the heat exchanger is in its retracted
position and is not in
contact with the interior surface of the welded pipes in accordance with an
embodiment of the
present patent application;
[00167] FIG. 123 shows a perspective view of the cooler system, wherein fluid
nozzles
configured to apply a cooling liquid onto the interior surface of the welded
pipes to remove
heat from the welded pipes are shown in accordance with another embodiment of
the present
patent application;
[00168] FIGS. 124 and 125 show a perspective view and a front view of a heat
exchanger
element or a fin member of the cooler system in accordance with another
embodiment of the
present patent application;
[00169] FIGS 126-128 show perspective views of a system that is configured to
facilitate
the placement of the cooler system within and/or withdrawal of the cooler
system from the
pipes in accordance with another embodiment of the present patent application;
[00170] FIG. 129 shows a partial perspective view of the cooler system, where
a plurality of
rollers configured to engage the interior surface of one or more of the pipes
and a drive motor
configured to drive the rollers so as to move a frame assembly of the cooler
assembly are
shown in accordance with another embodiment of the present patent application;
[00171] FIG. 130 shows a perspective view of a cooler system in accordance
with another
embodiment of the present patent application;
[00172] FIG. 131 shows a top view of a motor power source carried by the frame
assembly
of the cooler system in accordance with another embodiment of the present
patent application;
[00173] FIG. 132 shows a heat exchanger of the cooler system positioned in
contact with
the interior surface of the welded pipes to remove heat from the welded pipes
in accordance
with another embodiment of the present patent application;
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[00174] FIGS. 133 and 134 show perspective views of a cooler system in
accordance with
another embodiment of the present patent application;
[00175] FIGS. 135 and 136 show a perspective view and a partial cross-section
view of a
cooler system in accordance with another embodiment of the present patent
application;
[00176] FIG. 136A shows a perspective view of an ultrasound inspection station
that is
configured to inspect the weld between the welded metal pipes in accordance
with an
embodiment of the present patent application;
[00177] FIG. 136B shows a method showing the pipeline deployment procedures in
accordance with an embodiment of the present patent application;
[00178] FIGS. 136C and 136D show schematic views of the S-lay procedure and of
the J-
lay procedure in accordance with an embodiment of the present patent
application;
[00179] FIG. 136E shows S-lay and J-lay unspooling barges in accordance with
an
embodiment of the present patent application;
[00180] FIG. 137A shows a system for facilitating field system testing or
operations thereof
in accordance with another embodiment of the present patent application;
[00181] FIG. 137B shows communication links between the remote computer
system, the
field computer system of the field system, and other components of the field
system in
accordance with another embodiment of the present patent application;
[00182] FIG. 137C shows communication links between the remote computer system
and
components of the field system without the field computer system in accordance
with another
embodiment of the present patent application;
[00183] FIG. 138 shows a flowchart of a method for facilitating, by a field
system, field
testing and physical operations based thereon in accordance with another
embodiment of the
present patent application;
[00184] FIG. 139-142 show flowcharts of methods for facilitating, by a
computer system,
field testing and physical operations based thereon in accordance with other
embodiments of
the present patent application;
[00185] FIG. 143 depict an example of a pipeline in accordance with another
embodiment
of the present patent application;
[00186] FIG. 144 shows a welding station in accordance with another embodiment
of the
present patent application;
[00187] FIG. 145 show a plurality of pipeline welding stations in accordance
with another
embodiment of the present patent application;
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[00188] FIG. 146 is a schematic diagram of a system with a plurality of
welding stations in
communication with a plurality of control and log collection stations in
accordance with
another embodiment of the present patent application;
[00189] FIG. 147 is a schematic diagram of a system with a plurality of
welding stations in
communication with a plurality of control and log collection stations in
accordance with
another embodiment of the present patent application;
[00190] FIG. 148 is a schematic diagram of welding station in communication
with a
network via a WiFi connection in accordance with another embodiment of the
present patent
application;
[00191] FIG. 149 is a schematic diagram of a plurality of job sites in
communication with a
cloud server via a worldwide network (internet) in accordance with another
embodiment of
the present patent application;
[00192] FIG. 150 is a schematic diagram of a plurality of welding stations in
communication with intermediate computing devices (lead technicians,
inspectors, engineers,
etc.) which are in turn in communication with a cloud server through the
internet in
accordance with another embodiment of the present patent application;
[00193] FIG. 151 is a schematic diagram of a plurality of welding stations in
communication with an intermediate computer system (Engineer, quality and Tech
terminals)
through a wireless (e.g., WiFi) communication channel in accordance with
another
embodiment of the present patent application;
[00194] FIG. 152 is a schematic diagram of a plurality of welding stations in
communication with a computer system through a wireless (e.g., WiFi)
communication
channel in accordance with another embodiment of the present patent
application;
[00195] FIG. 153 is a schematic diagram of a plurality of welding stations in
communication with a plurality of intermediate computer systems (Engineer,
quality and
Tech terminals) which in turn are in communication with a cloud server in
accordance with
another embodiment of the present patent application;
[00196] FIG. 154 shows an example graphical user interface ("GUI") for a "Main
Screen"
of an application for cloud based universal data logging (uLog) implemented by
a computer
system at the welding station, at the intermediate computer system or at the
cloud server in
accordance with another embodiment of the present patent application;
[00197] FIG. 155 shows an example GUI for a "Live Log" screen of the
application for
cloud based universal data logging (uLog) showing voltages versus time at one
welding
station in accordance with another embodiment of the present patent
application;
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[00198] FIG. 156 shows an example GUI for a "Get Log" screen of the
application for
cloud based universal data logging (uLog) showing weld data parameters
including type of
weld event, time, zone, weld travel speed, lead wire travel speed in
accordance with another
embodiment of the present patent application;
[00199] FIG. 157 shows an example GUI for a summary report screen of the
application for
cloud based universal data logging (uLog) displaying various welding
parameters including
weld time, weld station identification number, weld arc voltage, etc., in
accordance with
another embodiment of the present patent application;
[00200] FIG. 158 shows an example GUI for a "Save Data on Log" screen of the
application for cloud based universal data logging (uLog) displaying various
in accordance
with another embodiment of the present patent application;
[00201] FIG. 159 shows an example GUI for an "Analytics" screen of the
application for
cloud based universal data logging (uLog) showing two icons for selecting a
type of analysis
performed (e.g., trends, moving average) in accordance with another embodiment
of the
present patent application;
[00202] FIG. 160 shows an example GUI for a "Welding Parameter" screen of the
application for cloud based universal data logging (uLog) showing two various
for selecting a
type of function to be performed in accordance with another embodiment of the
present
patent application;
[00203] FIG. 161A depicts schematically an example of a spool that is
configured to carry a
weld wire in accordance with another embodiment of the present patent
application;
[00204] FIG. 161B depicts schematically a lateral view of a hub-transducer
that is
configured to measure a weight of the spool in accordance with another
embodiment of the
present patent application;
[00205] FIG. 161C depicts another lateral view of the hub-transducer showing
the
positioning of transducer elements or strain sensors/gauges for measuring
weight strain when
the spool is mounted on the hub in accordance with another embodiment of the
present patent
application;
[00206] FIG. 162 depicts schematically an arrangement where a weld wire in
spool
mounted to hub is pulled by a motor assembly for feeding the wire 82 to the
weld device (not
shown) in accordance with another embodiment of the present patent
application;
[00207] FIG. 163 is a flow chart depicting a process of comparing the measured
weight and
the theoretical weight determined based on the wire feed speed in accordance
with another
embodiment of the present patent application;
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[00208] FIGS. 164A and 164B depict enlarged lateral cross-sections of the
motor assembly
in accordance with another embodiment of the present patent application;
[00209] FIG. 165 is a diagram of a configuration of the welding system
depicting the
interconnections of various components of the system in accordance with
another
embodiment of the present patent application;
[00210] FIG. 166 shows a non-destructive testing system overview in accordance
with
another embodiment of the present patent application;
[00211] FIG. 167 shows a generic embodiment of a non-destructive testing
system in
accordance with another embodiment of the present patent application;
[00212] FIG. 168 shows an ultrasonic testing embodiment of a non-destructive
testing
system in accordance with another embodiment of the present patent
application; and
[00213] FIG. 169 shows a radiographic testing embodiment of a non-destructive
testing
system in accordance with another embodiment of the present patent
application.
DETAILED DESCRIPTION
[00214] FIGS. lA and 1B show block diagrams of a method 1000 for welding pipe
sections
or segments 1022 (e.g., 1022a and 1022b as shown in FIG. 2) of a pipeline 1024
(as shown in
FIG. 2) together. For example, FIG. lA shows a high level block diagram of the
method 1000,
while FIG. 1B shows a more detailed block diagram of the method 1000.
[00215] FIG. 2 shows a cross-sectional view of a weld joint 1026 connecting
the pipe
segments 1022 (e.g., 1022a and 1022b) of the pipeline 1024. The pipe segments
1022 (e.g.,
1022a and 1022b) may interchangeably be referred to herein as pipes or pipe
sections. In one
embodiment, the weld joint 1026 is a complete circumferential weld connecting
the pipe
segments 1022 (e.g., 1022a and 1022b) end-to-end circumferentially. In one
embodiment, the
weld joint 1026 may be referred to as a girth weld or a butt weld. In one
embodiment, as
described in detail below, the pipe segments 1022a and 1022b are welded
together at their
beveled end portions.
[00216] In one embodiment, the first pipe segment 1022a and the second pipe
segment
1022b have a length of at least 30 feet. In one embodiment, the first pipe
segment 1022a and
the second pipe segment 1022b have a length of at least 31.5 feet. In one
embodiment, the
first pipe segment 1022a and the second pipe segment 1022b have a length of at
least 33 feet.
In one embodiment, the first pipe segment 1022a and the second pipe segment
1022b have a
length of at least 34.5 feet. In one embodiment, the first pipe segment 1022a
and the second
pipe segment 1022b have a length of at least 36 feet.
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[00217] In one embodiment, the first pipe segment 1022a and the second pipe
segment
1022b have an exterior diameter of 24 inches or less. In one embodiment, the
exterior
diameter of the pipe segment may also be referred to as the outer diameter of
the pipe
segment.
[00218] In one embodiment, the first pipe segment 1022a and the second pipe
segment
1022b have a nominal exterior diameter of 24 inches or less. In one
embodiment, the first
pipe segment 1022a and the second pipe segment 1022b each have an exterior
diameter of
24.1875 inches or less. In one embodiment, the first pipe segment 1022a and
the second pipe
segment 1022b each have an exterior diameter of 23.8125 inches or less.
[00219] In one embodiment, the first pipe segment 1022a and the second pipe
segment
1022b have an exterior diameter of 22.8 inches or less. In one embodiment, the
first pipe
segment 1022a and the second pipe segment 1022b have an exterior diameter of
21.6 inches
or less. In one embodiment, the first pipe segment 1022a and the second pipe
segment 1022b
each have an exterior diameter of 20.4 inches or less. In one embodiment, the
first pipe
segment 1022a and the second pipe segment 1022b each have an exterior diameter
of 19.2
inches or less.
[00220] In one embodiment, the first pipe segment 1022a and the second pipe
segment
1022b each have an exterior diameter in the range of 26 to 28 inches.
[00221] In one embodiment, the first pipe segment 1022a and the second pipe
segment
1022b are made of a metal material. In one embodiment, the first pipe segment
1022a and the
second pipe segment 1022b are made of a carbon steel material. In one
embodiment, the first
pipe segment 1022a and the second pipe segment 1022b are made of an alloy
steel material.
In one embodiment, the first pipe segment 1022a and the second pipe segment
1022b are
made of a low-alloy steel material. In one embodiment, the first pipe segment
1022a and the
second pipe segment 1022b are made of a stainless steel material. In one
embodiment, the
first pipe segment 1022a and the second pipe segment 1022b may be made of a
American
Petroleum Institute specification (API) 5L grade X52 (i.e., 52000 PSI minimum
yield
strength and 66000 PSI minimum tensile strength) material. In one embodiment,
the first pipe
segment 1022a and the second pipe segment 1022b may be made of an API 5L grade
X60
(i.e., 60000 PSI minimum yield strength and 75000 PSI minimum tensile
strength) material.
[00222] In one embodiment, the first pipe segment 1022a and the second pipe
segment
1022b may be made completely or in-part from a Corrosion Resistant Alloy
(CRA). In one
embodiment, the Corrosion Resistant Alloy may include both iron-based alloys
such as
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various grades of stainless steel or nickel-based alloys (i.e., typically
known by the trade
name, Inconel).
[00223] In one embodiment, some CRA materials may require shield gas on both
sides of
the weld. In one embodiment, in such an instance, a purge and inspection
system 7001 (as
will be described in detail with respect to FIGS. 86-100) may be used within
the pipes 1022a,
1022b to provide a purge gas chamber inside (at interface region of) the pipes
to be welded
and an external weld system 7500 (as shown in FIG. 97) may be used outside the
pipes 1022a,
1022b. In one embodiment, the external weld system 7500 may be configured to
provide
shield gas outside (e.g., at joint of) the pipes to be welded.
[00224] In one embodiment, the first pipe segment 1022a and the second pipe
segment
1022b may be made of the same material. In one embodiment, the first pipe
segment 1022a
and the second pipe segment 1022b may be made of the different materials.
[00225] In one embodiment, the first pipe segment 1022a and the second pipe
segment
1022b may be made of bi-metallic materials where the inner portion of the pipe
segment is a
CRA material and the outer portion of the pipe segment may be either carbon
steel or a
different CRA material than the inner portion.
[00226] In one embodiment, as shown in FIG. 2G, the first pipe segment 1022a
and the
second pipe segment 1022b includes a metal pipe interior 5244 surrounded by an
insulator/a
coating material 5246. In one embodiment, the end portions of the first pipe
segment 1022a
and the second pipe segment 1022b to be welded have the insulator/coating
material 5246
removed and the metal pipe interior 5244 exposed.
[00227] In one embodiment, the first pipe segment 1022a and the second pipe
segment
1022b may be coated on its external surface with a corrosion resistant
material/coating when
the first pipe segment 1022a and the second pipe segment 1022b are used in
corrosive
environments (e.g., sea/salt water/ocean, chemical, etc.). In one embodiment,
the first pipe
segment 1022a and the second pipe segment 1022b may be coated on its external
surface
with a wear resistant material/coating. In one embodiment, the first pipe
segment 1022a and
the second pipe segment 1022b may be coated on its external surface with an
insulator
material/coating. In one embodiment, the first pipe segment 1022a and the
second pipe
segment 1022b may be coated on its interior surface with the corrosion
resistant
material/coating, the wear resistant material/coating, the insulator
coating/material or a
combination thereof In one embodiment, the first pipe segment 1022a and the
second pipe
segment 1022b may be coated on both its interior and exterior surfaces with
the corrosion
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resistant material/coating, the wear resistant material/coating, the insulator
coating/material
or a combination thereof
[00228] In one embodiment, as shown in FIGS. 2A and 2B, an end 1038a of the
pipe 1022a
is welded to a second end 1038b of the pipe 1022b. In one embodiment, the end
1038a of the
pipe 1022a has an internal bevel surface 5228 and an external bevel surface
5230. In one
embodiment, the end 1038b of the pipe 1022b has an internal bevel surface 5232
and an
external bevel surface 5234. In one embodiment, as will be clear from the
discussions below,
a root pass weld layer of weld material is disposed in a region IBR defined by
the first
internal bevel surface 5228 and the second internal bevel surface 5232 when an
internal weld
system 5004 is used to deposit the root pass weld layer from within the pipes
1022a, 1022b.
[00229] In one embodiment, the external bevel surfaces 5230 and 5234 each may
include
first external bevel surfaces 5230a and 5234a and second bevel surfaces 5230b
and 5234b,
respectively. In one embodiment, the first external bevel surfaces 5230a and
5234a are
beveled at an angle EBi with respect to an axis N-N that is perpendicular to a
longitudinal
axes A-A of the pipe segments 1022a, 1022b. In one embodiment, the angle EBi
may be 50
.
[00230] In one embodiment, the second external bevel surfaces 5230b and 5234b
are
beveled at an angle EB2 with respect to the axis N-N. In one embodiment, the
angle EB2 is
greater than the angle EBi. In one embodiment, the angle EB2 may be 45 .
[00231] In one embodiment, the external bevel surfaces 5230 and 5234 may each
include a
single bevel surface. In one embodiment, the external bevel surfaces 5230 and
5234 may each
include a single continuous surface having a J-shaped configuration.
[00232] In one embodiment, the internal bevel surfaces 5228 and 5232 are
beveled at an
angle IB with respect to the axis N-N. In one embodiment, the angle IB may be
37.5 . In one
embodiment, the internal bevel surfaces 5228 and 5232 may have a distance B
measured
along axis N-N from their respective inner pipe surfaces 5130 and 5132. In one
embodiment,
the distance B measured along axis N-N from their respective inner pipe
surfaces 5130 and
5132 is 0.05 inches.
[00233] In one embodiment, the external bevel surfaces 5230 and 5234 and the
internal
bevel surfaces 5228 and 5232 may be separated from each other by a non-bevel
surface. In
one embodiment, the non-bevel surface may have a distance NB measured along
the axis N-
N. In one embodiment, the distance NB measured along axis N-N is 0.05 inches.
In one
embodiment, the non-bevel surface is optional and the external bevel surfaces
5230 and 5234
and their corresponding internal bevel surfaces 5228 and 5232 may be next to
(and touching)
each other.
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[00234] In one embodiment, the internal bevel surfaces 5228 and 5232 of the
pipe segments
1022a, 1022b may have the same bevel angle. In one embodiment, the external
bevel surfaces
5230 and 5234 of the pipe segments 1022a, 1022b may have the same bevel
angle(s). In
another embodiment, the bevel angle of the internal bevel surfaces 5228 and
5232 of the pipe
segments 1022a, 1022b may vary. In another embodiment, the bevel angle(s) of
external
bevel surfaces 5230 and 5234 of the pipe segments 1022a, 1022b may vary.
[00235] In one embodiment, the dimensions B of the internal bevel surfaces,
the dimension
NB of the non-bevel surface, and the bevel angles TB, EBi and EB2 may vary and
depend on
the thickness T of the pipe segments 1022a, 1022b.
[00236] In one embodiment, the end 1038a of the pipe 1022a and the end 1038b
of the pipe
1022b are joined to have a weld groove 5236 formed therebetween. In one
embodiment, the
weld groove 5236 may have a V-shaped cross-section. In one embodiment, the end
1038a of
the pipe 1022a and the end 1038b of the pipe 1022b are constructed and
arranged to have J-
shaped configurations such that the weld groove formed by joining the end
1038a of the pipe
1022a and the end 1038b of the pipe 1022b together has a U-shaped
configuration. In another
embodiment, the shape of the weld groove depends on the welding parameters or
conditions.
[00237] Referring to FIG. 2, in one embodiment, a weld material 1034 is
configured to
connect the first pipe segment 1022a and the second pipe segment 1022b. In one
embodiment,
the weld material 1034 may include Inconel material or Inconel alloy material.
In one
embodiment, the weld material 1034 may include a material that has a higher
strength than
the material of the pipes. In one embodiment, the weld material 1034 may be a
different
material than the material of the pipes. For example, in one embodiment, the
weld material
may include Inconel material or Inconel alloy material and the material of the
first pipe
segment 1022a and the second pipe segment 1022b may include a stainless steel
material.
[00238] In one embodiment, the weld material 1034 and/or weld joint 1026
includes a
plurality of pass weld layers 1014, 1016, 1018 and 1020. For example, in one
embodiment,
the plurality of pass weld layers 1014, 1016, 1018 and 1020 may include the
root pass weld
layer 1014, the hot pass weld layer 1016, one or more fill pass weld layers
1018 and the cap
pass weld layer 1020 as will be explained in detail below. The pass weld
layer(s) may
interchangeably be referred to herein as pass layer(s). In one embodiment, the
weld pass (e.g.,
root pass, hot pass, fill pass(es), cap pass) may be a single advancement of
the weld tool or
weld system along the weld joint 1026. In one embodiment, a weld bead or a
weld layer is
formed as a result of each weld pass.
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[00239] In one embodiment, referring to FIGS. 1A, 1B and 2, the method 1000
for welding
pipe sections or segments 1022a and 1022b together generally includes a root
pass weld
procedure 1002, a hot pass weld procedure 1004, a fill and cap pass weld
procedure 1006, a
weld inspection procedure 1008, a heating procedure 1010 and a coating
procedure 1012. In
one embodiment, the fill and cap pass weld procedure 1006 may include one or
more of fill
pass weld procedures 1006a and a cap pass weld procedure 1006b. In one
embodiment, the
method 1000 is generally a multi-pass weld or multi-layer weld procedure that
includes, for
example, the root pass weld procedure 1002, the hot pass weld procedure 1004,
and the fill
and cap weld procedure 1006.
[00240] In one embodiment, one or more of the weld passes (e.g., root pass,
hot pass, fill
pass(es), cap pass) of the multi-pass weld or a multi-layer weld method 1000
may be
performed by the same weld system or tool at different times. In one
embodiment, the weld
passes may be performed sequentially by same weld system or tool. For example,
in one
embodiment, the root and hot pass weld procedures may be performed
sequentially by an
internal weld system 5004 (as will be described in detail below) from interior
of the pipes. In
one embodiment, the fill and cap pass weld procedures may be performed
sequentially by an
external weld system 7500 from the exterior of the pipes.
[00241] In one embodiment, the internal weld system 5004 is generally
configured to weld
the pipe segments 1022a and 1022b from inside the pipeline 1024 and the
external weld
system 7500 is generally configured to weld the pipe segments 1022a and 1022b
from outside
the pipeline 1024. In one embodiment, the welding performed by the internal
weld system
5004 may result in a K-shaped weld bead or layer and the welding performed by
the external
weld system 7500 may result in a J-shaped weld bead or layer.
[00242] In one embodiment, the hot, fill and cap pass weld procedures may be
performed
sequentially by the external weld system 7500 from the exterior of the pipes,
while only the
root pass weld procedure is performed by the internal weld system 5004 (as
will be described
in detail below) from interior of the pipes.
[00243] In one embodiment, one or more of the weld passes (e.g., root pass,
hot pass, fill
pass(es), cap pass) of the multi-pass or multi-layer weld method 1000 may be
performed by
different weld systems or tools at same or different times. In one embodiment,
the weld
passes may be performed sequentially by different weld systems or tools.
[00244] In one embodiment, each of the hot, fill and cap pass weld procedures
may be
performed in its corresponding weld shack from the exterior of the pipes. In
one embodiment,
the weld shack is a relatively small enclosure, for example, approximately 12
feet wide, 10
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feet long and 8 feet high where an external weld system is mounted and carried
from one pipe
joint to the next by a back end rig. The weld shack typically is a lightweight
metal frame
covered with thin sheet metal. The weld shack has a special floor designed to
pivot up to
allow the weld shack to be lowered onto the pipes and then pivot back down to
allow easy
access to the pipe. In one embodiment, each of the one or more fill pass weld
procedures may
be performed in different weld shacks each having an external weld system.
[00245] In one embodiment, the root pass weld procedure 1002 is the first
welding
procedure of the multi-pass or multi-layer weld method 1000. In one
embodiment, the root
pass weld procedure 1002 is performed by the internal weld system 5004. In one
embodiment,
the root pass weld procedure 1002 may be performed by a tie-in internal weld
system 3001
(as will be described in detail below) having on-board weld power.
[00246] In one embodiment, the root pass weld procedure 1002, when performed
with the
internal weld system 5004, may take up to 1.03 minutes. In one embodiment, the
cycle time
for the root pass weld procedure is 4 minutes (this timing is calculated from
when a reach rod
or umbilical 5034 is set on an auto travel). In one embodiment, the total
cycle time for three
cycles of the root pass weld procedure (performed by the internal weld system
5004) is 13.15
minutes (including a 2.30 minutes for the spool/weld wire change procedure),
and the
average cycle time for the root pass weld procedure (performed by the internal
weld system
5004) is 4.42 minutes.
[00247] In one embodiment, the root pass weld procedure 1002 may be performed
by an
external weld system 7500. In one embodiment, the root pass weld procedure
1002 may be
performed by the external weld system 7500 with the purge and inspection
system 7001. In
one embodiment, the root pass weld procedure 1002 may be performed by the
external weld
system with tie-in clamps. In one embodiment, the root pass weld procedure
1002 may be
performed by the external weld system 7500 with internally disposed clamps
7050, 7052. In
one embodiment, the internally disposed clamps may be standard clamps or purge
clamps
(e.g., the purge and inspection system 7001).
[00248] In one embodiment, the root pass weld procedure 1002 forms the root
pass weld
layer 1014. In one embodiment, as shown in FIGS. lA and 1B, the root pass weld
layer 1014
is the first weld bead or layer deposited in the multiple pass or a multi-
layer welding method
1000. In one embodiment, the root pass layer may also be referred to as a root
sealer bead or
layer. In one embodiment, the root pass weld procedure 1002 is performed by
Gas Metal Arc
Welding (GMAW). In one embodiment, the root pass weld procedure 1002 is
performed by
Gas Tungsten Arc Welding (GTAW). In one embodiment, the root pass weld
procedure 1002
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is performed by Short Circuit Gas Metal Arc Welding (GMAW-S). In another
embodiment,
the root pass weld procedure 1002 is performed by other welding processes as
would be
appreciated by one skilled in the art.
[00249] In one embodiment, the hot pass weld procedure 1004 is the second
welding
procedure of the multi-pass or multi-layer weld method 1000. In one
embodiment, the hot
pass weld procedure 1004 is performed by the internal weld system 5004. In one
embodiment,
the hot pass weld procedure 1004 may be performed by the tie-in internal weld
system 3001
having on-board weld power.
[00250] In another embodiment, the hot pass weld procedure 1004 is performed
by the
external weld system 7500. In one embodiment, the hot pass weld procedure 1004
is
performed by the external weld system with internally disposed clamps. In one
embodiment,
the internally disposed clamps may be standard clamps or purge and inspection
clamps. In
another embodiment, the hot pass weld procedure 1004 may be performed by a
manual
welder. In such an embodiment, the pipe ends are configured to include a 300
bevel angle.
[00251] In one embodiment, the hot pass weld procedure 1004, when performed
with the
external weld system (in a weld shack) and in a ditch side location, may take
up to 1.06
minutes. In one embodiment, the hot pass weld procedure 1004, when performed
with the
external weld system (in a weld shack) and in a work side location, may take
up to 58
seconds. In one embodiment, the cycle time for the hot pass weld procedure is
2.38 minutes
(this timing is calculated from when the hot pass weld shack is set on the
pipe). In one
embodiment, the total cycle time for three cycles the hot pass weld procedure
performed by
the external weld system in a weld shack is 11.35 minutes, and the average
cycle time for the
hot pass weld procedure performed by the external weld system in a weld shack
is 3.45
minutes.
[00252] In one embodiment, the hot pass weld procedure 1004 forms the hot pass
weld
layer 1016. In one embodiment, as shown in FIG. 2, the hot pass weld layer
1016 is the
second weld bead or layer deposited in the multiple pass or a multi-layer weld
method 1000.
In one embodiment, the hot pass weld procedure 1004 immediately follows the
root pass
weld procedure 1002. In one embodiment, the hot pass weld procedure 1004 is
performed by
Gas Metal Arc Welding (GMAW). In one embodiment, the hot pass weld procedure
1004 is
performed by Gas Tungsten Arc Welding (GTAW). In one embodiment, the hot pass
weld
procedure 1004 is performed by Short Circuit Gas Metal Arc Welding (GMAW-S).
In
another embodiment, the hot pass weld procedure 1004 is performed by other
welding
processes as would be appreciated by one skilled in the art.
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[00253] In one embodiment, the one or more of fill pass weld procedures 1006a
and the cap
weld procedure 1006b of the fill and cap pass weld procedure 1006 are
performed by the
external weld system 7500. In one embodiment, the fill and cap pass weld
procedure 1006
may be performed at multiple stations. In another embodiment, the fill and cap
pass weld
procedure 1006 may be performed by a manual welder. In such an embodiment, the
pipe ends
are configured to include a 300 bevel angle.
[00254] In one embodiment, the one or more fill pass weld procedures 1006a
follow (or are
performed after) the hot pass weld procedure 1004. In one embodiment, the one
or more fill
pass weld procedures 1006a form the fill pass weld layer(s) 1018. The fill
pass weld layer(s)
1018 are configured to fill the weld groove and be substantially flush with
the surfaces of the
pipe segments 1022a and 1022b of the pipeline 1024. In one embodiment, the
number of fill
pass weld procedures 1006a in the multiple pass or multi-layer weld method
1000 may vary.
In one embodiment, the number of fill pass weld procedures 1006a in the
multiple pass or
multi-layer weld method 1000 may depend on the thickness of the pipe segments
1022a and
1022b of the pipeline 1024 being welded together.
[00255] In one embodiment, the fill pass weld procedures 1006a are performed
by Gas
Metal Arc Welding (GMAW). In one embodiment, the fill pass weld procedures
1006a are
performed by Gas Tungsten Arc Welding (GTAW). In one embodiment, the fill pass
weld
procedures 1006a are performed by Pulsed Gas Metal Arc Welding (GMAW-P). In
another
embodiment, the fill pass weld procedures 1006a are performed by other welding
processes
as would be appreciated by one skilled in the art.
[00256] In one embodiment, the cap pass weld procedure 1006b is the last or
final weld
procedure of the multi-pass or multi-layer weld method 1000. In one
embodiment, the cap
pass weld procedure 1006b follows (or is performed after) the fill pass weld
procedure(s)
1006a. In one embodiment, as shown in FIG. 2, the cap pass weld layer 1020 is
the weld bead
or layer deposited subsequent the fill pass weld procedures 1006a. In one
embodiment, the
cap pass weld procedure 1006b may also be referred to as a cover pass weld
procedure. In
one embodiment, the cap pass weld procedure 1006b forms the cap pass weld
layer 1020. In
one embodiment, as shown in FIG. 2, the cap pass weld layer 1020 is the last
or final weld
bead deposited in the multiple pass or a multi-layer weld method 1000. In one
embodiment,
the cap pass weld layer 1020 is configured to be substantially higher than the
surfaces of the
pipe segments 1022a and 1022b of the pipeline 1024.
[00257] In one embodiment, the cap pass weld procedure 1006b is performed by
Gas Metal
Art Welding (GMAW). In one embodiment, the cap pass weld procedure 1006b is
performed
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by Gas Tungsten Art Welding (GTAW). In one embodiment, the cap pass weld
procedure
1006b is performed by Pulsed Gas Metal Arc Welding (GMAW-P). In another
embodiment,
the cap pass weld procedure 1006b is performed by other welding processes as
would be
appreciated by one skilled in the art.
[00258] In one embodiment, the root pass weld procedure 1002 may be the only
pass weld
procedure of the multi-pass or multi-layer weld method 1000 that is performed
by the internal
weld system 5004, while the hot pass weld procedure 1004 and the fill and cap
pass weld
procedure 1006 are all performed using the external weld system 7500.
[00259] In another embodiment, both the root pass weld procedure 1002 and the
hot pass
weld procedure 1004 of the multi-pass or multi-layer weld method 1000 are
performed by the
internal weld system 5004, while the fill and cap pass weld procedure 1006 is
performed
using the external weld system 7500.
[00260] In yet another embodiment, the root pass weld procedure 1002, the hot
pass weld
procedure 1004 and the fill and cap pass weld procedure 1006 are performed
using the
external weld system 7500. In one embodiment, the purge and inspection clamps
are used
inside the pipes 1022a, 1022b, while the external weld system 7500 performs
the root pass
weld procedure 1002, the hot pass weld procedure 1004 and the fill and cap
pass weld
procedure 1006.
[00261] FIGS. 2G-2I show cross-sectional views of pipelines 1024 with weld
joints 1026
formed therebetween.
[00262] FIG. 2G shows a cross-sectional view of the pipeline 1024 with the
weld joint 1026
formed therebetween. For example, the weld joint 1026 of FIG. 2G includes the
root pass
weld layer 1014 and the hot pass weld layer 1016 formed by the internal weld
system 5004
from interior of the pipes 1022a, 1022b, while the one or more fill pass weld
layers 1018 and
the cap pass weld layer 1020 are formed by the external weld system 7500 from
the exterior
of the pipes 1022a, 1022b.
[00263] The individual weld pass layers (e.g., root pass weld layer 1014, hot
pass weld
layer 1016, fill and cap pass weld layers 1018 and 1020) may also be clearly
seen in FIG. 2.
The border 1032 between the weld material 1034 and pipe material 1036 may be
easily and
clearly distinguished in FIG. 2. In one embodiment, the shape of the border
1032 (as
illustrated by the line ABCDE) is unique to the pipeline 1024 that is welded
(e.g., the root
pass weld procedure 1002 and/or the hot pass weld procedure 1004) from the
inside the
pipeline 1024.
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[00264] In one embodiment, when both the root pass weld procedure 1002 and the
hot pass
weld procedure 1004 of the multi-pass or multi-layer weld method 1000 are
performed by the
internal weld system 5004 from inside the pipeline 1024, the locations of the
root pass weld
layer 1014 and hot pass weld layer 1016 will swap (e.g., when compared to the
weld joint in
which the root pass weld procedure is performed by the internal weld system
5004 from
inside the pipeline 1024 and the hot pass weld procedure 1004 is performed by
the external
weld system from outside the pipeline 1024). In one embodiment, as shown in
FIGS. 2 and
2G, the hot pass weld layer 1016 is positioned closer to an interior
longitudinal axis A-A of
the welded first and second pipes 1022a and 1022b than the root pass weld
layer 1014.
[00265] In one embodiment, the hot pass weld layer 1016 of the weld material
1034 has at
least a portion 5238 thereof disposed closer to the longitudinal axis A-A than
interior surfaces
5130, 5132 of the welded pipes 1022a and 1022b in regions 5240 and 5242 of the
welded
pipes 1022a and 1022b immediately adjacent to the weld material 1034 on
opposite sides of
the weld material 1034. In one embodiment, as shown in FIGS. 2 and 2G, when
both the root
pass weld procedure 1002 and the hot pass weld procedure 1004 of the multi-
pass or multi-
layer weld method 1000 are performed by the internal weld system 5004 from
inside the
pipeline 1024, the necked-down area 1028 of the weld joint 1026 occurs further
from the
inner walls 5130, 5132 of the pipeline 1024.
[00266] In one embodiment, the root pass weld layer 1014 is disposed in the
internal bevel
surfaces 5228, 5232 of the first and second pipe 1022a and 1022b and the hot
pass weld layer
1016 is disposed on top of the root pass weld layer 1014 (i.e., closer to the
interior
longitudinal axis A-A). In one embodiment, the internal weld system 5004 is
constructed and
arranged to perform more than one welding pass from inside the pipeline 1024.
In one
embodiment, the internal weld system 5004 is constructed and arranged to be
actuated in the
radial direction so that the internal weld system 5004 can adjust the height
of the weld torch
5502 between the two passes (e.g., the root pass weld procedure 1002 and the
hot pass weld
procedure 1004).
[00267] In one embodiment, additional weld pass layer(s) may be disposed on
top of the hot
pass layer 1016 and positioned closer to the interior longitudinal axis A-A of
the welded first
and second pipes 1022a, 1022b than the hot pass layer 1016. For example, in
one
embodiment, the one or more fill pass weld layers 1018 may be performed by the
internal
weld system 5004 such that the one or more fill pass weld layers 1018 are
disposed on top of
the hot pass layer 1016 and positioned closer to the interior longitudinal
axis A-A of the
welded first and second pipes 1022a, 1022b than the hot pass layer 1016. For
example, in one
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embodiment, the one or more fill pass weld layers 1018 and the cap pass weld
layers 1020
may be performed by the internal weld system 5004 such that the one or more
fill pass weld
layers 1018 and the cap pass weld layers 1020 are disposed on top of the hot
pass layer 1016
and positioned closer to the interior longitudinal axis A-A of the welded
first and second
pipes 1022a, 1022b than the hot pass layer 1016.
[00268] In another embodiment, the one or more fill pass weld layers 1018 and
the cap pass
weld layer 1020 are disposed in the external bevel surfaces 5230, 5234 of the
first and second
pipe 1022a and 1022b and may be performed by the external weld system 7500
from outside
the pipeline 1024.
[00269] FIG. 2H shows a cross-sectional view of the pipeline 1024 with the
weld joint 1026
formed therebetween. For example, the weld joint 1026 of FIG. 2H includes the
root pass
weld layer 1014 formed by the internal weld system 5004 from interior of the
pipes 1022a,
1022b, while the hot pass weld layer 1016, the one or more fill pass weld
layers 1018, and the
cap pass layer 1020 are formed by the external weld system 7500 from the
exterior of the
pipes 1022a, 1022b. In one embodiment, the root pass weld layer 1014 is
disposed in the
internal bevel 5228, 5232 of the first and second pipe 1022a and 1022b. In one
embodiment,
the hot pass weld layer 1016, the one or more fill pass weld layers 1018 and
the cap pass
weld layer 1020 are disposed in the external bevel surfaces 5230, 5234 of the
first and second
pipe 1022a and 1022b.
[00270] FIG. 21 shows a cross-sectional view of the pipeline 1024 with the
weld joint 1026
formed therebetween. For example, the weld joint 1026 of FIG. 21 includes the
root pass weld
layer 1014, the hot pass weld layer 1016, the one or more fill pass weld
layers 1018 and 1020
formed by the external weld system 7500 from the exterior of the pipes 1022a,
1022b. In one
embodiment, the root pass weld layer 1014, the hot pass weld layer 1016, the
one or more fill
pass weld layers 1018 and the cap pass weld layer 1020 are all disposed in the
external bevel
surfaces 5230, 5234 of the first and second pipe 1022a and 1022b.
[00271] In one embodiment, after the weld joint 1026 is completed, the weld
joint 1026
may be inspected during the weld inspection procedure 1008. In one embodiment,
the weld
inspection procedure 1008 is performed after the fill and cap pass weld
procedure 1006. In
one embodiment, the weld joint 1026 may be cleaned before the weld inspection
procedure
1008. In one embodiment, a significant amount of heat may be generated during
the welding
procedures (e.g., procedures 1002, 1004, and 1006). In one embodiment, the
weld inspection
procedure 1008 is carried out at an operating temperature that is less than at
the higher weld
temperature. In one embodiment, the weld joint 1026 may be cooled before the
weld
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inspection procedure 1008 by an internal cooling system 2010 or 6500 (as
described in detail
below). In one embodiment, the weld inspection procedure 1008 may include any
type of
nondestructive testing/inspection of the weld joint 1026.
[00272] In one embodiment, the weld inspection procedure 1008 may include an
Automated
Ultrasound Testing (AUT). In one embodiment, the Automated Ultrasound Testing
of the
weld joint 1026 may be used for both onshore and offshore pipeline weld
applications. In one
embodiment, the AUT is configured to be used in high-production environments.
In one
embodiment, the AUT is configured to be used for detecting and sizing weld
flaws.
[00273] In one embodiment, the Automated Ultrasound Testing is performed by an
AUT
scanner system (e.g., 6801 as shown in FIG. 136A). In one embodiment, the AUT
scanner
system includes an ultrasonic sensor system. In one embodiment, the AUT
scanner system
may be portable. In one embodiment, the AUT scanner system may also include a
data
acquisition system that is operatively connected to the ultrasonic sensor
system. In one
embodiment, the ultrasonic sensor system may include an emitter that is
configured to send,
for example, ultrasonic signals (e.g., wave pulses) into the pipe segments
1022a and 1022b
and/or the girth weld 1026 therebetween. In one embodiment, the ultrasonic
signals or pulses
may be sent at a rate from 1 Hz to 20,000 Hz. In one embodiment, the frequency
of the
ultrasonic sound wave may vary from 0.5 MHz to 23 MHz.
[00274] In one embodiment, the ultrasonic signals or pulses, sent by the
emitter, are
configured to reflect off the boundaries where the density of the girth weld
1026 changes. In
one embodiment, the ultrasonic sensor system may include a receiver that is
configured to
receive/detect the reflected pulses. In one embodiment, the receiver is
configured to measure
the intensity of the reflected pulse and produce an electronic signal
proportional to the
intensity of the reflected pulse. In one embodiment, the emitter and receiver
of the ultrasonic
sensor system may have multiple elements or components. In one embodiment, the
emitter of
the ultrasonic sensor system may be selectively activated to target the
ultrasonic pulse at a
specific location.
[00275] In one embodiment, a range of Automated Ultrasonic Testing (AUT) may
include
Time of Flight Diffraction (ToFD), Phased Array (PA), corrosion mapping,
and/or complete
weld inspection. In one embodiment, the Time of Flight Diffraction (ToFD)
ultrasonic weld
inspection may be used when multiple weld bevels are to be evaluated.
[00276] In one embodiment, the AUT weld inspection procedure may include a
full-
coverage pulse-echo ultrasonic weld inspection. In one embodiment, the pulse-
echo
ultrasonic inspection techniques use Phased Array (PA) probes coupled with
ToFD
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inspection to provide very accurate weld flaw measurements. In one embodiment,
the welds
may be divided into zones (zonal discrimination) that are evaluated
individually, with the
results being reassembled into a comprehensive weld analysis. In one
embodiment, a linear
and sectorial scanning may provide superior weld examination. In one
embodiment, the
ToFD ultrasonic weld inspection may be used to supplement the full-coverage
pulse-echo
ultrasonic weld inspection.
[00277] In yet another embodiment, the weld inspection procedure 1008 may
include an X-
ray radiography Testing. In one embodiment, the X-ray radiography Testing is
performed by
an X-ray radiography system. In one embodiment, the X-ray radiography system
includes an
emitter that is configured to send an X-ray radiation into the pipe segments
1022a and 1022b
and the girth weld 1026 therebetween. In one embodiment, the intensity of the
X-ray
radiation may be attenuated by the material of the pipe segments 1022a and
1022b and girth
weld 1026 therebetween. In one embodiment, the X-ray radiography system
includes a
receiver that is configured to measure the intensity of the X-ray radiation
that passes through
the material of the pipe segments 1022a and 1022b and girth weld 1026
therebetween.
[00278] In one embodiment, the weld inspection procedure 1008 may include
Gamma and
close proximity radiography inspection. In one embodiment, the weld inspection
procedure
1008 may include Magnetic Particle Inspection (MPI) or Dye Penetrant
Inspection (DPI). In
one embodiment, the weld inspection procedure 1008 may include any other Non-
Destructive
Testing (NDT), for example, but not limited to, Guided Wave Ultrasonic
testing, eddy current
testing, hardness testing, Tank Floor Testing (MFL), Positive Material
Identification,
Corrosion Mapping Surveys, etc. In one embodiment, the Non-Destructive Testing
(NDT)
may generally refer to any testing configured to identify weld defects without
damaging the
pipes and/or the weld formed therebetween.
[00279] Referring to FIG. 2G, in one embodiment, as discussed above, each pipe
segment
1022a, 1022b includes the metal pipe interior 5244 surrounded by external
protective
coatings (e.g., an insulator material) 5246. In one embodiment, end portions
5248 and 5250
of the pipe segments 1022a, 1022b to be welded have the metal pipe interior
exposed.
[00280] In one embodiment, after the weld inspection procedure 1008, external
protective
coatings are applied back to the weld joint 1026. For example, an insulator is
applied to the
exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b such that the
insulator
5246A (as shown in FIG. 118) is adhered to an exterior surface 5254 of the
metal pipe
interior 5244, thus insulating the formerly exposed end portions 5248, 5250 of
the pipes
1022a, 1022b.
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[00281] In one embodiment, to facilitate the application of the external
protective coatings
or the insulator, the weld joint 1026 and the surrounding portions of the pipe
segments 1022a
and 1022b of the pipeline 1024 are heated to a predetermined coating
temperature. In one
embodiment, the exposed end portions 5248, 5250 of the welded pipes 1022a,
1022b are
heated. In one embodiment, the predetermined coating temperature is the
temperature that is
required for the application of the external protective coatings or the
insulator. In one
embodiment, the predetermined coating temperature is configured to provide a
good adhesion
or bonding between the external protective coatings or the insulator and the
pipeline 1024.
[00282] In one embodiment, the heating procedure 1010 is performed after the
weld
inspection procedure 1008. In one embodiment, an induction pre-heating
procedure may be
used to heat the exposed end portions 5248, 5250 of the welded pipes 1022a,
1022b of the
pipeline 1024 in preparation for application of the coating material(s) or the
insulator.
[00283] In one embodiment, the heating procedure 1010 is performed by a
heating system
5304 (shown and explained with respect to FIGS. 115A and 115B). In one
embodiment, the
heating system may include an electrical heating system. In one embodiment,
the heating
system may include Ultra high frequency (UHF) induction coils that are
configured to rapidly
heat the exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b of
the pipeline
1024 up to the required coating temperature. In one embodiment, the heating
system is also
configured to regulate the temperature of the exposed end portions 5248, 5250
of the welded
pipes 1022a, 1022b of the pipeline 1024 to maintain a suitable coating
application
temperature. In one embodiment, the heating system may include a heating
feedback system
configured to enable the heating system to achieve and maintain the required
coating
temperature and a temperature sensor operatively coupled to the feedback
system. In one
embodiment, the temperature sensor may be a contact or a non-contact
temperature sensor. In
one embodiment, the heating feedback system may include one or more sensors
that are
configured to sense other parameters of the heating procedure ¨ heating time,
etc.
[00284] In one embodiment, the coating procedure 1012 is performed immediately
after the
heating procedure 1010. In one embodiment, the coating procedure 1012 is
performed in a
coating shack (i.e., similar in construction to the weld shack) having a
coating head that is
constructed and arranged to apply/spray/provide insulator/coating/epoxy
mixture to the
exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b of the
pipeline 1024. In
one embodiment, the coating head completes the coating procedure in less than
a minute. In
one embodiment, the coating head completes the coating procedure in 50
seconds.
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[00285] In one embodiment, an insulator/coating is applied to the heated
exposed end
portions 5248, 5250 of the welded pipes such that the insulator/coating 5246A
(as shown in
FIG. 118) is adhered to the exterior surface 5254 of the metal pipe interior,
thus insulating the
formerly exposed end portions 5248, 5250 of the pipes 1022a, 1022b.
[00286] In one embodiment, the coatings are applied to external surfaces or
areas of the
pipe segments 1022a and 1022b surrounding the weld joint 1026 to provide an
insulation
barrier in order to prevent or minimize corrosion at weld areas.
[00287] In one embodiment, the coatings may include polypropylene coatings. In
one
embodiment, the coatings may include polyethylene coatings. In one embodiment,
the
coatings may include polyurathane coatings. In one embodiment, the coatings
may include
insulation (e.g., heat loss) coatings. In one embodiment, the coatings may
include anti-
corrosion coatings. In one embodiment, the coatings may include wear-resistant
coatings. In
one embodiment, the coatings may include fusion bonded epoxy (FBE). In one
embodiment,
the coatings may include fusion bonded epoxy (FBE) plus chemically modified
polypropylene (CMPP) or polyethylene (CMPE) dual powder base layers. In one
embodiment, the chemically modified polypropylene (CMPP) or polyethylene
(CMPE) layer
is then followed immediately by the polypropylene (PP) or polyethylene (PE)
tape. In one
embodiment, the coatings may include Multi-Component Liquid coatings (MCL)
(e.g.,
urethane and epoxy based MCL coatings). In one embodiment, the coatings may
include a
field joint coating (FJC).
[00288] In one embodiment, the coatings may include an Injection Molded
polypropylene.
In such an embodiment, the pipeline 1024 is pre-heated to a temperature of 180
C to receive
the Injection Molded polypropylene coating.
[00289] In one embodiment, an automated equipment may be used to apply coating
materials at the weld joint 1026. In one embodiment, the coating delivery
system may include
Injection Molded Coating System as shown and described in detail with respect
to FIGS.
117A and 117B. In one embodiment, the coating delivery system may include a
flame-spray
coating system. In one embodiment, the insulation/coatings may be applied to
the exposed
regions of the weld joint using a nozzle device. In one embodiment, the nozzle
device is
configured to spray insulation materials onto the exposed region of pipe at
the region of the
welds. In one embodiment, the nozzle device is shown and described with
respect to FIGS.
116A-116B.
[00290] In one embodiment, an abrasive blasting procedure may be used to
prepare the
pipeline 1024 for the coatings. In one embodiment, the abrasive blasting
procedure may be
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performed prior to the heating procedure 1010. In one embodiment, the oxidized
pipe weld
joint is sandblasted to remove all contaminants.
[00291] In one embodiment, the coating system may include a coating feedback
system
configured to enable the coating system to achieve the desired coatings on the
pipeline 1024
and one or more sensors operatively connected to the coating feedback system.
In one
embodiment, the one or more sensors are configured to sense the following
parameters of the
coating procedure ¨ heating time, heating temperature, coating material
temperature, coating
material volume, etc.
[00292] In one embodiment, the method 1000 may include other procedures that
are not
shown in FIG. 1A. In one embodiment, these other procedures of the method 1000
are shown
in and explained with respect to FIG. 1B.
[00293] In one embodiment, the method 1000 may include a pipe preparation
procedure
1040, a pipe alignment procedure 1042, an optional weld inspection procedure
1044, a repair
procedure 1046, a cooling procedure 1048, and a pipeline deployment procedure
1050. In one
embodiment, each of these procedures is optional.
[00294] In one embodiment, the pipe preparation procedure 1040 is performed
prior to the
root pass weld procedure 1002. In one embodiment, the pipe preparation
procedure 1040 is
performed prior to the pipe alignment procedure 1042.
[00295] In one embodiment, the pipe preparation procedure 1040 may include a
cutting
procedure 1040a. In one embodiment, the cutting procedure 1040a is performed
for
preparation of the edge or end portions of the pipe segments 1022a, 1022b for
welding. In
one embodiment, during the cutting procedure 1040a, the pipe segments 1022a
and 1022b
that are to be welded together are cut into the desired dimensions. In one
embodiment, the
cutting procedure 1040a may be performed at the manufacturer's location.
[00296] In one embodiment, the method may include a stringing procedure in
which the
pipes are distributed according to a design plan (before the pipe
joining/welding procedure).
In one embodiment, each joint of the pipe segment has a specific place in the
pipeline. The
stringing crew ensures that each piece of pipe is placed where it belongs.
Inspectors check the
pipe's designated numbers to ensure that the joints are in the correct order.
[00297] In one embodiment, the method may include a bending procedure in which
the
pipes are bent to fit the right-of-way's topography. In one embodiment, the
pipe is inserted
into a bender and a mandrel is then positioned in the pipe. The mandrel is
constructed and
arranged to apply pressure inside the pipe to prevent buckling while bending.
The operator
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positions the pipe and makes the bend. The pipe is removed from the bender
after the bend is
made. After the bending procedure, each piece of pipe is set in place.
[00298] In one embodiment, the pipe preparation procedure 1040 may include a
beveling
procedure 1040b. In one embodiment, the beveling procedure 1040b is performed
for
preparation of the edge or end portions of the pipe segments 1022a and 1022b
for welding. In
one embodiment, during the beveling procedure 1040b, the end portions of the
pipe sections
or segments 1022a and 1022b that are to be welded together are beveled into
the desired
dimensions. In one embodiment, the desired bevels may be machined into the end
portions of
the pipe segments 1022. In one embodiment, a pipe facing machine is inserted
in the pipe and
is anchored to the pipe (by raising its internal clamp shoes). In one
embodiment, the beveling
procedure 1040b may take 10 seconds. In one embodiment, the operator may
manually check
the formed bevel using a bevel gage 5801 shown in FIGS. 2C-2F. FIGS. 2C-2E
show a front
view, a perspective view and a side view of the bevel gage 5801, respectively,
while FIG. 2F
shows a detailed view of detail A in FIG. 2C. In one embodiment, the beveling
procedures
1040a, 1040b may be performed at the manufacturer's location.
[00299] In one embodiment, the standard bevel depth for field welding from the
inside of
the pipe is .050 inches. In one embodiment, the weld bead is about 3
millimeters tall so that
the weld bead protrudes from the surface by 0.05 to 0.07 inches. For making
two weld passes
(e.g., root and hot pass welds), in one embodiment, the bevel may be cut to a
depth of 0.150
to 0.170 inches.
[00300] In one embodiment, the pipe alignment procedure 1042 is performed
prior to the
root pass weld procedure 1002. In one embodiment, the pipe alignment procedure
1042 is
performed between the pipe preparation procedure 1040 and the root pass weld
procedure
1002. In one embodiment, a preheat procedure may be performed, prior to the
welding
procedure (i.e., root pass weld procedure), to heat the pipe to over 100 C so
as to evaporate
all moisture from the surface of the pipe.
[00301] In one embodiment, referring to FIG. 2G, the pipe alignment procedure
1042 may
include providing a second pipe 1022a at the second end 1038b of the first
pipe 1022b, and
aligning the ends 1038a, 1038b of the first and second pipes 1022a, 1022b that
are to be
welded. In one embodiment, the internal weld system 5004 may include a
feedback system
(e.g., using inspection detector 5056, one or more processors 5140,
orientation motors 5030,
5074, external cradle 5330, 6010A, 6010B, internal clamps 5144, 5144, 7050,
7052 as will be
explained in detail below) that is configured to sense whether the ends 1038a,
1038b of the
first and second pipes 1022a, 1022b are properly aligned. The term "motor" as
used herein
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broadly refers to any type of electromechanical motor, such as an electric
motor, hydraulic
motor, pneumatic motor, just for example.
[00302] In one embodiment, the optional weld inspection procedure 1044 may be
performed between the hot pass weld procedure 1004 and the fill and cap weld
procedure
1006. In one embodiment, the optional weld inspection procedure 1044 may
include X-ray
radiography inspection. In one embodiment, the X-ray radiography inspection is
performed
by an X-ray radiography system. In one embodiment, the X-ray radiography
system includes
an emitter that is configured to send an x-ray radiation into the pipe
segments 1022a and
1022b and the root and hot pass weld layers formed therebetween. In one
embodiment, the
intensity of the X-ray radiation may be attenuated by the material of the pipe
segments 1022a
and 1022b and the root and hot pass weld layers 1014, 1016 formed
therebetween. In one
embodiment, the X-ray radiography system includes a receiver that is
configured to measure
the intensity of the x-ray radiation that passes through the material of the
pipe segments
1022a and 1022b and the root and hot pass weld layers 1014, 1016 formed
therebetween. In
another embodiment, the weld inspection procedure 1044 may include Gamma and
close
proximity radiography inspection.
[00303] In one embodiment, the repair procedure 1046 is performed after the
weld
inspection procedure 1008 and before the heating and coating procedures 1010
and 1012. In
one embodiment, the repair procedure 1046 is configured to repair any weld
defects that are
detected during the weld inspection procedure 1008.
[00304] The weld repair procedure noted herein can be one of a variety of
types. In one
embodiment, an additional welding operation is performed on top of the
previous weld to
remedy any weld defect. In another embodiment, the defective weld may be
ground down or
optionally entirely cut out (manually or automatically) before any subsequent
repair welding
operation is conducted.
[00305] In one embodiment, after the heating and coating procedures 1010 and
1012, the
pipeline 1024 is allowed to cool to a suitable temperature before further
processing steps can
occur (e.g., before spooling of the connected pipe segments or handling
/placement of the
pipe segments in water or at some other suitable location on land). In one
embodiment, the
cooling procedure 1048 is performed after the coating procedure 1012. In one
embodiment,
the cooling procedure 1048 is performed by a cooling system 2010, 2110, 2210,
6500 (as
shown in and described with respect to FIGS. 104-112B and 119-136) that is
configured to
remove heat from the welded pipes so as to reduce their temperature to an
acceptable
temperature for effective spooling. For example, the pipeline should be below
a
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predetermined temperature (e.g., 50 to 70 C) to carry out the spooling
procedure, the S-lay
procedure, etc. In one embodiment, the cooling system may be an internal
cooling system
that is configured to cool the welded pipes from inside the pipeline 1024.
[00306] In one embodiment, the welded pipes may also be allowed to air cool
over time. In
one embodiment, the welded pipes may be cooled by spraying or pouring water on
the
outside of the insulation/coatings on the pipeline. In one embodiment, the
water spraying or
pouring procedure may be carried out in one or more stations.
[00307] In one embodiment, the cooling procedure 1048 is performed, for
example, for a
barge welding procedure, a spool base Tie-in welding procedure, and a spool
base main line
welding procedure. In one embodiment, the onshore main line welding procedure
and the
onshore tie-in welding procedure may not have a separate cooling procedure.
[00308] In one embodiment, the pipeline deployment/lowering procedure 1050 is
performed
after the coating procedure 1012. In one embodiment, the pipeline
deployment/lowering
procedure 1050 is performed after the cooling procedure 1048.
[00309] In one embodiment, the pipeline deployment procedure 1050 may include
a
spooling procedure 1050a, a S-lay procedure 1050b, or a pipeline lowering
procedure 1050c.
[00310] In one embodiment, the spooling procedure 1050a is configured to spool
the
pipeline onto the vessel, which transports the pipeline to its final
destination or location. In
one embodiment, the pipeline should be below a predetermined temperature
(e.g., 50 to 70 C)
to carry out the spooling procedure 1050a. In one embodiment, the
predetermined
temperature (e.g., 50 to 70 C) is configured to avoid any damage during the
spooling
procedure 1050a.
[00311] In one embodiment, the S-lay procedure is an offshore pipe-lay
procedure in which
the pipeline is lowered to the sea in a horizontal position. In one
embodiment, during the S-
lay procedure 1050b, the pipeline is pushed off the end of the vessel in an S-
shaped curve. In
one embodiment, the pipeline should be below a predetermined temperature
(e.g., 50 to 70 C)
to carry out the S-lay procedure 1050b. In one embodiment, the predetermined
temperature
(e.g., 50 to 70 C) is configured to avoid any damage during the S-lay
procedure 1050b.
[00312] The spooling procedure, the S-lay procedure and the J-lay procedure
are described
in detail with respect to FIGS. 136B-E.
[00313] In one embodiment, the pipeline lowering procedure 1050c is configured
to
position/lower the pipeline into a pre-dug ditch.
[00314] In one embodiment, the pipeline weld condition/situations may be
classified into
five categories, namely, onshore main line weld procedure, onshore tie-in weld
procedure,
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spool base main line weld procedure, spool base tie-in weld procedure, and
barge weld
procedure.
[00315] The onshore main line welding procedure is shown in FIG. 3. The
onshore main
line welding procedure is generally performed at a ground level and adjacent
to a pre-dug
ditch in which the pipeline will be disposed. In one embodiment, the onshore
pipelines are
welded together in sections, for example, up to 1 mile long. The welding
stations of the
onshore welding are near each other. The before welding procedures and after
welding
procedures of the onshore welding process are decoupled from the actual
welding procedure
itself so that the before and after welding procedures can occur at their own
pace. After the
segments of pipeline are welded together, they are lowered into the pre-dug
ditch.
[00316] The onshore tie-in weld procedure is shown in FIG. 4. The onshore tie-
in weld
procedure generally occurs in a pre-dug ditch in which the pipeline will be
disposed. That is,
the sections or segments are cut to length and welded together in the pre-dug
ditch.
[00317] The spool base main line weld procedure is shown in FIG. 5. The spool
base main
line weld procedure is generally performed in a factory-like setting. All
procedures of the
spool base main line weld procedure happen within the factory-like setting and
in a
coordinated, assembly line process. For example, the pipes are welded,
inspected and coated
along a firing line to form a pipe stalk (e.g., sometimes as long as 7
kilometers). The pipe
stalks are stored until they can be spooled onto a vessel for transport to
their final location.
That is, when the ship/barge is away from the spool base, the welded pipe is
stored in long
sections. The pipe stalks are reeled onto big spools on barges (typically J-
lay) and unspooled
when the barge arrives at the job location.
[00318] The spool base tie-in weld procedure is shown in FIG. 6. The spool
base tie-in weld
procedure is used to join the pre-assembled pipeline sections or segments
together as they are
being spooled onto the vessel/ship, which generally transports the pipeline to
its final location.
It is the cooling of this joint after coating that limits the spooling rate.
All procedures of the
spool base Tie-In weld are performed at the same station.
[00319] Barge weld procedure is shown in FIG. 7. The barge weld procedure is
generally
performed in a factory-like setting on-board a floating vessel. All procedures
of the barge
weld procedure are generally performed within the factory-like setting and in
a coordinated,
assembly line process. The pipeline is deployed in its final location as it
comes off the vessel.
[00320] Each of these pipeline weld situations may have one or more weld
procedures
described with respect to FIGS. lA and 1B. One or more systems described in
this patent
application (e.g., the internal weld system 5004, the tie-in internal weld
system 3001, purge
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and inspection system 7001, the external weld system 7500, and the internal
cooling system
2010) may be used in the operational procedures of these pipeline weld
situations.
[00321] For example, referring to FIG. 3, the onshore main line weld procedure
begins the
with pipe preparation procedure in which an automated weld-friendly bevel is
machined into
each end of the pipes. This may be done by an advance crew that is working a
short distance
ahead of the welding crew. After the pipe preparation procedure, a root pass
weld procedure
is performed. In one embodiment, the root pass weld procedure may be performed
by the
internal weld system 5004. In another embodiment, the root pass weld procedure
may be
performed by an external weld system 7500 with internal positioned clamp(s)
7050, 7052.
After the root pass weld procedure, the hot pass weld procedure is performed.
The hot pass
weld procedure may be performed either by the external weld system or by the
internal weld
system 5004.
[00322] In one embodiment, both the hot and root pass weld procedures are
performed by
the internal weld system 5004. In another embodiment, only the root pass weld
procedure is
performed by the internal weld system 5004, while the hot pass weld procedure
is performed
by the external weld system 7500.
[00323] In one embodiment, the fill and cap pass weld procedure is performed
after the hot
pass weld procedure. In one embodiment, the fill and cap pass weld procedure
may be
performed by the external weld system 7500. In one embodiment, the fill and
cap pass weld
procedure may be performed at multiple stations.
[00324] After the fill and cap pass weld procedure, the weld inspection
procedure is
performed. For example, Ultrasonic, x-ray radiography or Magnetic inspection
may be used
to inspect the weld area. Any weld defects detected during the weld inspection
procedure are
repaired during the weld repair procedure. The welded pipe is coated with
Fusion Bonded
Epoxy coating. The Fusion Bonded Epoxy coating is applied to the (heated)
exposed end
portions of the welded pipes such that the Fusion Bonded Epoxy coating is
adhered to an
exterior surface of the pipe interior. The coating procedure may be done by an
autonomous
crew that is working behind the repair crew. The pipeline is then lowered into
the pre-dug
ditch. The pipeline lowering procedure may be done by an autonomous crew that
is working
behind the coating crew.
[00325] Referring to FIG. 4, the onshore tie-in weld procedure begins with the
pipe
preparation procedure. The exact pipe lengths are not known in advance, so
overlap is
designed into the onshore tie-in weld procedure. Once the pipes are in the
ditch, one pipe is
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cut to the correct length and the desired bevel is machined into the end of
the pipe. After the
pipe preparation procedure, a root pass weld procedure is performed.
[00326] In one embodiment, the root pass weld procedure may be performed by
the tie-in
internal weld system 3001. In another embodiment, the root pass weld procedure
may be
performed by the tie-in clamp system with an external weld system 7500. In
another
embodiment, the root pass weld procedure may be performed by a manual welder
with
externally positioned clamps.
[00327] After the root pass weld procedure, the hot pass weld procedure is
performed. In
one embodiment, the hot pass weld procedure may be performed by the tie-in
internal weld
system 3001. In another embodiment, the hot pass weld procedure may be
performed by the
external weld system 7500. In another embodiment, the hot pass weld procedure
may be
performed by a manual welder.
[00328] In one embodiment, both the hot and root pass weld procedures are
performed by
the tie-in internal weld system 3001. In another embodiment, only the root
pass weld
procedure is performed by the tie-in internal weld system 3001, while the hot
pass weld
procedure is performed by the external weld system 7500.
[00329] The fill and cap pass weld procedure is performed after the hot pass
weld procedure.
In one embodiment, the fill and cap pass weld procedure may be performed by
the external
weld system 7500. In another embodiment, the fill and cap pass weld procedure
may be
performed by the manual welder. The fill and cap pass weld procedure is done
from the
exterior of the pipes. After the fill and cap pass weld procedure, the weld
inspection
procedure is performed. For example, Ultrasonic, x-ray radiography or Magnetic
inspection
may be used to inspect the weld area. The weld inspection procedure is done by
an
autonomous crew that is working behind the welding crew. Any weld defects
detected during
the weld inspection procedure are repaired during the weld repair procedure.
The repair
procedure is performed by an autonomous crew that is working behind the
inspection crew.
The welded pipe is coated with Fusion Bonded Epoxy coating. The Fusion Bonded
Epoxy
coating is applied to the (heated) exposed end portions of the welded pipes
such that the
Fusion Bonded Epoxy coating is adhered to an exterior surface of the pipe
interior. The
coating procedure may be done by an autonomous crew that is working behind the
repair
crew.
[00330] Referring to FIG. 5, the spool base main line weld procedure begins
with the pipe
preparation procedure in which an appropriate bevel is machined into the ends
of the pipe.
After the pipe preparation procedure, a root pass weld procedure is performed.
In one
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embodiment, the root pass weld procedure may be performed by the internal weld
system
5004. In another embodiment, the root pass weld procedure may be performed by
the purge
and inspection system 7001 with the external weld system 7500. In another
embodiment, the
root pass weld procedure may be performed by the internal clamps with the
external weld
system.
[00331] After the root pass weld procedure, the hot pass weld procedure is
performed. In
one embodiment, the hot pass weld procedure may be performed by the internal
weld system
5004. In another embodiment, the hot pass weld procedure may be performed by
the external
weld system 7500.
[00332] In one embodiment, both the hot and root pass weld procedures are
performed by
the internal weld system 5004. In another embodiment, only the root pass weld
procedure is
performed by the internal weld system 5004, while the hot pass weld procedure
is performed
by the external weld system 7500. In yet another embodiment, the root pass
weld procedure
is performed by the external weld system 7500 with internal purge clamps 7001,
while the
hot pass weld procedure is performed by the external weld system 7500.
[00333] The X-ray radiography weld inspection procedure is performed after the
hot pass
weld procedure. The X-ray radiography weld inspection procedure is optional.
[00334] The fill and cap pass weld procedure is performed after the hot pass
weld procedure
and X-ray radiography weld inspection procedure. In one embodiment, the fill
and cap pass
weld procedure may be performed by the external weld system. In one
embodiment, the fill
and cap pass weld procedure may be performed at multiple stations.
[00335] After the fill and cap pass weld procedure, the weld inspection
procedure is
performed to perform the weld inspection of the weld joint. For example,
Ultrasonic, x-ray
radiography or Magnetic inspection may be used to inspect the weld area. Any
weld defects
detected during the weld inspection procedure are repaired during the weld
repair procedure.
The welded pipe is coated with the Injection Molded Polypropylene coating. The
Injection
Molded Polypropylene coating is applied to the (pre-heated to 180 C) exposed
end portions
of the welded pipes such that the Injection Molded Polypropylene coating is
adhered to an
exterior surface of the pipe interior. Cooling procedure is performed after
the coating
procedure. The pipes may be allowed to air cool over time.
[00336] Referring to FIG. 6, the spool base tie-in weld procedure begins with
the pipe
preparation procedure in which an appropriate bevel is machined into the ends
of the pipe.
After the pipe preparation procedure, a root pass weld procedure is performed.
In one
embodiment, the root pass weld procedure may be performed by the tie-in
internal weld
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system 3001. In another embodiment, the root pass weld procedure may be
performed by the
purge clamp system 7001 with an external weld system 7500. In another
embodiment, the
root pass weld procedure may be performed by the internal clamps with the
external weld
system.
[00337] After the root pass weld procedure, the hot pass weld procedure is
performed. In
one embodiment, the hot pass weld procedure may be performed by the tie-in
internal weld
system 3001. In another embodiment, the hot pass weld procedure may be
performed by the
external weld system.
[00338] In one embodiment, both the hot and root pass weld procedures are
performed by
the tie-in internal weld system 3001. In another embodiment, only the root
pass weld
procedure is performed by the tie-in internal weld system 3001.
[00339] The X-ray radiography weld inspection procedure is performed after the
hot pass
weld procedure. The X-ray radiography weld inspection procedure is optional.
[00340] The fill and cap pass weld procedure is performed after the hot pass
weld procedure.
In one embodiment, the fill and cap pass weld procedure may be performed by
the external
weld system. In one embodiment, the fill and cap pass weld procedure may be
performed at
multiple stations.
[00341] After the fill and cap pass weld procedure, the weld inspection
procedure is
performed to perform the weld inspection of the weld joint. For example,
Ultrasonic, x-ray
radiography or Magnetic inspection may be used to inspect the weld area. Any
weld defects
detected during the weld inspection procedure are repaired during the weld
repair procedure.
The welded pipe is coated with the Injection Molded Polypropylene coating. The
Injection
Molded Polypropylene coating is applied to the (pre-heated to 180 C) exposed
end portions
of the welded pipes such that the Injection Molded Polypropylene coating is
adhered to an
exterior surface of the pipe interior. Cooling procedure is performed after
the coating
procedure. In one embodiment, the pipes may be cooled by pouring or spraying
water on the
outside surfaces of the insulation. In another embodiment, the pipes may be
cooled by an
internal cooling system. In one embodiment, the pipes may be spooled onto the
vessel after
the cooling procedure. In one embodiment, the pipes should be below a
temperature of
between 50 and 70 C during the spooling procedure so as to avoid any damage
during the
spooling process. In one embodiment, all the procedures of the spool base tie-
in weld
sequence may occur at the same location.
[00342] Referring to FIG. 7, the barge weld procedure begins with the pipe
preparation
procedure in which an appropriate bevel is machined into the ends of the pipe.
After the pipe
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preparation procedure, a root pass weld procedure is performed. In one
embodiment, the root
pass weld procedure may be performed by the internal weld system 5004. In
another
embodiment, the root pass weld procedure may be performed by the purge clamp
system
7001 with an external weld system 7500. In another embodiment, the root pass
weld
procedure may be performed by the internal clamps with the external weld
system 7500.
[00343] After the root pass weld procedure, the hot pass weld procedure is
performed. In
one embodiment, the pipes advance to the hot pass weld procedure after the
root pass weld
procedure is complete. In one embodiment, the hot pass weld procedure may be
performed by
the internal weld system 5004. In another embodiment, the hot pass weld
procedure may be
performed by the external weld system.
[00344] In one embodiment, both the hot and root pass weld procedures are
performed by
the internal weld system 5004. In another embodiment, only the root pass weld
procedure is
performed by the internal weld system 5004. The X-ray radiography weld
inspection
procedure is performed after the hot pass weld procedure. The X-ray
radiography weld
inspection procedure is optional.
[00345] The fill and cap pass weld procedure is performed after the hot pass
weld procedure
and X-ray radiography weld inspection procedure. In one embodiment, the fill
and cap pass
weld procedure may be performed by the external weld system. In one
embodiment, the fill
and cap pass weld procedure may be performed at multiple stations.
[00346] After the fill and cap pass weld procedure, the weld inspection
procedure is
performed to perform the weld inspection. For example, Ultrasonic, x-ray
radiography or
Magnetic inspection may be used to inspect the weld area. Any weld defects
detected during
the weld inspection procedure are repaired during the weld repair procedure.
The welded pipe
is coated with the Injection Molded Polypropylene coating. The Injection
Molded
Polypropylene coating is applied to the (pre-heated to 180 C) exposed end
portions of the
welded pipes such that the Injection Molded Polypropylene coating is adhered
to an exterior
surface of the pipe interior. The cooling procedure is performed after the
coating procedure.
In one embodiment, the pipes may be cooled by pouring or spraying water on the
outside
surfaces of the insulation. In one embodiment, the cooling procedure may be
performed at
multiple stations. In another embodiment, the pipes may be cooled by an
internal cooling
system. In one embodiment, the pipes may be pushed off the end of the vessel
in a S-shaped
configuration. In one embodiment, the pipes should be below a temperature of
between 50
and 70 C during the S-lay procedure so as to avoid any damage during the S-
lay procedure.
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[00347] In one embodiment, a field system 5000 for welding two pipes 1022a,
1022b is
provided. The term "field system" as used herein is a generic term intended to
refer to the
system(s) disclosed herein as a whole, and/or any of the subsystems by
themselves. Just for
example, the "field system" can refer to the combination of the internal
inspection system,
external welder, internal pipe cooler, and ultrasound non-destructive testing
system, together
with the remote uLog processing system (e.g., remote computer system 13704).
In another
example, the "field system" can refer to the internal weld system alone, the
internal
inspection system alone, the internal cooling system alone, the tie-in welder
alone, for
example. That is, the "field system" can refer to the internal weld system
5004 alone, the
internal inspection system 7001 alone, the internal cooling system 6500 alone,
the tie-in
welder 3001 alone, for example.
[00348] As shown in FIGS. 8, 9, 10-1, 10-2 and 10-3, in one embodiment, each
pipe
segment 1022a or 1022b has the longitudinal axis as shown by arrow A-A. As
will be clear
from the discussion below, the field system 5000 is configured to support
multiple pipe
segments 1022a, 1022b and adjust their positions and/or orientations until the
pipe segments
1022a, 1022b are both aligned such that their longitudinal axes A-A are
collinear and one end
of each of the pipe segments 1022a, 1022b abuts at interface edges. FIG. 9
illustrates an
enlarged detailed view of the field system 5000 of FIG. 8 in which the edges
form a pipe
interface 5002 (also known as a "fit up" joint). In one embodiment, the field
system 5000
includes an internal weld system 5004 that applies a weld to the interior of
the interface 5002
from inside the fitted up pipe segments 1022a, 1022b. To apply a weld to the
interior of joint
5002, the internal weld system 5004 is rolled into an end of one of the pipe
segments 1022b
as shown in FIG. 10-1. The second pipe segment 1022a is then placed and
manipulated until
both pipe segments 1022a, 1022b are satisfactorily aligned. In one embodiment,
the internal
weld system 5004 applies a weld (e.g., a gas metal arc weld "GMAW") from
inside the pipe
segments 1022a, 1022b to a face or edge joint of the pipe segment 1022a, 1022b
and into a v-
shaped opening formed by chamfered/beveled edges of the two pipe segments
1022a, 1022b
(other cross-sectional shapes other than a v-shaped opening may also be used).
[00349] FIG. 9A shows a partial cross-sectional view of the pipeline 1024
displaying an
ideal alignment of a weld torch 5502 of the internal weld system 5004 to the
internal bevel
surfaces 5228 and 5232 (along longitudinal axes A-A of the pipes 1022a,
1022b). In the
illustrated embodiment, the pipes 1022a, 1022b are perfectly aligned with each
other and do
not have any Hi-Lo (i.e., a height difference between the bevel edges of the
pipes 1022a,
1022b after the pipe alignment).
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[00350] In one embodiment, the field system 5000 may include external clamps
5302 that
are used to clamp pipes together from the outside (external to the pipes). In
one embodiment,
the external clamps 5302 have bars across the weld joint and welding may be
done manually.
In one embodiment, the external clamps 5302 may be hydraulically operated or
may be
mechanically operated (e.g., using a hand lever). For example, in one
embodiment, the
external clamps 5302 may be a tipton clamp as shown in FIGS. 7A and 7B.
[00351] In one embodiment, the internal weld system 5004 is connected to an
external
structure/system (i.e., external to the pipes 1022a, 1022b being welded) by an
umbilical 5034
(as shown in FIG. 10-1). In one embodiment, the external system is the remote
uLog
processing system. In one embodiment, the umbilical 5034 may be between 40 and
80 feet
long (e.g., for a pipe that is 40 or 80 feet long). In one embodiment, the
umbilical 5034 may
be referred to as a reach rod. In one embodiment, the reach rod/umbilical 5034
may be
fixedly connected to the internal weld system 5004. That is, the reach
rod/umbilical 5034 is a
permanent piece of the internal weld system 5004. In one embodiment, the
umbilical 5034
includes a structural tubular member that protects all of the cables, wiring
and hoses (e.g.,
that connect the external structure/system and the internal weld system 5004)
from damage.
[00352] In one embodiment, when the internal weld system 5004 is traveling
from one pipe
(weld) joint to the next pipe (weld) joint, the umbilical 5034 is disconnected
at a
disconnection point, DP (as shown in FIG. 10-2). This disconnection
facilitates the
new/incoming pipe segment 1022a to be placed in position with respect to the
first pipe
1022b. FIG. 10-2 shows that the cables, hoses and wires (e.g., that connect
the external
structure/system and the internal weld system 5004) at the end of the reach
rod/umbilical
5034 are disconnected and that the new/incoming pipe segment 1022a is being
placed in
position with respect to the first pipe 1022b.
[00353] As shown in FIG. 10-3, in one embodiment, after the incoming pipe
1002a is
placed in position with respect to the first pipe 1002b, the umbilical 5034
may hang/extend
out of the incoming pipe 1002a by a distance, HD. In one embodiment, the
distance, HD that
the umbilical 5034 may hang/extend out of the incoming pipe 1002a is in
between 1 and 5
feet.
[00354] The umbilical 5034 is generally used to convey fluids (compressed
air), send
electrical signals and/or send communication signals between the external
structure/system
and the internal weld system 5004. In one embodiment, the tie-in internal weld
system 3001
does not include the reach rod or the umbilical.
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[00355] For example, the umbilical 5034 may include weld power lines
configured to
deliver power to the weld torches. In one embodiment, the umbilical 5034
includes three
weld power lines to independently deliver power to the three associated weld
torches in the
internal weld system 5004. In one embodiment, the number of weld power lines
in the
umbilical 5034 may vary and depend on the number of weld torches in the
internal weld
system 5004.
[00356] In one embodiment, the umbilical 5034 may include communication lines
configured to communicate with the inspection detector 5056, the inspection
camera 5112,
and/or other electronic modules (e.g., to start or stop welding) of the
internal weld system
5004. In one embodiment, the communications to the internal weld system 5004,
including to
the inspection detector 5056, to the inspection camera 5112, and/or to other
electronic
modules of the internal weld system 5004, may be performed wirelessly. It
should be
appreciated that where a plurality of weld torches are provided, a plurality
of inspection
detectors/lasers 5056 may also be provided.
[00357] In one embodiment, the umbilical 5034 may include a fluid
communication line
configured to supply compressed air to the internal weld system 5004. In one
embodiment,
the umbilical 5034 may include another (separate) power line configured to
deliver power to
the batteries 5116 to recharge them. In one embodiment, the separate power
line to recharge
the batteries 5116 is optional. In one embodiment, the umbilical 5034 may
include a separate
power line configured to deliver power to one or more electronic modules
and/or the motors
of the internal weld system 5004. In another embodiment, this separate power
line is optional.
[00358] In one embodiment, the internal weld system 5004 is used for pipes
having an
internal diameter of 26 to 28 inches with 0 to 1 inch pipe wall thickness.
Therefore, the
internal weld system 5004 is configured to fit in holes between 24 and 28
inches. In one
embodiment, the internal weld system 5004 is used for pipes having an internal
diameter of
24 inches or less with pipe wall thickness of 0 to 1 inch. In one embodiment,
the internal
weld system 5004 is used for pipes having an external diameter of 24 inches or
less. In one
embodiment, the internal weld system 5004 is used for pipes having an external
diameter of
26 to 28 inches.
[00359] FIG. 10A shows the internal weld system 5004 being constructed, sized
and
positioned in pipes having an internal diameter of 26 inches with 1 inch pipe
wall thickness.
For example, in one embodiment, the external diameter of the frame structure
of the internal
weld system 5004 is 23.32 inches in relation to the internal diameter of 26
inches (with 1 inch
pipe wall thickness) of the pipes. For example, for 26 inch internal diameter
pipe (with 1 inch
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pipe wall thickness), the outer diameter of the frame structure (not including
its wheels) of
the internal weld system 5004 is 23.32 inches.
[00360] FIG. 10B shows the internal weld system 5004 being constructed, sized
and
positioned in pipes having an internal diameter of 24 inches with 1 inch pipe
wall thickness.
For example, in one embodiment, the external diameter of the frame structure
of the internal
weld system 5004 is 21.32 inches in relation to the internal diameter of 24
inches (with 1 inch
pipe wall thickness) of the pipes. For example, for 24 inch internal diameter
pipe, the outer
diameter of the frame structure (not including its wheels) of the internal
weld system 5004 is
21.32 inches.
[00361] In one embodiment, the diameter of the frame of the internal weld
system 5004
may be a function of the internal weld system's ability to fit through the
pipe bends. In one
embodiment, the standard minimum bend radius of the pipe is 30 times D, where
D is the
external or outer diameter of the pipe. That is, the radius of the centerline
of the pipe is 30
times the outer or external diameter of the pipe. For example, for a 26" outer
or external
diameter pipe, the minimum bend radius the internal weld system 5004 needs to
traverse is
780 inches (i.e., (26 inches) x 30). For example, for a 24" outer or external
diameter pipe, the
minimum bend radius the internal weld system 5004 needs to traverse is 720
inches (i.e., (24
inches) x 30). In one embodiment, the longer the frame of the internal weld
system 5004 is
constructed, the narrower it has to get.
[00362] In one embodiment, as shown in the FIGS. 10C and 10D, the field system
5000
may include a cradle 5330 for carrying and moving the first pipe 1022a and the
second pipe
1022b. In one embodiment, the cradle 5330 is configured to provide the second
pipe 1022a at
the second end 1038b of the first pipe 1022b after the frame assembly of the
internal weld
system 5004 is positioned at the second end of the first pipe 1022b. In one
embodiment, the
cradle 5330 may be referred to as a Line Up Module (LUM).
[00363] In one embodiment, there may be as many cradles as needed to hold the
pipe 1022a,
1022b. For example, if the pipe 1022a or 1022b is small and flexible, there
may be as many
as four cradles spaced along the length of the pipe 1022a or 1022b. If the
pipe 1022a or
1022b is large and stiff, there may be as few as two cradles along the length
of the pipe 1022a
or 1022b.
[00364] In one embodiment, two cradles may be used for carrying and moving the
pipe
such that each cradle is positioned at an end of the pipe. In one embodiment,
three cradles
may be used for carrying and moving the pipe such that two cradles are
positioned at the ends
of the pipe and one cradle is positioned at the center section of the pipe. In
one embodiment,
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the centrally positioned cradle is configured to simply provide support and is
not configured
to be articulated. In one embodiment, the cradles 5330 used for incoming pipe
1022a may all
be configured to be actuatable to carry, move, and provide the incoming pipe
1022a at the
second end of the first pipe 1022b (after the frame assembly of the internal
weld system 5004
is positioned at the second end of the first pipe 1022b) and re-align the
incoming pipe 1022a
in the event the pre-weld profile data determines adjustment is required.
[00365] In one embodiment, the cradle 5330 may include a set of actuated
rollers 5332
external to the pipes 1022a, 1022b. In one embodiment, the rollers 5332 of the
cradle 5330
may be referred to as the exterior rotatable members. In one embodiment, an
exterior surface
5346 and/or 5348 (as shown in FIG. 2G) of the first pipe 1022a and/or the
second pipe 1022b
is movably engaged by the exterior rotatable member(s) 5332 to facilitate
adjustment of the
relative positioning of the pipes 1022a, 1022b based on the instructions from
the one or more
process ors 5140.
[00366] In one embodiment, the cradle 5330 includes a fixed frame 5334 that is
configured
to be fixedly connected to a surface (e.g., ground), a first moveable frame
5336 that is
configured to be moveable to position the pipe horizontally, and a second
moveable frame
5338 that is configured to be moveable to position the pipe vertically.
[00367] In one embodiment, the cradle 5330 may be hydraulically operated. For
example,
hydraulic cylinders 5340 positioned on the sides of the cradle 5330 may be
configured to
move the second moveable frame 5338. In one embodiment, the hydraulic
cylinder(s) 5342
positioned under the cradle 5330 may be configured to move the first moveable
frame 5336.
In one embodiment, the motion of the cradles 5330 (positioned at both ends of
the pipes) may
be coordinated to adjust the linear movement of the pipe 1022a or 1022b in all
three
directions (up-down, left-right, forward-back) and adjust the angular movement
of the pipe
1022a or 1022b in in two directions (pitch, yaw)).
[00368] In one embodiment, the cradle 5330 is operatively associated with to
the one or
more processors 5140. In one embodiment, the cradle 5330 is connected
wirelessly or using a
wired connection to the one or more processors 5140 such that, in the event
the pre-weld
profile data determines adjustment is required, the hydraulic cylinders 5340
and 5342 are
adjusted to move and re-align the incoming pipe 1022a based on the pre-weld
profile data. In
one embodiment, the externally positioned rollers 5332 may be operatively
connected to and
controlled by the one or more processors 5140 via the first moveable frame
5336 and/or the
second moveable frame 5338.
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[00369] In one embodiment, the cradle 5300 may be electrically operated. For
example,
FIG. 73 shows electrically operated cradles 6010A and 6010B. In one
embodiment, the
rollers of the cradles 6010A and 6010B may be driven by motors to move the
pipe 1022a or
1022b linearly and/or angularly. In one embodiment, the cradles 6010A and
6010B may
include motors operatively connected to lead screw arrangements that enable
the movement
of the first moveable frame and/or the second moveable frame.
[00370] In general, when aligning the pipes for the welding procedure, there
may be two
pipe alignment errors, for example, an angular pipe alignment error and
positional pipe
alignment error. As shown in FIG. 10E, the angular alignment error causes a
gap 5344 on one
side of the pipe. As shown in FIG. 10F, the positional alignment error causes
opposite Hi-Lo,
i.e. high on one side (e.g., 1022b), low on the other side (e.g., 1022a).
[00371] In one embodiment, the cradles 5330 or the cradles 6010A and 6010B may
be used
in the offshore pipeline alignment and welding procedures. In the offshore
pipeline
applications, both angular and positional pipe alignment errors may be
corrected by sending
the control signals from the one or more processors 5140 to the cradles 5330
or the cradles
6010A and 6010B (to control the associated rollers 5332). Thus, the one or
more processors
5140 are configured to adjust the relative positioning between the pipes (to
correct their
alignment errors) by controlling the cradles 5330 or the cradles 6010A and
6010B. In one
embodiment, the one or more processors 5140 are configured to operate the
cradle 5330 to
enable relative movement between the first pipe 1022a and the second pipe
1002b based on
the pre-weld profile data to alter an interface region 5136 between the pipes
1022a, 1022b
prior to the welding operation based on the instructions from the one or more
processors 5140.
[00372] In one embodiment, the pipes 1022a, 1002b may be aligned by a crane
and the
clamp (internal or external). In one embodiment, the clamp may be constructed
and arranged
to align the two pipes 1022a, 1002b both horizontally and vertically. In one
embodiment, the
crane is configured to control axial position and the two angles (pitch and
yaw).
[00373] In one embodiment, referring to FIG. 11, the internal weld system 5004
includes a
forward-most section 5006, a center section 5008 and a drive section 5010.
[00374] In one embodiment, frame members of the forward-most section 5006, the
center
section 5008 and the drive section 5010 may be together may be referred to as
a frame
assembly or as the frame of the internal weld system 5004. In one embodiment,
the frame or
frame assembly of the internal weld system 5004 may be configured to support
all of the
components of each of the forward-most section 5006, the center section 5008
and the drive
section 5010. In one embodiment, the frame or frame assembly of the internal
weld system
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5004 may include forward-most section frame 5026 (as shown in FIG. 12), center
section
frame 5068 (as shown in FIG. 23), and drive section frame 5278 (as shown in
FIG. 32A). In
one embodiment, the frame or frame assembly of the internal weld system 5004
is configured
to be placed within the pipes 1022a, 1022b.
[00375] In one embodiment, the forward-most section 5006 is the section where
external
cables, wiring and hoses from the external system/structure (external to the
pipes to be
welded) connect. In one embodiment, the forward-most section 5006 is
configured to house
all of the weld support components as described in detail below. In one
embodiment, the
center section 5008 is configured to align the pipe segments 1022a, 1022b and
perform the
welding procedures. In one embodiment, the drive section 5010 is configured to
move the
internal weld system 5004 from one pipe joint to the next pipe joint. In one
embodiment, the
drive section 5010 is also configured to house batteries, compressed air and
shield gas that
the rest of the internal weld system 5004 needs to operate.
[00376] In one embodiment, some components of the internal weld system 5004
are
positioned such that half of the component is positioned in the forward-most
section 5006 and
the remaining half of the component is positioned in the center section 5008.
In one
embodiment, some components of the internal weld system 5004 are positioned in
the one of
the three sections of the internal weld system 5004 but are connected to
another of the three
sections of the internal weld system 5004. For example, a component of the
internal weld
system 5004 is positioned in the forward-most section 5006 of the internal
weld system 5004
and is connected to only the center section 5008 of the internal weld system
5004.
[00377] FIG. 12 shows a detailed view of the forward-most section 5006 of the
internal
weld system 5004. In one embodiment, the forward-most section 5006 of the
internal weld
system 5004 includes a tow hitch 5012, a forward-most electronics module 5014,
a front slip
ring 5016, a front clamp control valve 5018, a wire feed assembly 5020, a
front position
sensor 5022, adjustable ramps 5024, a forward-most section frame 5026, guide
wheels 5028,
a front rotation motor 5030, and a front rotary union 5032. In one embodiment,
the forward-
most electronics module 5014 may include the one or more processors 5014. In
one
embodiment, the front clamp control valve 5018, the front position sensor
5022, and the front
rotation motor 5030 may be operatively connected to the one or more processors
5140.
[00378] FIGS. 13-22 show views of various components of the forward-most
section 5006
of the internal weld system 5004. For example, FIG. 13 shows the tow hitch
5012, FIG. 14
shows the front rotary union 5032, FIG. 15 shows the front slip ring 5016,
FIG. 16 shows the
forward-most section frame 5026, FIG. 17 shows the adjustable ramps 5024, FIG.
18 shows
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the guide wheels 5028, FIG. 19 shows the front rotation motor 5030, FIG. 20
shows the front
clamp control valve 5018, FIG. 21 shows the front position sensor 5022, and
FIG. 22 shows
the wire feed assembly 5020, respectively.
[00379] FIG. 11A shows a view of the umbilical 5034 in which the internal weld
system
5004 is configured to attached at a first end 5035 of the umbilical 5034 and
an operator
control system 5039 is configured to be attached to a second end 5037 of the
umbilical 5034.
In one embodiment, the first end 5035 of the umbilical 5034 is connected to
the tow hitch
5012 of the forward-most section 5006 of the internal weld system 5004. In one
embodiment,
the communications (of the internal weld system 5004) with the Ulog system are
configured
to happen through one or more processors or modules in the operator control
system 5039. In
one embodiment, the operator control system 5039 is positioned external to the
pipes 1022a,
1022b being welded.
[00380] In one embodiment, the forward-most section frame 5026 is constructed
and
arranged to house/support all of the components of the forward-most section
5006 of the
internal weld system 5004. In one embodiment, the forward-most section frame
5026 is
constructed and arranged to provide mounting points for all of the components
at the front of
the internal weld system 5004 and protect these components from damage. In one
embodiment, the forward-most section frame 5026 is constructed and arranged to
guide new
pipe segments into alignment with the old/existing pipe segments. In one
embodiment, the
forward-most section frame 5026 may be made from steel or any other material
as would be
appreciated by one skilled in the art.
[00381] In one embodiment, the forward-most frame 5026 is constructed and
arranged to
have a nose cone shaped configuration to enable the internal weld system 5004
to easily
move into the new pipe segment when joining/welding the new pipe segment with
the
old/existing pipe segment. In one embodiment, the nose cone shaped
configuration of the
forward-most frame 5026 may function as an alignment structure that is
configured to
facilitate alignment of the second pipe 1022b with the first pipe 1022a. In
one embodiment,
the nose cone shaped alignment structure is configured to project outwardly
from the second
end of the first pipe 1022a to facilitate alignment of the second pipe 1022b
with the first pipe
1022a.
[00382] In one embodiment, referring to FIG. 12, the forward-most section
frame 5026
includes a sensor 5352 configured to sense an end of the pipe when the frame
of the internal
weld system 5004 returns to pipe opening after welding a preceding pipe. In
one embodiment,
the sensor 5352 may be configured to be moveable with the frame of the
internal weld system
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5004. In one embodiment, the sensor 5352 is operatively connected to or
associated with the
one or more processors 5140.
[00383] In one embodiment, the sensor 5352 may be a rotary switch. For
example, the
rotary switch may have a downwardly projecting prod or wire biased into the
interior pipe
surface and configured to slidingly engage the interior pipe surface until it
reaches the pipe
and extends downwardly after reaching the pipe end to actuate the rotary
switch,
thus detecting the end of the pipe. For example, when the forward-most section
frame 5026
reaches the end of the pipe, where a portion thereof will project outwardly of
the pipe
for receiving the end of the next pipe to be welded, the wire is configured to
extend
outwardly from its normal position to detect the end of the pipe. In another
embodiment, the
sensor 5352 may be a linear encoder that is configured to be operatively
connected to the
wheels/rollers of the internal weld system 5004 to determine the distance
traveled by the
internal weld system 5004 and use that information to sense/detect the end of
the known pipe
length.
[00384] In one embodiment, the sensor 5352 is configured to detect the
interface region
5136 between the pipes 1022a, 1022b. In one embodiment, the one or more
processors 5140
are configured to operate drive motors 5124 to move the frame of the internal
weld system
5004 through at least one of the pipes 1022a, 1022b until the sensor 5352
detects the interface
region 5136. In one embodiment, the sensor 5352 is configured to detect when
the frame of
the internal weld system 5004 is positioned at the interface region between
the pipes 1002a,
1022b. In one embodiment, the sensor 5352 may be the inspection sensor 5056.
In one
embodiment, the sensor 5352 may be a laser. In one embodiment, the sensor 5352
may be the
inspection camera 5112. In one embodiment, the inspection detector 5056 and/or
the
inspection camera 5112 are configured to also perform the sensing function of
the sensor
5352.
[00385] In one embodiment, referring to FIG. 12, an end portion 5208 of the
forward-most
section frame 5026 is configured to be connected to a flange portion 5210 (as
shown in FIG.
23) of a front clamp 5142 of the center section 5008. In one embodiment, the
end portion
5208 of the forward-most section frame 5026 is configured to be connected to
the flange
portion 5210 of the front clamp 5142 of the center section 5008 using
fastening members, for
example, bolts 5212 (as shown in FIG. 23).
[00386] The front rotary union 5032 in the forward-most section 5006 is shown
in FIGS. 12
and 14. A rotary union is generally a union or a coupling that is constructed
and arranged to
allow for rotation of two combined/united members. The rotary union is
constructed and
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arranged to provide a seal between a stationary supply passage (pipe or
tubing) and a rotating
member (drum, cylinder or spindle) to permit the flow of a fluid into and/or
out of the
rotating member. Fluids generally used with the rotary unions include
compressed air and
purge gas. The rotary union generally includes a housing, a shaft, a seal and
a bearing. The
bearings and seal are assembled around the shaft. The bearings are used to
allow a member of
the rotary joint, either the shaft or the housing, to rotate. The seal is
constructed and arranged
to prevent the fluid medium (e.g., compressed air or purge gas) from leaking
outside the
rotary union while in operation. A rotary union locks onto an input valve
while rotating to
meet an outlet valve. During this time the fluid flows into the rotary union
from its source and
is held within the rotary union during its movement. This fluid leaves the
rotary union when
the valve openings meet during rotation and more fluid flows into the rotary
union again for
the next rotation.
[00387] In one embodiment, the front rotary union 5032 is configured to allow
for the flow
of compressed air therethrough. In one embodiment, the front rotary union 5032
(e.g.,
described in connection with FIG. 25, for example) is constructed and arranged
to receive the
compressed air from a rear rotary union 5072 (via, e.g., a rear slip ring
5080, a rotatable hub
5078 and the front slip ring 5016). The rear rotary union has essentially the
same components
and operates in essentially the same way as the front rotary union 5032 and
hence not
illustrated in the same detail as front rotary union 5032.
[00388] In one embodiment, the front rotary union 5032 is constructed and
arranged to send
a portion of the received compressed air to the front clamp control valve 5018
(to actuate and
operate the front clamp 5142) via the valve 5204. In one embodiment, the front
rotary union
5032 is constructed and arranged to send the remaining portion of the received
compressed
air to a compressor or an external air supply tank 5029 (as shown in FIG. 70)
to recharge the
system (e.g., fill the tank with compressed air) via the valve 5204. In one
embodiment, the
remaining portion of the received compressed air sent to the compressor or
external air
supply tank 5029 (as shown in FIG. 70) passes through the front rotary union
5032.
[00389] In one embodiment, referring to FIG. 70, two valves 5115 and 5117 are
configured
to be closed until the start of the refill procedure. During the refill
procedure, the compressed
air from the external air supply tank 5029 travels through the valve 5115,
5117, and 5204 to
the front rotary union 5032, from the front rotary union 5032 to the rear
rotary union 5072,
and then through the valves 5198, 5196, 5194 and 5113 to the compressed air
tank 5128 to
refill the compressed air tank 5128 with the compressed air. In one
embodiment, the entire
fluid communication path (or the supply fluid communication line) between the
external air
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supply tank 5029 and the compressed air tank 5128 is maintained at tank
pressure during the
refill procedure.
[00390] In one embodiment, the front rotary union 5032 in the forward-most
section 5006 is
also configured to allow the compressed air from the umbilical 5034 to be
connected to the
wire feed assembly 5020 which is rotatably mounted on a rotatable hub 5078 of
the center
section 5008.
[00391] The front slip ring 5016 in the forward-most section 5006 is shown in
FIGS. 12 and
15. A slip ring is an electromechanical device (electrical connector) that is
constructed and
arranged to allow the transmission of power and communication signals from a
stationary
structure to a rotating structure. A slip ring can be used in any
electromechanical system that
requires unrestrained, continuous rotation while transmitting power and/or
data signals. The
slip ring includes a stationary structure (brush) which rubs on the outside
diameter of a
rotating structure. As the rotating structure turns, the electric current or
signal is conducted
through the stationary structure to the rotating structure making the
connection. The
stationary structure may be a graphite or metal contact (brush) and the
rotating structure may
be a metal ring. Additional ring/brush assemblies are stacked along the
rotating axis if more
than one electrical circuit is needed. Either the brushes or the rings are
stationary and the
other component rotates.
[00392] In one embodiment, the front slip ring 5016 is configured to allow the
transmission
of communication signals from the forward-most electronics module 5014 to a
wire feed
electronics module 5046 of the wire feed assembly 5020. In one embodiment, the
front slip
ring 5016 is also configured to allow the transmission of (welding) power and
the
transmission of communication signals from the umbilical 5034 to the internal
weld system
5004.
[00393] In one embodiment, as shown in FIGS. 12 and 17, the adjustable ramps
5024 are
constructed and arranged to improve the alignment of the pipe segments 1022a,
1022b. In one
embodiment, the adjustable ramps 5024 are constructed and arranged to be
adjustable to
accommodate different pipe sizes. In one embodiment, the adjustable ramps 5024
are
constructed and arranged to also protect the center section 5008 from being
hit by the
incoming pipe segment 1022b. In one embodiment, the adjustable ramps 5024 of
the internal
weld system 5004 are constructed and arranged to be adjustable to extend a
little more than
the retracted clamp shoes (i.e., the clamp shoes 5157 in their retracted
positions) but extend
less than the extended clamp shoes (i.e., the clamp shoes 5157 in their
extended positions).
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[00394] In one embodiment, as shown in FIGS. 12 and 18, the guide wheels 5028
are
constructed and arranged to prevent the incoming pipe segment 1022b from
scraping the
sides of the forward-most section 5006. In one embodiment, the guide wheels
5028 are
constructed and arranged to be adjustable to accommodate different pipe sizes.
In one
embodiment, the guide wheels 5028 are passive members.
[00395] In one embodiment, as shown in FIGS. 12, the forward-most electronics
module
5014 includes communication connections to the umbilical 1034 and to the front
slip ring
5016. For example, in one embodiment, the forward-most electronics module 5014
is
configured to communicate power and communication signals to and from the
umbilical 5034
and is configured to communicate power and communication signals to and from
the front
slip ring 5016.
[00396] In one embodiment, the forward-most electronics module 5014 is also
configured
to control the operation of the front rotation motor 5030 and the front clamp
control valve
5018. In one embodiment, the forward-most electronics module 5014 is further
configured to
receive signals from the front position sensor 5022.
[00397] The front rotation motor 5030 in the forward-most section 5006 is
shown in FIGS.
12 and 19. In one embodiment, the front rotation motor 5030 is electronically
synchronized
with a rear rotation motor 5074 positioned in the center section 5008
(described below). In
one embodiment, together the two rotation motors 5030 and 5074 are configured
to rotate the
rotatable hub 5078 of the center section 5008 while maintaining the front and
rear clamps
5142 and 5144 stationary.
[00398] In one embodiment, the front rotation motor 5030 may include an offset
gear drive
(due to packaging constraints). For example, in one embodiment, the front
rotation motor
5030 has an electric motor having a rotor, a rotary shaft rotated by the
rotor, and an external
gear 5021a supported by the rotary motor shaft and having external teeth
thereon. The
external gear 5021a may engage an offset gear 502 lb, also having external
teeth. An opposite
end of the offset gear 502 lb also has external teeth 5021c. The external
teeth 5021c of the
external/driver gear are constructed and arranged to engage with internal
teeth 5023 (as
shown in FIG. 19) formed on an inner circumferential surface on a driven
(annulus) gear
member 5021 of the wire feed assembly 5020 to transmit torque from the front
rotation motor
5030 to the wire feed assembly 5020. In one embodiment, the external teeth
5021c of the
external/driver gear are constructed and arranged to engage with the internal
teeth 5023
formed on the driven (annulus) gear member 5021 of the wire feed assembly 5020
using a
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gear train arrangement (see FIG. 19) to transmit torque from the front
rotation motor 5030 to
the wire feed assembly 5020.
[00399] In one embodiment, as shown in FIGS. 12 and 20, the front clamp
control valve
5018 is configured to receive the compressed air from the stationary side of
the front rotary
union 5032.
[00400] In one embodiment, the front clamp control valve 5018 is operatively
connected to
receive control signals from the forward electronics module 5014. In one
embodiment, the
front clamp control valve 5018 is configured to supply the compressed air to
actuate and
operate the front clamp 5142, when it receives signals from the forward-most
electronics
module 5014.
[00401] In one embodiment, as shown in FIGS. 12 and 21, the front position
sensor 5022
may be a proximity sensor and specially profiled encoder wheel. In one
embodiment, the
encoder wheel is constructed and arranged to be rotatably mounted on the wire
feed assembly
5020 so as to be rotated with the rotatable hub 5078.
[00402] In one embodiment, the front position sensor 5022 is operatively
connected to send
control signals to the forward electronics module 5014. In one embodiment, the
proximity
sensor of the front position sensor 5022 may be configured to send control
signals to the
forward-most electronics module 5014 when the sensor is at a high point on the
encoder
wheel. In one embodiment, the forward-most electronics module 5014 is
configured to use
the signals received from the front position sensor 5022 to determine the
orientation of the
forward-most section 5006 relative to the rest of the internal weld system
5004 (e.g., rotatable
hub 5078).
[00403] In one embodiment, as shown in FIGS. 12, 22, 22A and 22B, the wire
feed
assembly 5020 includes a wire spool holder 5036, a wire straightener 5038, a
weld wire
bowden (guide) tube 5040, a shield gas control valve 5042, a wire feed system
5044, the wire
feed electronics module 5046, and a wire feed assembly frame 5048. In one
embodiment, an
exemplary weld wire spool 5272 is shown in FIG. 22A. In one embodiment, the
wire
straightener 5038, the shield gas control valve 5042, and the wire feed system
5044 may be
operatively connected to one or more processors 5140. In one embodiment, the
wire feed
electronics module 5046 may include one or more processors 5140.
[00404] In one embodiment, the wire feed assembly 5020 is constructed and
arranged to
house the wire spools 5272, the wire spool holders, the wire straighteners,
the wire feed
system, and the shield gas control valves for each of three illustrated weld
torches 5502 in the
center section 5008 of the internal weld system 5004. In the illustrated
embodiment, the wire
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feed assembly 5020 includes three wire spool holders 5036, three wire
straighteners 5038,
three weld wire bowden (guide) tubes 5040, three shield gas control valves
5042, and three
wire feed systems 5044 associated with three illustrated weld torches 5502 in
the center
section 5008 of the internal weld system 5004. In one embodiment, the number
of the wire
spool holders, the wire straighteners, the weld wire bowden (guide) tubes, the
shield gas
control valves, the weld wire/electrode spools and the wire feed systems in
the internal weld
system 5004 may vary and depend on the number of the weld torches.
[00405] In one embodiment, the weld wire spool 5272 has a size of 7 (7/8)
inches and a
weight of 10 pounds. In one embodiment, the size of the electrode or weld wire
is 0.03 inches.
In one embodiment, the electrode or weld wire is made of a carbon steel
material. In one
embodiment, the electrode or weld wire is a ER70S-6 carbon steel MIG weld wire
manufactured, for example, by Chicago Electric Welding Systems. In one
embodiment, the
electrode or weld wire is designed for use with various shield gas mixtures
such as 100%
Carbon dioxide (CO2), a mixture of 75 % Argon and 25% CO2' or a mixture of 98
% Argon
and 2% 02.
[00406] In one embodiment, the wire feed assembly 5020 is constructed and
arranged to be
connected to the rotatable hub 5078 of the center section 5008, so that
rotation of the wire
feed module 5020 via the front rotation motor is directly translated to the
rotatable hub 5078.
In one embodiment, the wire feed assembly 5020 is constructed and arranged to
be fastened
(e.g., using fastening members) to the rotatable hub 5078 of the center
section 5008. In one
embodiment, the wire feed assembly 5020 is also constructed and arranged to
house
electronics for operating all of the motors in the wire feed assembly 5020 and
the rotatable
hub 5078.
[00407] In one embodiment, the wire feed assembly frame 5048 is constructed
and arranged
to be hollow so as to allow power, communication signals, shield gas, weld
wire/electrode,
motor control signals, and compressed air to pass into, out of, and through
it.
[00408] In one embodiment, as shown in FIG. 22, the wire spool holder 5036 is
constructed
and arranged to receive and hold weld wire/electrode spools (not shown) for
use by the
internal weld system 5004. In one embodiment, the wire spool holder 5036 may
include a
retainer member 5220 configured to retain the weld wire/electrode spool
therein.
[00409] In one embodiment, the retainer member 5220 may be removable
positioned on a
shaft 5226 of the wire spool holder 5036 using a lock member 5222 attached to
the retainer
member 5220. The lock member 5222 may include a smaller diameter region and a
larger
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diameter region. In one embodiment, a lock member receiving opening may be
formed on the
shaft 5226 as having a cross-sectional shape of a generally enclosed circle,
with a side
opening 5224 extending outwardly from the shaft 5226. With such a
configuration, the lock
member 5222 may slidably be positioned such that either the larger diameter
region or the
smaller diameter region is within the generally enclosed circular cross-
sectional shape of the
lock member receiving opening. When the larger diameter region is positioned
in the lock
member receiving opening, the shaft 5226 surrounds the larger diameter region,
which is
unable to pass through the side opening 5224, locking the retainer member 5220
to the shaft
5226 due to the engagement between the lock member 5222 and the lock member
receiving
opening. Alternatively, where the lock member 5222 is positioned such that the
smaller
diameter region is generally surrounded by the lock member receiving opening,
the retainer
member 5220 may freely be removed from the shaft 5226, as the smaller diameter
region
may pass through the side opening 5224. In another embodiment, the retainer
member 5220
may be removable attached to the shaft 5226 of the wire spool holder 5036
using a retaining
screw.
[00410] The weld wire or electrode that comes off of the weld wire/electrode
spool may
have a permanent bend to it. In one embodiment, the wire straightener 5038 is
configured to
remove the permanent bend and make the weld wire straight (e.g., by bending
the weld wire
in the other direction). The straight configuration of the weld wire helps the
weld wire to pass
through the weld wire bowden (guide) tube 5040 more easily. Also, providing
straight weld
wire to the weld torch 5502 results in more consistent welds. In one
embodiment, the wire
straightener 5038 is optional.
[00411] In one embodiment, the weld wire bowden (guide) tube 5040 is
constructed and
arranged to guide the weld wire/electrode from the wire feed system 5044 to
the weld torch
5502. In one embodiment, the weld wire bowden (guide) tube 5040 attached at
both its ends.
In one embodiment, the weld wire is sheathed by the weld wire bowden (guide)
tube 5040.
[00412] In one embodiment, the wire feed system 5044 is constructed and
arranged to pull
the weld wire through the wire straightener 5038 from the weld wire spool 5272
and push the
weld wire through the weld wire bowden (guide) tube 5040 to the weld torch
5502.
[00413] In one embodiment, the wire feed system 5044 is configured to be
automatically
controlled to deliver the appropriate amount of wire to the weld torch 5502.
In one
embodiment, the wire feed system 5044 may include motor and two serrated
wheels that are
configured pull weld wire through the wire straightener 5038 from the weld
wire spool 5272
and push the weld wire through the weld wire bowden (guide) tube 5040 to the
weld torch
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5502. In one embodiment, the motor(s) of the wire feed system 5004 may include
an encoder
that is configured to measure the revolutions of the motor. In one embodiment,
the motor(s)
of the wire feed system 5004 are operatively connected to the one or more
processors 5140.
This information may be used by the one or more processors 5140 to determine
how much
wire is fed to the weld torch 5502 and to regulate the amount of the weld wire
is being fed to
the weld torch 5502. In one embodiment, as the rotatable hub 5078 is rotated,
the weld
wire/electrode is fed to the torch 5502 by the wire feed assembly 5020.
[00414] In one embodiment, the shield gas control valve 5042 is configured to
control the
flow of the shield gas to the weld torch through a shield gas line. In one
embodiment, each
weld torch 5502 has a corresponding shield gas control valve 5042 connected to
it.
[00415] In one embodiment, the shield gas is stored in the drive section 5010
and is brought
to the wire feed assembly 5020 by a hose/shield gas line for distribution to
the one or more
weld torches 5502. In one embodiment, the shield gas control valve 5042 is
configured to
receive the shield gas from the rear rotary union 5072 (e.g., via the rear
slip ring 5080 and the
rotatable hub 5078).
[00416] In one embodiment, the shield gas control valve 5042 is operatively
connected to
receive control signals from the wire feed electronics module 5046. In one
embodiment, the
shield gas control valve 5042 is configured to supply the shield gas to the
corresponding weld
torch, when it receives signals from the wire feed electronics module 5046.
[00417] In one embodiment, the wire feed electronics module 5046 is configured
to send
and receive power and communication signals upstream through the front slip
ring 5016 to
the forward-most electronics module 5014. In one embodiment, the wire feed
electronics
module 5046 is configured to send and receive power and communication signals
downstream through the rear slip ring 5080 to a center section electronics
module 5064.
[00418] In one embodiment, the wire feed electronics module 5046 is configured
to control
all of the motors and valves attached to the rotatable hub 5078 of the center
section 5008. For
example, the wire feed electronics module 5046 is configured to control the
wire feed system,
axial motion of the weld torch 5502, radial motion of the weld torch 5502,
tilt motion of the
weld torch 5502, and/or flow and delivery of the shield gas. That is, the wire
feed electronics
module 5046 is operatively connected to the shield gas control valve(s) 5042
to control the
flow and delivery of the shield gas to the weld torch (es) 5502.
[00419] In one embodiment, the wire feed electronics module 5046 is
operatively connected
to the axial weld torch motor 5550 to control the axial motion of the weld
torch 5502. In one
embodiment, the wire feed electronics module 5046 is operatively connected to
the radial
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weld torch motor 5512 to control the radial motion of the weld torch 5502. In
one
embodiment, the wire feed electronics module 5046 is operatively connected to
the tilt weld
torch motor 5588 to control the tilt motion of the weld torch 5502. In one
embodiment, the
axial weld torch motor 5550, the radial weld torch motor and the tilt weld
torch motor 5588
may either individually or together be referred to as "weld torch motor(s)".
[00420] In one embodiment, the wire feed electronics module 5046 is configured
to
communicate with and control an inspection detector 5056 and an inspection
camera 5112
both rotatably mounted on the rotatable hub 5078. In one embodiment, the
inspection
detector 5056 is carried by the frame assembly of the internal weld system
5004. In one
embodiment, the inspection camera 5112 is carried by the frame assembly of the
internal
weld system 5004.
[00421] In one embodiment, the inspection detector 5056 may include an
inspection laser, a
three dimensional inspection camera, an inspection ultrasound sensor system,
an inspection
electrical capacitive probe, and any other inspection detectors as would be
appreciated by one
skilled in the art.
[00422] FIGS. 23 and 24 show a front view and a cross-sectional view of the
center section
5008 of the internal weld system 5004. In one embodiment, as discussed above,
the forward-
most frame 5026 of the forward-most section 5006 is connected to the front
clamp 5142 of
the center section 5008, and the wire feed assembly 5020 is rotatably
connected to the
rotatable hub 5078.
[00423] In one embodiment, the center section 5008 of the internal weld system
5004
includes the front clamp 5142 (or first pipe engagement structure 5052), the
inspection
detector 5056, a weld head assembly or torch module 5500, a rear clamp 5144
(and second
pipe engagement structure 5054), a rear clamp control valve 5062, the center
section
electronics module 5064, toe wheels 5066, a center section frame 5068,
adjustable ramps
5070, the rear rotary union 5072, the rear rotation motor 5074, a rear
position sensor 5076,
the rotation module 5078, and the rear slip ring 5080.
[00424] In one embodiment, the front clamp 5142 (or first pipe engagement
structure 5052),
the inspection detector 5056, the weld head assembly or torch assembly 5500,
the rear clamp
5144 (and second pipe engagement structure 5054), the rear clamp control valve
5062, the
rear rotation motor 5074, the rear position sensor 5076 are operatively
connected to the one
or more processors 5140. In one embodiment, the inspection camera 5112 is
operatively
connected to the one or more processors 5140. In one embodiment, the center
section
electronics module 5064 may include the one or more processors 5140.The term
"pipe
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engagement structure" as used herein can refer to a clamp for fixedly securing
to a pipe
surface, or an interior seal that is configured to create a gas seal against
the pipe interior
surface, or the combination of both the aforementioned clamp and seal. For
example, in one
embodiment, the first pipe engagement structure 5052 may be the first clamp
5142, the first
seal 5146 or a combination thereof In one embodiment, the second pipe
engagement
structure 5054 may be the second clamp 5144, the second seal 5148 or a
combination thereof
In one embodiment, the first and second pipe engagement structures 5052 and
5054 are
carried by the frame assembly of the internal weld system 5004.
[00425] FIGS. 25-31 show views of various components of the center section
5008 of the
internal weld system 5004. For example, FIG. 25 shows the rear rotary union
5072, FIG. 26
shows the rear slip ring 5080, FIG. 27 shows the center section frame 5068 and
the adjustable
ramps 5070, FIG. 28 shows the toe wheels 5066, FIG. 29 shows the rear clamp
control valve
5062, FIG. 30 shows the front clamp 5142, and FIG. 31 shows the rotation
module 5078,
respectively.
[00426] The rear rotary union 5072 in the center section 5008 is shown in
FIGS. 23, 24 and
25. In one embodiment, the structure and operation of the rear rotary union
5072 is similar to
the front rotary union 5032, and hence the structure and operation of the rear
rotary union
5072 will not be described in detail here, except for the differences noted
below.
[00427] In one embodiment, the rear rotary union 5072 is configured to allow
for the flow
of compressed air and the flow of shield gas (or purge gas) therethrough. In
one embodiment,
the rear rotary union 5072 in the center section 5008 is configured to allow
the compressed
air from a compressed air tank 5128 (as shown in FIGS. 32A and B) of the drive
section 5010
to be connected through the rotatable hub 5078 of the center section 5008 to
the front rotary
union 5032. In one embodiment, the rear rotary union 5072 in the center
section 5008 is also
configured to connect shield gas tanks 5114 (as shown in FIGS. 32A and 32B) in
the drive
section 5010 to the shield gas control valves 5042 in the wire feed assembly
5020 of the
forward-most section 5006.
[00428] In one embodiment, the rear rotary union 5072 is constructed and
arranged to send
a portion of the received compressed air to the rear clamp control valve 5062
(to operate the
rear clamp 5144). In one embodiment, the rear rotary union 5072 is constructed
and arranged
to send the remaining portion of the received compressed air to the front
rotary union 5032
(e.g., via the rear slip ring 5080, the rotatable hub 5078 and the front slip
ring 5016). In one
embodiment, the remaining portion of the received compressed air sent to the
front rotary
union 5032 passes through the rear rotary union 5072.
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[00429] In one embodiment, the front and rear rotary unions 5032 and 5072 of
the present
patent application may be of the type which is available commercially under
the name Series
012 2 Pass Threaded Shaft Unions, manufactured by the Rotary Systems, Inc. In
another
embodiment, the front and rear rotary unions of the present patent application
may be any
rotary union that would be appreciated by one skilled in the art.
[00430] In one embodiment, the structure and operation of the rear slip ring
5080 is similar
to the front slip ring 5016, and hence the structure and operation of the rear
slip ring 5080
will not be described in detail here, except for the differences noted below.
[00431] In one embodiment, as shown in FIGS. 23, 24 and 26, the rear slip ring
5080 in the
center section 5008 is configured to allow the transmission of communication
signals
between the wire feed electronics module 5046 and the center section
electronics module
5064.
[00432] In one embodiment, the front and rear slip rings 5016 and 5080 of the
present
patent application may be of the type which is available commercially under
the name
AC6275, manufactured by the Moog, Inc. In one embodiment, the front and rear
slip rings
5016 and 5080 of the present patent application may be rated 50 amps. In
another
embodiment, the front and rear slip rings of the present patent application
may be any rotary
union that would be appreciated by one skilled in the art.
[00433] In one embodiment, as shown in FIGS. 23 and 24, the center section
electronics
module 5064 in the center section 5008 includes communication cables to the
wire feed
assembly 5020 through the rear slip ring 5080 and communication cables to the
drive section
5010. In one embodiment, the center section electronics module 5064 in the
center section
5008 is configured to control the rear rotation motor 5074 and receive signals
from the rear
position sensor 5076. In one embodiment, the center section electronics module
5064 in the
center section 5008 is also configured to control the rear clamp control valve
5062.
[00434] In one embodiment, as shown in FIGS. 23, 24 and 27, the center section
frame
5068 is constructed and arranged to house/support all of the components of the
center section
5008 of the internal weld system 5004. In one embodiment, the center section
frame 5068 is
constructed and arranged to provide mounting points for all of the components
located in the
center section 5008 and protects these components from damage. In one
embodiment, the
center section frame 5068 is also constructed and arranged to connect to the
drive section
5010 through a U-joint that allows the internal weld system 5004 to bend in
curved pipes. In
one embodiment, the center section frame 5068 may be made from steel or any
other material
as would be appreciated by one skilled in the art.
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[00435] In one embodiment, an end portion 5214 of the center section frame
5068 is
configured to be connected to a flange portion 5216 of the rear clamp 5144. In
one
embodiment, the end portion 5214 of the center section frame 5068 is
configured to be
connected to the flange portion 5216 of the rear clamp 5144 using fastening
members, for
example, bolts 5218.
[00436] In one embodiment, as shown in FIGS. 23, 24 and 27, the adjustable
ramps 5070
are constructed and arranged to help center the internal weld system 5004 when
the internal
weld system 5004 is being placed into a pipe. In one embodiment, the
adjustable ramps 5070
are also constructed and arranged to protect the center section 5008 from
being hit by the end
of the pipe segment. In one embodiment, the adjustable ramps 5070 are
constructed and
arranged to be adjustable to accommodate different pipe sizes.
[00437] In one embodiment, as shown in FIGS. 23, 24 and 28, the toe wheels
5066 are
constructed and arranged to support the weight of the center section 5008. In
one
embodiment, the toe wheels 5066 are constructed and arranged to be sprung to
protect the
internal weld system 5004 from jarring shocks when the internal weld system
5004 crosses
over a weld bead. In one embodiment, the toe wheels 5066 are constructed and
arranged to
have an adjustable toe angle to help the internal weld system 5004 run
straight in the pipe. In
one embodiment, the toe wheels 5066 are constructed and arranged to be
adjustable in height
for different pipe sizes. In one embodiment, the toe wheels 5066 are passive
members.
[00438] In one embodiment, as shown in FIGS. 23, 24 and 29, the rear clamp
control valve
5062 is constructed and arranged to receive the compressed air from the
stationary side of the
rear rotary union 5072.
[00439] In one embodiment, the rear clamp control valve 5062 is operatively
connected to
receive control signals from the center section electronics module 5064. In
one embodiment,
the rear clamp control valve 5062 is configured to supply the compressed air
to actuate and
operate the rear clamp 5144, when it receives signals from the center section
electronics
module 5064.
[00440] In one embodiment, as shown in FIG. 24, the rear position sensor 5076
may be a
proximity sensor and specially profiled encoder wheel. In one embodiment, the
encoder
wheel is constructed and arranged to be rotatably mounted on the rotatable hub
5078.
[00441] In one embodiment, the rear position sensor 5076 is operatively
connected to send
control signals to the center section electronics module 5064. For example, in
one
embodiment, the proximity sensor of the rear position sensor 5076 may be
configured to send
control signals to the center section electronics module 5064 when the sensor
is at a high
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point on the encoder wheel. In one embodiment, the center section electronics
module 5064 is
configured to use the signals received from the rear position sensor 5076 to
determine the
orientation of the center section 5008 relative to the rest of the internal
weld system 5004
(e.g., rotatable hub 5078).
[00442] The rear rotation motor 5074 in the center section 5008 is shown in
FIG. 24. In one
embodiment, the rear rotation motor 5074 is electronically synchronized with
the front
rotation motor 5030 such that the rotation motors 5030 and 5074 together are
configured to
rotate the rotatable hub 5078 of the center section 5008 while maintaining the
front and rear
clamps 5142, 5144 stationary. In one embodiment, the rotation motors 5030 and
5074 are
configured to rotate the weld torch 5502 circumferentially (360 rotation)
along an interface
region 5136. In one embodiment, the rotation motors 5030 and 5074, configured
to direct the
inspection beam of radiation, are also configured to drive the weld torch 5502
at least 360
relative to the pipe axis A-A so as to complete a rotationally continuous,
root pass weld.
[00443] In one embodiment, the front rotation motor 5030 and the rear rotation
motor 5074
may be referred to as the orientation motors. In one embodiment, the front
rotation motor
5030 and the rear rotation motor 5074 are operatively associated with the one
or more
process ors 5140.
[00444] In one embodiment, the rear rotation motor 5074 has an electric motor
having a
rotor, a rotary shaft rotated by the rotor, and a driver gear supported by the
rotary shaft and
having teeth thereon. The teeth of the driver gear are constructed and
arranged to engage with
teeth formed on a driven gear member 5079 of the rotatable hub 5078 to
transmit torque from
the rear rotation motor 5074 to the rotatable hub 5078.
[00445] In one embodiment, the rotatable hub 5078 is constructed and arranged
to rotate
during welding, pre-weld scan and post-weld scan procedures. In one
embodiment, the
rotatable hub 5078 is positioned between the first and second clamps 5142 and
5144. Since
the first and second clamps 5142 and 5144 are not physically linked to each
other, the front
rotation motor 5030 and the rear rotation motor 5074 at each end of the
rotatable hub 5078
are synchronized to keep the two pipes 1022a, 1022b from moving relative to
each other. In
one embodiment, the two pipe engagement structures 5142, 5144 may be rotated
relative to
each other by turning the front rotation motor 5030 and the rear rotation
motor 5074, for
example, at different speeds and/or different directions. In one embodiment,
only when the
front rotation motor 5030 and the rear rotation motor 5074 are turning at the
same speed and
in the same direction, that the weld torch 5502 and the inspection detector
5056 rotate along
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the interface region 5136 between the pipes 1022a, 1022b (e.g., without moving
the pipe
engagement structures 5142, 5144).
[00446] In one embodiment, a central portion 5077 of the rotatable hub 5078
includes
slots/openings through which the shield gas hoses, the bowden tubes, the weld
power cables,
the motor cables, the inspection detector cables, and the camera cables are
configured to pass.
[00447] In one embodiment, as shown in FIGS. 23, 24 and 30, the front clamp
5142 has a
hollow configuration. In one embodiment, an opening 5082 through the center of
the front
clamp 5142 is constructed and arranged to be large enough to allow all of the
required cables
and hoses to pass therethrough. In one embodiment, the opening 5082 of the
front clamp
5142 is also constructed and arranged to allow for a structural member that is
required to
support the weight of the front half of the internal weld system 5004 as well
as to maintain
alignment of the two halves/pipe segments 1022a, 1022b of the weld joint. In
one
embodiment, the front and rear clamps 5142, 5144 are constructed and arranged
to be
mounted to the rotatable hub 5078, for example, by angular contact ball
bearings 5108, 5098
that are preloaded to provide stiffness.
[00448] In one embodiment, the interior surface 5130, 5132 of the first pipe
1022a and/or
the second pipe 1022b is engaged and manipulated by the first clamp 5142 and
the second
clamp 5144, respectively to adjust the relative positioning of the pipes based
on the
instructions from the one or more processors 5140. In one embodiment, the
adjustment of the
relative positioning of the pipes 1022a, 1022b is achieved without disengaging
the first pipe
engagement structure 5144 from the interior surface 5132 of the first pipe
1022b and without
disengaging the second pipe engaging structure 5142 from the interior surface
5130 of the
second pipe 1022a. This can be done because the rotation motors 5030 and 5074
are
configured to rotate the pipes 1022a, 1022b without disengaging the pipe
engagement
structures 5144, 5142 as described in this application.
[00449] In one embodiment, as shown in FIGS. 23, 24 and 30, the front clamp
5142
generally includes a piston 5084, a cylinder 5086, a bushing 5088, clamp shoe
pin members
5090, link members 5092, a shaft 5094, a hub 5096, a front bearing 5098, a
spider member
5100, a bell housing 5102, a front plate 5104, a rear plate 5106, a rear
bearing 5108, and a
sleeve 5110. In one embodiment, the rear bearing 5108 and the front bearing
5098 are
configured to support the rotatable hub 5078. In one embodiment, the rear
clamp 5144 has
the same structure, configuration and operation as described above with
respect to the front
clamp 5142 and hence the structure, configuration and operation of the rear
clamp 5144 will
not be described in detail here.
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[00450] In one embodiment, the front clamp 5142 is configured to clamp one of
the pipes
1022a, 1022b and the second clamp 5144 is configured to clamp the other of the
pipes 1022a,
1022b. In one embodiment, one of the clamps 5142, 5144 may be referred to as a
first clamp
and the other of the clamps 5142, 5144 may be referred to as the second clamp.
In one
embodiment, the clamps 5142, 5144 of the internal weld system 5004 may either
individually
or together be referred to as the brake system of the internal weld system
5004 that secures
the frame of the internal weld system 5004 at a desired location within the
pipes 1022a,
1022b. In one embodiment, the front and rear clamps 5142, 5144 are radially
extending
clamps that engage the interior surface 5130, 5132 of the pipes 1022a, 1022b,
respectively to
secure the frame of the internal weld system 5004 from movement. The operation
of the front
and rear clamps 5142 and 5144 will be discussed in detail below.
[00451] In one embodiment, the internal weld system 5004 includes the first
pipe
engagement structure 5052, the second pipe engagement structure 5054, the
inspection
detector 5056, the one or more processors 5140; and the weld torch 5502. In
one embodiment,
the inspection detector 5056, the inspection camera 5112, the weld torch 5502
and the weld
head assembly 5500 are rotatably mounted on the rotatable hub 5078. The
structure,
configuration and operation of each of the first pipe engagement structure
5052, the second
pipe engagement structure 5054, the inspection detector 5056, the inspection
camera 5112,
the weld torch 5502 and the weld head assembly 5500 are described in detail
with respect to
the FIGS. 30 and 33-59 and their related descriptions.
[00452] FIGS. 32A and 32B show detailed side and top views of the drive
section 5010 of
the internal weld system 5004. In one embodiment, the drive section 5010 of
the internal
weld system 5004 includes the shield gas tanks 5114, batteries 5116, drive
section electronics
module 5118, pneumatic valves 5120, drive wheels or rollers 5122, drive motors
5124,
brakes 5126 and the compressed air tank 5128. In one embodiment, the pneumatic
valves
5120 include a brake valve 5190 and a drive wheel valve 5192 (both shown in
FIG. 70). In
one embodiment, the drive section 5010 of the internal weld system 5004
includes drive
section frame 5278. In one embodiment, the drive section frame 5278 may be
made from
steel or any other material as would be appreciated by one skilled in the art.
[00453] In one embodiment, the drive section electronics module 5118 may
include the one
or more processors 5140. In one embodiment, the pneumatic valves 5120 (the
brake valve
5190 and the drive wheel valve 5192), and the drive motors 5124 may be
operatively
connected to the one or more processors 5140.
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[00454] In one embodiment, the drive section 5010 may be connected to the
center section
5008 via a universal joint 5123 and spring members 5125.
[00455] In one embodiment, the shield gas tanks 5114 are constructed and
arranged to hold
the shield gas required for the weld torches 5502. In one embodiment, the
hoses are
constructed and arranged to connect the shield gas tanks 5114 to the rear
rotary union 5072 in
the center section 5008.
[00456] In one embodiment, the batteries 5116 are Lithium ion batteries. In
one
embodiment, the batteries 5116 are configured to power all of the electronics
as well as the
electric drive motors 5124 of the internal weld system 5004. For example, in
one embodiment,
the batteries 5116 are configured to power the center section electronics
module 5064, the
forward-most section electronics module 5014, the drive section electronics
module 5118 and
the weed feed electronics module 5046. In one embodiment, the batteries 5116
may be
operatively connected to the one or more processors 5114.
[00457] In one embodiment, the batteries 5116 are also configured to power the
radial weld
torch motor 5512, the tilt weld torch motor 5588, the axial weld torch motor
5550, the motors
of the wire feed systems 5044, the front and rear rotation motors 5030 and
5074, and the
drive motors 5124. In one embodiment, the batteries 5116 are not configured to
supply to
weld power. In one embodiment, the batteries 5116 are configured to deliver
power to just
the drive section electronics module 5118 and the drive motors 5124, while the
power to the
rest of the motors and the electronic modules of the internal weld system
5004, including the
radial weld torch motor 5512, the tilt weld torch motor 5588, the axial weld
torch motor 5550,
the motors of the wire feed systems 5044, the front and rear rotation motors
5030 and 5074,
the center section electronics module 5064, the forward-most section
electronics module
5014, and the weed feed electronics module 5046, is supplied from an external
power source
via the reach rod/umbilical 5034.
[00458] In one embodiment, the drive motors 5124 are configured to drive the
rollers or
wheels 5122 to move the frame assembly (including the first pipe engagement
structure 5052,
the second pipe engagement structure 5054, the weld torch(es) 5502 and the
inspection
detector 5056) of the internal weld system 5004, from the first end of the
pipe 1022a, 1022b
to the second end of the pipe 1022a, 1022b along an interior 5130, 5132 of the
pipe 1022a,
1022b. In one embodiment, the drive motors 5124 of the drive section 5010 are
configured to
move the frame of the internal weld system 5004 down the pipeline 1004 after
each weld is
completed. In one embodiment, the drive motors 5124 of the drive section 5010
are
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configured to both accelerate and decelerate the internal weld system 5004 in
the pipeline
1004.
[00459] In one embodiment, the power source is carried by the frame assembly
of the
internal weld system 5004 and is configured to power the drive motors 5124. In
one
embodiment, the drive motors 5124 of the drive section 5010 are electrically
powered. In one
embodiment, the drive motors 5124 of the drive section 5010 are powered by the
batteries
5116.
[00460] In one embodiment, the drive rollers 5122 are configured to engage the
interior
surfaces 5130, 5132 of one or more of the pipes 1022a, 1022b. In one
embodiment, the drive
rollers 5122 are operatively connected to the drive motors 5124 of the drive
section 5010. In
one embodiment, the drive rollers 5122 is configured to be actuated by a
pneumatic cylinder
5137 that is operatively associated with the pneumatic valves 5120 to receive
the compressed
air from the compressed air tank 5128. In one embodiment, the drive rollers
5122 are made of
an elastomeric material or a rubber material.
[00461] In one embodiment, the drive rollers 5122 are configured to enable the
movement
of the internal weld system 5004 down the pipeline 1004 after each weld is
completed. In one
embodiment, the internal weld system 5004 may include a plurality of drive
rollers 5122 that
are configured to rotatably support the frame or frame assembly of the
internal weld system
5004. For example, in one embodiment, the internal weld system 5004 includes
four active
drive wheels. That is, two drive wheels on each side that are 1800 apart. In
one embodiment,
the number of drive wheels may vary. In one embodiment, the drive rollers 5122
may include
treads thereon to increase their traction when the internal weld system 5004
is driving
through the pipeline.
[00462] In one embodiment, two of the four drive rollers 5122 may be directly
connected to
and driven by their respective drive motors 5124. In one embodiment, the other
two drive
rollers 5122 may be connected to the motor driven drive wheels by chains 5111
and are
driven by the motor driven drive wheels.
[00463] In one embodiment, the drive rollers 5122 are constructed and arranged
for driving
the weld system 5004 inside the pipes 1022a, 1022b until the weld system 5004
is at the
desired location. In one embodiment, the drive rollers 5122 are constructed
and arranged to
be pressed against the inside of the pipe by a pneumatic cylinder.
[00464] In one embodiment, the brake 5126 is configured to be actuated by a
pneumatic
cylinder 5133 that is operatively associated with the pneumatic valves 5120 to
receive the
compressed air from the compressed air tank 5128. In one embodiment, the brake
5126 of the
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internal weld system 5004 is for emergency use. For example, the brake 5126
can be used in
case the drive motors 5124 of the drive section 5010 fail to decelerate the
internal weld
system 5004 for some reason. For example, the brake 5126 may be applied on
hillsides to
keep the internal weld system 5004 from rolling deep into the pipeline 1004 or
falling out of
the pipe depending on slope direction. In one embodiment, the brake 5126 is
configured to be
either manually or automatically controlled.
[00465] In one embodiment, the brake 5126 may also be used to secure the frame
of the
internal weld system 5004 in place within the pipes during the welding
procedure, the pre-
weld scan procedure and/or the post weld scan procedure. For example, the
brake 5126 may
be configured to secure the frame of the internal weld system 5004 from
movement at a
desired location within the pipes during the welding procedure, the pre-weld
scan procedure
and/or the post weld scan procedure.
[00466] In one embodiment, the compressed air tank 5128 is constructed and
arranged to
hold the air for operating the brake 5126, the drive rollers 5122, and the
front and the rear
clamps 5142, 5144. In one embodiment, the compressed air tank 5128 is
constructed and
arranged to be connected to the umbilical 5034 through both the front and rear
rotary unions
5032, 5072 so that compressed air tank 5128 may be refilled as needed.
[00467] In one embodiment, the pneumatic valves 5120 are constructed and
arranged to
control air to the two pneumatic cylinders that are configured to engage and
operate the brake
5126 and the drive rollers 5122, respectively.
[00468] In one embodiment, the drive section electronics module 5118 is
configured to
allow the transmission of the communication signals upstream to the center
section
electronics module 5064. In one embodiment, the drive section electronics
module 5118 is
also configured to control the drive motors 5124 and the two pneumatic valves
5120.
[00469] In one embodiment, the one or more processors 5140 are configured to
operate the
drive motors 5124 to move the frame of the internal weld system 5004 through
at least one of
the pipes 1022a, 1022b until the sensor 5352 detects the interface region 5136
between the
pipes 1022a, 1022b. In one embodiment, the one or more processors 5140 are
configured to
operate the brake system of the internal weld system 5004 to secure the frame
of the internal
weld system 5004 from movement at a location within the pipes 1022a, 1022b
that positions
the inspection detector 5056 in relation to the interface region 5136 to
enable the inspection
detector 5056 to detect the profile of the interface region 5136 between the
pipes 1022a,
1022b.
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[00470] FIG. 33 shows a view of the center section 5008 of the internal weld
system 5004
being positioned inside the pipe segments 1022a, 1022b, where some components
of the
center section 5008 are not shown for sake of clarity. For example, the front
and rear clamps
5142, 5144, the rotatable hub 5078, the weld head assembly 5500, the
inspection detector
5056 and the inspection camera 5112 are shown in FIG. 33.
[00471] In one embodiment, the field system 5000 for welding two pipes
includes a
computer system 5138 for facilitating pipe welding. In one embodiment, the
computer system
5138 includes the one or more processors 5140 that are communicatively
connected to the
weld system 5004. In one embodiment, the computer system 5138 and its one or
more
processors 5140 may be communicatively connected to the weld system 5004 (and
one or
more components thereof) via one or more wired or wireless communication
links. As an
example, the wired communication links may comprise one or more Ethernet
links, coaxial
communication links, Fiber Optic communication links, or other wired
communication links.
As another example, the wireless communication links may comprise one or more
Wi-Fi
communication links, Bluetooth communication links, near-field communication
(NFC)
communication links, cellular communication links, or other wireless
communication links.
In one embodiment, one or more components of the weld system 5004 may be
communicatively connected to one another via one or more of the foregoing
wired or wireless
communication links. In one embodiment, it may be advantageous to utilize one
or more
wireless communications links to enable the one or more processors 5140 or one
or more
components of the weld system 5004 to communicate with one another to reduce
the number
of communication cables in the weld system 5004 to reduce potential
entanglement of the
cables that could delay operations or damage other components of the weld
system 5004. For
example, by reducing the number of communication cables in the weld system
5004 in some
embodiments may reduce potential entanglement of the cables during rotation of
an
inspection device (e.g., inspection laser, inspection camera, or other
inspection device), a
weld torch, or other component of the weld system 5004.
[00472] In one embodiment, the computer system 5138 and its one or more
processors 5140
may be positioned in the field system 5000. In another embodiment, the
computer system
5138 and its one or more processors 5140 may be positioned remotely from the
field system
5000. In one embodiment, the one or more processors 5140 may include a digital
processor,
an analog processor, a digital circuit designed to process information, an
analog circuit
designed to process information, a state machine, and/or other mechanisms for
electronically
processing information.
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[00473] It should be appreciated that the "one or more processors" as
disclosed herein may
constitute a single processor that is located on-board and local to the
particular system or
component being discussed, off-board and local to the particular system or
component being
discussed, or remotely located to the particular system or component being
discussed. In
addition, the connection with the one or more processors can be wired or
wireless. Further,
the "one or more processors" may also refer to a plurality of processors that
are on-board and
local, a plurality of processors that are off-board and local, a plurality of
processors that are
remote, or any combination of on-board (and local), off-board (and local), and
remote
processors. In referring to on-board processors, such processors refer to
processors that are
carried physically (i.e., physically connected, and move with) by the
particular system or
component. In referring to off-board processors, these refer to processors
that are local to a
job-site and communicate wirelessly with on-board electronics. Off-board
processors can
also refer to electronics that are tethered to the on-board system (e.g.,
through a reach rod),
and are local to the job site. Seen in another light, if the processor moves
with the reach rod,
it may also be considered an "on-board" processor.
[00474] In one embodiment, the first pipe engagement structure 5052 is
configured to
engage an interior surface 5130 of the first pipe 1022a to enable the first
pipe engagement
structure 5052 to be fixed relative to the first pipe 1022a. In one
embodiment, the second pipe
engagement structure 5054 is configured to engage an interior surface 5132 of
the second
pipe 1022b to enable the second pipe engagement structure 5054 to be fixed
relative to the
second pipe 1022b.
[00475] In one embodiment, the inspection detector 5056 is positioned between
the first
pipe engagement structure 5052 and the second pipe engagement structure 5054
and is
configured to emit an inspection beam of radiation. In one embodiment, an
inspection
detector motor is operatively associated with the inspection detector 5056 to
direct the
inspection beam of radiation along the interface region 5136 between the pipes
1022a, 1022b.
In one embodiment, the front and rear rotation motors 5030 and 5074 may
individually or
together be referred to as the inspection detector motor. In one embodiment,
the front and
rear rotation motors 5030 and 5074 are configured to rotationally move the
inspection
detector 5056 along the interface region 5136. In one embodiment, the
inspection detector
5056 is configured to generate signals based upon a profile of the interface
region 5136
between the pipes 1022a, 1022b. In one embodiment, the interface region 5136
is an annular
interface region. In one embodiment, the interface region 5136 is in the
interior of the pipes
1022a, 1022b at regions of the pipes 1022a, 1022b adjacent to where the weld
would go.
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[00476] The term "interface region" as used herein refers to the interior
surfaces of the
pipes to be welded in the area, and optionally in the adjacent vicinity, where
the weld
material is to be deposited. The interface region includes at least a portion,
or optionally the
entirety, of the internal bevel of both pipes to be welded, if such bevels are
provided. In one
embodiment, the interface region includes the entirety of the beveled surfaces
and also
extends beyond the beveled surface, if bevels are provided.
[00477] In one embodiment, the wheels 5028 on the forward-most section 5006 of
the
internal weld system are constructed and arranged to keep the clamps from
dragging on the
inner surfaces of the pipe. The less the wheels 5028 extend out, the easier
the internal weld
system fits through the pipe bends. In one embodiment, the wheels 5028 may be
adjustable.
In one embodiment, the wheels 5028 may not be adjustable. In one embodiment,
the sprung
or toe wheels 5066 (as shown in FIG. 23) at the rear clamp 5144 and the
adjustable wheels
5276 (as shown in FIG. 32A) at the back of the drive section 5008 are
constructed and
arranged so that the clamp centerline is about 0.25 inches below the pipe
centerline. With this
configuration, when the clamps expand against the inner surfaces of the pipe,
the expander
picks the clamp up off of the wheels rather than compress the wheels into the
pipe's inner
walls
[00478] In some embodiments, the "pipe engagement structure" comprises a clamp
that
securely engages a pipe surface. The clamp, for example, can include one or
more shoes or
other support structure configured to fixedly engage with a pipe surface so as
to prevent
movement thereof In another embodiment, the "pipe engagement structure"
comprises a seal
that sealingly engages the interior surface of a pipe so as to inhibit gas
from passing
therethrough. Such seal may comprise, for example, an inflatable bladder, a
resilient structure,
or other engineered structure that engages the interior pipe surface to
inhibit gas from passing
therethrough. Such seal can be used in a purging operator to remove oxygen
from a region in
the pipe to be welded, so as to prevent or reduce oxidation as a result of the
welding process.
In yet another embodiment, the pipe engagement structure comprises a
combination of a
clamp and a seal, or one or more clamps and/or one or more seals.
[00479] In one embodiment, the first pipe engagement structure 5052 includes
the first
clamp 5142 and the second pipe engagement structure 5054 includes the second
clamp 5144.
[00480] In one embodiment, the first pipe engagement structure 5052 includes a
first seal
5146 and the second pipe engagement structure 5054 includes a second seal
5148.
[00481] In one embodiment, the second seal 5148 and the second clamp 5144 may
be
referred to as the rear seal 5148 and the rear clamp 5144, respectively. In
one embodiment,
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the first seal 5146 and the first clamp 5142 may be referred to as the front
seal 5146 and the
front clamp 5142, respectively.
[00482] In one embodiment, the first pipe engagement structure 5052 includes
the clamp
5142 and the second pipe engagement structure 5054 includes the seal 5148. In
one
embodiment, the first pipe engagement structure 5052 includes the seal 5146
and the second
pipe engagement structure 5054 includes the clamp 5144.
[00483] In one embodiment, the first pipe engagement structure 5052 includes
the clamp
5142 and the seal 5146 and the second pipe engagement structure 5054 includes
the clamp
5144 and the seal 5148. In one embodiment, the first pipe engagement structure
5052
includes the clamp 5142 and the seal 5146 and the second pipe engagement
structure 5054
includes the clamp 5144. In one embodiment, the first pipe engagement
structure 5052
includes the clamp 5142 and the seal 5146 and the second pipe engagement
structure 5054
includes the seal 5148. In one embodiment, the first pipe engagement structure
5052 includes
the clamp 5142 and the second pipe engagement structure 5054 includes the
clamp 5144 and
the seal 5148. In one embodiment, the first pipe engagement structure 5052
includes the seal
5146 and the second pipe engagement structure 5054 includes the clamp 5144 and
the seal
5148.
[00484] In the configuration where there is a seal on one side of the
inspection detector
5056 and the inspection camera 5112 and a clamp of the other (opposite) side
of the
inspection detector 5056 and the inspection camera 5112, a high pressure purge
gas is sent
into a region between the clamp and the seal. The purge gas from the region
between the
clamp and the seal may leak through the slight gap between the pipes about to
be welded and
may also be exhausted from the pipes on the side of the inspection detector
5056 and the
inspection camera 5112 where there is no seal and has just the clamp. This
optional
configuration prevents the over pressurization of the region between the clamp
and the seal
(e.g., in comparison with arrangements having two seals, one on either side of
the inspection
detector 5056 and the camera 5112), without the provision of a regulator to
regulate pressure
with the purge gas region, and/or a separate over pressurization relief valve
for the region
between the clamp and the seal. The continuous supply of the high pressure
purge gas into
the region between the clamp and the seal is configured to reduce the oxygen
in a region in
the vicinity of the weld torch during a welding operation.
[00485] In another embodiment, the first and the second seals may optionally
have openings
therethrough to prevent over pressurization of the purge gas chamber formed
between the
first and the second seals. In another embodiment, one or both of the seals,
where an
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inflatable seal bladder is provided for the seal, may be partially inflated to
provide a
predefined or calculated gap therearound to allow flow out of the purge area
at a desired rate.
[00486] Where two purge seals 5146, 5148 are provided, inert gas is introduced
into the
purge chamber therebetween. It should be understood, however, that the purge
seals 5146,
5148 need not (and typically do not) create a perfect seal. Inert gas is
leaked, for example,
through the gap between the two pipes 1022a, 1022b being welded. The inert
purge gas may
also leak around the seals 5146, 5148, which need not be perfect. Of course,
during the
welding operation, the gap between the pipes 1022a, 1022b is slowly closed and
sealed. As a
result, the pressure within the purge chamber between the pipes 1022a, 1022b
may rise as the
weld between the pipes 1022a, 1022b is created. As such, the pressure sensor
provided within
the purge chamber detects the pressure within the purge chamber and generates
signals to the
one or more processors 5140, which in turn communicates with one or more
valves and/ or
one or more regulators, so as to control or regulate the purge gas pressure
within the purge
chamber to prevent over-pressurization. Over-pressurization within the purge
chamber would
apply a greater than desired outwardly directed gas force through the gap
between the pipes
to be welded and potentially alter a desired outcome of the weld. In a
different embodiment,
only a single seal 5146, 5148 is provided to create a purge chamber that is
sealed on only one
side. This arrangement still provides a reasonable purge chamber, which is
largely devoid of
oxygen, and also prevents any possibility of over-pressurization. In such
embodiment, inert
purge gas will leak not only from the gap between the pipes, but also through
an end of the
pipe that is not sealed, and hence may consume more gas in comparison with the
double
sealed embodiment.
[00487] In one embodiment, the inspection detector 5056 and the inspection
camera 5112
are configured to be positioned axially (with respect to the pipe axis)
between the first clamp
5142 and the second seal 5148. That is, the first clamp 5142 and the second
seal 5148 are
each positioned on axially opposite sides of the inspection detector 5056 and
the inspection
camera 5112.
[00488] In one embodiment, the inspection detector 5056 and the inspection
camera 5112
are configured to be positioned axially (with respect to the pipe axis)
between the first seal
5146 and the second clamp 5144. That is, the first seal 5146 and the second
clamp 5144 are
each positioned on axially opposite sides of the inspection detector 5056 and
the inspection
camera 5112.
[00489] In one embodiment, the inspection detector 5056 and the inspection
camera 5112
are configured to be positioned axially (with respect to the pipe axis)
between the first clamp
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5142 and the second clamp 5144. That is, the first clamp 5142 and the second
clamp 5144 are
each positioned on axially opposite sides of the inspection detector 5056 and
the inspection
camera 5112.
[00490] In one embodiment, the inspection detector 5056 and the inspection
camera 5112
are configured to be positioned axially (with respect to the pipe axis)
between the first seal
5146 and the second seal 5148. That is, the first seal 5146 and the second
seal 5148 are each
positioned on axially opposite sides of the inspection detector 5056 and the
inspection camera
5112.
[00491] In one embodiment, the inspection detector 5056 and the inspection
camera 5112
are configured to be positioned axially (with respect to the pipe axis)
between the first seal
5146, the first clamp 5142, the second clamp 5144 and the second seal 5148.
That is, the first
seal 5146 and the first clamp 5142 are positioned axially on one side of the
inspection
detector 5056 and the inspection camera 5112 and the second clamp 5144 and the
second seal
5148 are positioned axially on the other side of the inspection detector 5056
and the
inspection camera 5112.
[00492] In one embodiment, the inspection detector 5056 and the inspection
camera 5112
are configured to be positioned axially (with respect to the pipe axis)
between the first seal
5146, the first clamp 5142 and the second seal 5148. That is, the first seal
5146 and the first
clamp 5142 are positioned axially on one side of the inspection detector 5056
and the
inspection camera 5112 and the second seal 5148 is positioned axially on the
other (opposite)
side of the inspection detector 5056 and the inspection camera 5112.
[00493] In one embodiment, the inspection detector 5056 and the inspection
camera 5112
are configured to be positioned axially (with respect to the pipe axis)
between the first seal
5146, the second seal 5148 and the second clamp 5144. That is, the second seal
5148 and the
second clamp 5144 are positioned axially on one side of the inspection
detector 5056 and the
inspection camera 5112 and the first seal 5146 is positioned axially on the
other (opposite)
side of the inspection detector 5056 and the inspection camera 5112.
[00494] In one embodiment, the inspection detector 5056 and the inspection
camera 5112
are configured to be positioned axially (with respect to the pipe axis)
between the first seal
5146, the first clamp 5142 and the second clamp 5144. That is, the first seal
5146 and the first
clamp 5142 are positioned axially on one side of the inspection detector 5056
and the
inspection camera 5112 and the second clamp 5144 is positioned axially on the
other
(opposite) side of the inspection detector 5056 and the inspection camera
5112.
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[00495] In one embodiment, the inspection detector 5056 and the inspection
camera 5112
are configured to be positioned axially (with respect to the pipe axis)
between the first clamp
5142, the second seal 5148 and the second clamp 5144. That is, the second seal
5148 and the
second clamp 5144 are positioned axially on one side of the inspection
detector 5056 and the
inspection camera 5112 and the first clamp 5142 is positioned axially on the
other (opposite)
side of the inspection detector 5056 and the inspection camera 5112.
[00496] In one or more embodiments, because the inspection detector 5056 is
positioned
between the clamps 5142, 5144, it is able to extract profile data from between
the clamps
5142, 5144 after the clamps 5142, 5144 have been clamped in place. As such the
inspection
detector 5056 can continue to scan and detect the profile of the interface
region 5136 during a
welding operation. This is beneficial for some applications, as the interface
region 5136 may
change slightly as the two pipes 1022a, 1022b are being welded, as the welded
connection
itself may change the interface region 5136 in other areas that have not been
welded yet.
Hence, the inspection detector 5056 allows for a detection and determination
of any change
in one or more characteristics of the interface region 5136 on-the-fly, or in
"real time" at
regions of the interface region 5136 about to be welded. In addition, because
the inspection
detector 5056 is positioned between the clamps 5142, 5144, it is able to
extract pre-weld
profile data from the interface region 5136 after the clamping force is
applied by the clamps
5142, 5144. The clamping force of the clamps 5142, 5144 themselves may alter
the interface
region 5136. For example, the clamping force may slightly alter the distance
between the pipe
ends and/a relative height displacement between the pipe ends at certain (or
all) regions of the
interface region 5136. In addition, the clamping force applied by the clamps
5142, 5144 may
change a roundness of one or both of the pipes (e.g., the first clamp may
alter the roundness
of the first pipe to be welded and/or the second clamp may alter the roundness
of the second
pipe to be welded. In one embodiment, for example, the clamp shoes for any one
of the
clamps 5142, 5144 are symmetrically provided and evenly circumferentially
spaced about the
interior of the pipe being engaged. In addition, the outermost surface of each
clamp shoe may
be equally spaced from the central axis of the clamp. The spacing of each
clamp shoe can be
set to be slightly larger than the inner diameter of the pipe. In that way, if
each clamp shoe is
extended to its maximum position, the clamping force of the clamp 5142, 5144
can be used to
change the shape of a slightly out of round pipe to one that is more rounded.
Until the fully
clamping force is applied by both clamps 5142, 5144, the profile of the
interface region 5136
is not yet fully determined because of the shape changing possibility. The
inspection detector
5136 describe herein can be used to determine the profile after clamping has
been applied.
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[00497] In one or more embodiments, because the inspection detector 5056
and/or camera
5112 is positioned between the two seals, the inspection detector 5056 and/or
camera 5112
are able to extract profile data from between the seals 5146, 5148 after the
seals 5146, 5148
have been engaged with the interior surfaces 5130, 5132 of the pipes 1022a,
1022b to be
welded. As such the inspection detector 5056 can continue to scan and detect
the profile of
the interface region 5136 before, during and/or after a welding operation in
which the regions
between the seals 5146, 5148 have been provided or filled with a purge gas.
This is beneficial
for some applications, as the interface region 5136 may be inspected by the
inspection
detector 5056 and/or camera 5112, before, during, and/or after a welding
operation without
breaking the seal 5146, 5148. If, for example, the inspection detector 5056
and/or camera
5112 (together with the one or more processors 5140) determine(s) that a
slight modification
to the weld, or an additional welding operation is desired, such modification
or additional
welding operation can be accomplished without the need to reestablish the
purge chamber
(for example, in comparison to a contemplated arrangement in which a post-weld
inspection
detector and/or camera are located outside the purge chamber, and introducing
the inspection
detector 5056 and/or camera 5112 to inspect the welded interface region 5136
only after the
purge chamber has been broken). Thus, the inspection detector 5056 can be used
to scan the
interface region 5136 between the pipes 1022a, 1022b to determine the profile
of the
interface region 5136 between the pipes 1022a, 1022b subsequent to a welding
operation and
generate post-weld profile data based on the scan, and this post-weld profile
data can be
obtained, and optionally a corrective or other additional weld can be achieved
based on the
post-weld profile data, without releasing the clamps 5142, 5144 and/or seals
5146, 5148.
[00498] In one embodiment, the clamps 5142, 5144 are configured to rotate. In
one
embodiment, the clamps 5142, 5144 are configured to rotate in opposite
directions to one
another.
[00499] In addition, as described herein, the present system enables relative
rotation
between the first clamp and the second clamp 5142, 5144, after they have been
clamped to
the first and second pipe interiors 5130, 5132 respectively. This can be
accomplished by the
one or more orientation motors 5030, 5074 operating one or both of the clamps
5142, 5144 as
described herein. Such relative rotation of the pipes 1022a, 1022b can be
conducted in
response to pre-weld profile data determining that a better rotational match
between the pipe
ends is available and can be accomplished by relative rotation of one or both
of the clamps
5142, 5144. Such relative rotation is accomplished without the need to unclamp
the first and
second clamps 5142, 5144, and while the inspection detector 5056 remains
axially positioned
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between the clamps 5142, 5144. After the first and/or second pipe 1022a, 1022b
is rotated, a
new profile of the interface region 5136 exists, and the inspection detector
5056 can be again
used to scan the interface region 5136 to obtain new pre-weld profile data. It
should be
appreciated that because neither clamp 5142, 5144 needs to be released to
obtain the new pre-
weld profile data, unnecessary downtime can be avoided. During the relative
rotation of the
pipes 1022a, 1022b, it should be appreciated that, in one embodiment, the
rollers 5332 of the
external cradle 5330 (6010A, 6010B) can be used (as instructed by the one or
more
processors 5140) to work in conjunction with the one or more clamps 5142, 5144
to effect
such relative rotation.
[00500] In one embodiment, the clamps 5142, 5144 and the seals 5146, 5148 are
positioned
inside the pipes 1022a, 1022b to form an internal sealed region/area. In one
embodiment, the
clamps 5142, 5144 and the seals 5146, 5148 are configured to seal opposite
sides of a seam to
be welded.
[00501] In one embodiment, the clamp 5142 and the seal 5146 are activated
together and
the clamp 5144 and the seal 5148 are activated together. In one embodiment,
the clamps 5142,
5144 and the seals 5146, 5148 are controlled by the same valve.
[00502] In one embodiment, the seals 5146, 5148 are activated with the clamp
5142. In one
embodiment, the seals 5146, 5148 are activated with the clamp 5144. In one
embodiment, the
clamp 5142 and the seal 5146 are activated independently and the clamp 5144
and the seal
5148 are activated independently. In one embodiment, a separate seal control
system may be
configured to operate both the seals 5146, 5148 that is independent (and
separate from) of a
clamp control system that is configured to operate both the clamps 5142, 5144.
[00503] In one embodiment, the clamp 5144 is positioned relative to the end of
the pipe
1022b. In one embodiment, the clamp 5142 and the seal 5146 are then activated
together. In
one embodiment, when the pipe 1022a is positioned relative to the pipe 1022b,
the clamp
5144 and the seal 5148 are activated together.
[00504] In one embodiment, the clamps 5142, 5144 are configured to be moveable
between
a retracted position (as shown in FIGS. 35B) where the clamps 5142, 5144 are
not in contact
with the inner surfaces 5130, 5132 of the pipes 1022a, 1022b and an extended
position (as
shown in FIGS. 35A) where the clamps 5142, 5144 are configured to apply clamp
forces on
the inner surfaces 5130, 5132 of the pipes 1022a, 1022b. In one embodiment,
the clamps
5142, 5144 are constructed and arranged to engage (make contact) with the
pipes 1022a,
1022b and transmit forces that grip and shape the pipes 1022a, 1022b.
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[00505] In one embodiment, the structure, configuration and operation of the
clamps 5142,
5144 are shown and explained with respect to FIGS. 30, and 33-42. For example,
FIG. 33 and
34 show a perspective and a cross-sectional of the center section 5008 of the
internal weld
system 5004 being positioned inside the pipe segments 1022a, 1022b, where both
clamps
5142, 5144 and seals 5146, 5148 are engaging the inner surfaces 5130 and 5132
of the pipes
segments 1022a, 1022b and where some components of the center section 5008 are
not
shown for sake of clarity; FIG. 35 shows a view of the center section 5008 of
the internal
weld system 5004 being positioned inside the pipe segments1022a, 1022b, where
only
clamps 5142, 5144 (no seals) are engaging the inner surfaces 5130 and 5132 of
the pipes
segments 1022a, 1022b and where some components of the center section are not
shown for
sake of clarity; FIG. 36 shows a perspective view of the clamp shoe 5157
attached to the
clamp shoe pin member 5090 positioned in the spider member 5100; FIG. 37 shows
a
perspective view of the spider member 5100; FIG. 38 shows a perspective view
of the clamp
shoe pin member 5090; and FIGS. 39 and 40 show perspective views of the hub
5096 of the
clamps 5142 or 5144 with the clamp shoe pin members 5090 and the link members
5092
connected thereto.
[00506] In one embodiment, as shown in FIG. 35C, the clamps 5142, 5144 are
shown in
retracted position to show how the ramps 5026, 5070 extend slightly higher. In
FIG. 35C, the
weld torches 5502 are shown in their extended positions. Typically, the weld
torches 5502
would only be extended after the clamps 5142, 5144 are extended.
[00507] In one embodiment, referring to FIG. 36, the weld system 5004 may
include a
plurality of first clamp shoes 5157 circumferentially, equally spaced apart
from each other on
its respective spider member 5100 and a plurality of second clamp shoes 5157
circumferentially, equally spaced apart from each other on its respective
spider member 5100.
[00508] In one embodiment, the clamp shoes 5157 may have different heights for
different
size pipes and may be fine-tuned, for example, with shims or any other
adjustment members.
In one embodiment, the clamps shoes 5157 may be self-centering members. In one
embodiment, the clamp shoes 5157 of the internal weld system 5004 are
constructed and
arranged to have a radial clearance of about 1 inch to the inner surfaces of
the pipe.
[00509] In one embodiment, each clamp shoe 5157 includes pipe surface contact
members
(or surfaces) 5156. In one embodiment, the pipe surface contact members 5156
are
constructed and arranged to frictionally engage, when the clamps 5152, 5154
are extended,
the inner surfaces 5130, 5132 of the pipes 1022a, 1022b on either side of the
interface region
5136.
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[00510] In one embodiment, referring to FIGS. 30 and 36-38, each clamp shoe
5157 is
constructed and arranged to be connected to and positioned on its associated
clamp shoe pin
member 5090. In one embodiment, the clamp shoe pin member 5090 is constructed
and
arranged to extend through its corresponding opening 5158 in the spider member
5100. In
one embodiment, the openings 5158 in the spider member 5100 are constructed
and arranged
to generally extend radially in the spider member 5100 so as to enable a
radial movement
(e.g., up and down radial movement) of the clamp shoe pin member 5090 in the
corresponding opening 5158 in the spider member 5100. In one embodiment, the
spider
member 5100 may be any member that is constructed and arranged to facilitate
movement of
the clamp shoe pin members 5090 such that the clamps 5142, 5144 apply clamping
forces on
the inner surfaces 5130, 5132 of the pipes 1022a, 1022b.
[00511] In one embodiment, referring to FIG. 38, one end 5164 of the clamp
shoe pin
member 5090 is attached to the clamp shoe 5157 and the other end 5166 of the
clamp shoe
pin member 5090 is connected to the link member 5092. In one embodiment, the
end 5166 of
the clamp shoe pin member 5090 includes a notch 5168 that is constructed and
arranged to
receive the link member 5092 therein. In one embodiment, the end 5166 of the
clamp shoe
pin member 5090 also includes openings 5170 that constructed and arranged to
receive
fastening members 5172 to connect the link member 5092 to the end 5166 of the
clamp shoe
pin member 5090.
[00512] In one embodiment, referring to FIG. 37, the spider member 5100 may
include
openings 5162 that are constructed and arranged to enable the connection
between the clamp
shoe pin members 5090 and the link members 5092. In one embodiment, the
openings 5162
of the spider member 5100 are also constructed and arranged to enable the
movement of the
link member 5092 when the clamps 5142, 5144 are moved between their retracted
and
extended positions. In one embodiment, the spider member 5100 is attached to
the respective
clamps 5142 or 5144.
[00513] In one embodiment, the link member 5092 is an elongated member with
openings
formed at its end portions. In one embodiment, the end portions of the link
member have
generally rounded configurations to enable the movement of the link member
5092 when the
clamps 5142, 5144 are moved between their retracted and extended positions
[00514] In one embodiment, referring to FIGS. 30, 39 and 40, one end of the
link member
5092 is connected to the clamp shoe pin member 5090 and the other end of the
link member
5092 is connected to the hub 5096. In one embodiment, each clamp shoe is thus
connected to
the hub 5096 via its associated clamp shoe pin member 5090 and link member
5092.
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[00515] In one embodiment, the hub 5096 may include notches 5174 (as shown in
FIG. 40)
that are constructed and arranged to enable the connections between the link
members 5092
and the hub 5096. In one embodiment, the notches 5174 of the hub 5096 are also
constructed
and arranged to enable the movement of the link members 5092 in the notches
5174 when the
clamps are moved between their retracted and extended positions.
[00516] In one embodiment, referring to FIG. 30, the clamp 5152 or 5154
includes the
cylinder 5086, the piston 5084 and the shaft 5094. In one embodiment, the
piston 5084 is
configured to be movable axially in the cylinder 5086, and the shaft 5094 is
secured to the
piston 5084. In one embodiment, the shaft 5094 is movable with the piston
5084.
[00517] In one embodiment, the hub 5096 is constructed and arranged to be
connected to
the shaft 5094 that is longitudinally moved by the axially, reciprocating
piston 5084, for
example, driven by fluid (hydraulic or pneumatic) pressure inside the cylinder
5086.
[00518] The clamps 5142, 5144 are moved from the retracted position (as shown
in FIGS.
35B) where the clamps 5142, 5144 are not in contact with the inner surfaces
5130, 5132 of
the pipes 1022a, 1022b to the extended position (as shown in FIGS. 35A) where
the clamps
5142, 5144 are configured to apply clamp forces on the inner surfaces 5130,
5132 of the
pipes 1022a, 1022b, by activating the cylinder 5086 so that the piston 5084 is
axially moved
in the cylinder 5086. In one embodiment, the compressed air from the front
rotary union 5032
through the front clamp control valve 5018 enter a port 5031 (as shown in FIG.
30). The
compressed air entering the port 5031 pushes the piston 5084 forward to move
the clamps
5142, 5144 to their extended position.
[00519] That is, the axial movement of the piston 5084 causes an axial
movement of the
shaft 5094 connected to the piston 5084. In one embodiment, the axial movement
of the shaft
5094 in turn causes an axial movement of the hub 5096. In one embodiment, the
axial
movement of the hub 5096 is translated to a radial movement of the clamp shoe
pin members
5090 via their link members 5092. Thus, the radial clamp forces are generated
by fluid
pressure of the compressed air acting on the piston 5084 that drives the link
members 5092
that convert the axial movement of the piston 5084 (via the shaft 5094 and the
hub 5096) to a
radial movement of the clamps shoes 5157.
[00520] In one embodiment, the size of the cylinder, the applied fluid
pressure, and the
sizes of various components of the clamps 5142 and 5144 may be changed to
control the
clamp forces being applied by the clamps on the inner surfaces 5130, 5132 of
the pipes 1022a,
1022b.
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[00521] In one embodiment, the seals 5146, 5148 have a generally donut or
annular shaped
configuration to allow a portion of the center section (e.g., the front clamp
5142 or the rear
clamp 5144) to pass therethrough. In one embodiment, the seals 5146, 5148 are
constructed
and arranged to be radially expandable members. In one embodiment, the seals
5146, 5148
are constructed and arranged to be connected to a pneumatic or a hydraulic
line that conveys
fluid to the seals 5146, 5148 to inflate them. As the seals 5146, 5148
inflate, they are
constructed and arranged to engage the inner surfaces 5130, 5132 of the pipes
1022a, 1022b,
respectively forming a chamber 5150 therebetween. In one embodiment, the seal
5146, when
inflated, engaged the inner surface 5130 of the pipe 1022a and the seal 5148,
when inflated,
engaged the inner surface 5132 of the pipe 1022b. In one embodiment, the seals
5146, 5148,
when inflated, engage on opposite sides of the interface region 5136. In one
embodiment, the
chamber 5150 is a closed volume that may be referred to as a purge gas
chamber. In one
embodiment, the chamber 5150 is constructed and arranged to receive a purge
gas therein.
[00522] In one embodiment, the internal weld system 5004 may include the purge
gas tank
configured to provide purge gas between the inflated first seal 5146 and the
inflated second
seal 5148 to reduce oxygen from between the inflated first and the second
seals 5146 and
5148 during a welding operation. In one embodiment, the purge tank may be
positioned in
the drive section 5010 of the internal weld system 5004. In one embodiment,
the purge gas is
configured to prevent oxidation during a welding procedure. In one embodiment,
the purge
gas is an inert gas. In one embodiment, the purge gas may include argon,
helium, nitrogen, or
a combination thereof. In one embodiment, the purge gas may include a
combination of argon
and CO2.
[00523] In one embodiment, the purge gas is pumped into the internal sealed
region that is
formed between the inflated first and the second seals 5146, 5148. By keeping
the sealed,
internal region free of oxygen, oxidation that may result from the extreme
heats that take
place during the welding procedure may be prevented.
[00524] In one embodiment, the internal weld system 5004 may include an oxygen
sensor
5176 and a pressure sensor 5178. In one embodiment, the oxygen and pressure
sensors 5176
and 5178 are operatively connected to the one or more processors 5140. In one
embodiment,
the oxygen and pressure sensors 5176 and 5178 are constructed and arranged to
be positioned
on the rotatable hub 5078. In another embodiment, the oxygen and pressure
sensors 5176 and
5178 are constructed and arranged to be positioned on the spider member 5100
(e.g., between
the clamps).
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[00525] In one embodiment, the oxygen sensor 5176 is configured to measure
oxygen
content of the gas in the purge chamber 5150 and send an oxygen content data,
which is
indicative of the oxygen content of the gas in the purge chamber 5150, to the
one or more
processors 5140. In one embodiment, the one or more processors 5140 are
configured to
receive the oxygen content data, compare the received oxygen content data to
its
predetermined oxygen content value, and generate an excess oxygen gas signal
if the oxygen
content data is greater than the predetermined oxygen content value. In one
embodiment,
based on the excess oxygen gas signal, the internal weld system 5004 may be
configured to
open a valve structure to allow purge gas (from the purge gas source/tank) to
flow into the
purge chamber 5150 until the measured oxygen content falls below the
predetermined oxygen
content value. In one embodiment, based on the excess oxygen gas signal, the
internal weld
system 5004 may be configured to stop the welding procedure.
[00526] In one embodiment, the pressure sensor 5178 is configured to measure
pressure of
the inert gas in the purge chamber 5150 and send pressure data, which is
indicative of the
pressure of the inert gas in the purge chamber 5150, to the one or more
processors 5140. In
one embodiment, the one or more processors 5140 are configured to receive the
pressure data,
compare the received pressure data to its predetermined pressure value, and
generate an
overpressure signal if the pressure data is greater than the predetermined
pressure value. In
one embodiment, based on the overpressure signal, the internal weld system
5004 may be
configured to open an exhaust valve structure to release the pressure in the
purge chamber
5150 until the measured pressure falls below the predetermined pressure value.
In one
embodiment, based on the overpressure signal, the internal weld system 5004
may be
configured to stop the welding procedure.
[00527] In one embodiment, the seals 5146, 5148, the purge gas tank, the purge
gas
chamber 5150 formed between the seals 5146, 5148, the oxygen and pressure
sensors 5176
and 5178 that monitor the gas in the purge gas chamber 5150 are all optional.
[00528] In one embodiment, referring to FIG. 33, the internal weld system 5004
includes
the inspection camera 5112 configured to be positioned between the first pipe
engagement
structure 5052 and the second pipe engagement structure 5054. In one
embodiment, the
inspection camera 5112 is constructed and arranged to be rotatably mounted on
and
connected to the rotatable hub 5078.
[00529] In one embodiment, the inspection camera 5112 is operatively connected
to the one
or more processors 5140. In one embodiment, the inspection camera 5112 is
configured to
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send camera inspection data prior to, subsequent to, or during a weld
operation to the one or
more processors 5140.
[00530] In one embodiment, the camera inspection data may generally include
image(s),
captured by the inspection camera 5112, of the weld joint. In one embodiment,
the inspection
camera 5112 is configured to capture image(s) of weld joint during or
subsequent to the weld
operation.
[00531] In one embodiment, the camera inspection data may generally include
image(s),
captured by the inspection camera 5112, of the interface region 5136 between
the pipes
1022a, 1022b. In one embodiment, the inspection camera 5112 is configured to
capture
image(s) of the interface region 5136 between the pipes 1022a, 1022b prior to
or during the
weld operation.
[00532] In one embodiment, the inspection camera 5112 may be any device that
is
configured for capturing/viewing the weld joint or the interface region 5136
between the
pipes 1022a, 1022b. In one embodiment, the camera device 5112 may be a two-
dimensional
(2D) camera for visual inspection of the weld joint or the interface region
5136 between the
pipes 1022a, 1022b.
[00533] In one embodiment, the inspection camera 5112 may be a two-dimensional
(2D)
charge-coupled device (CCD) color camera. In one embodiment, the one or more
processors
5140 that are associated with the inspection camera 5112 may be configured to
analyze the
image(s) captured by the inspection camera 5112 to detect any defects present
in the weld
joint. In one embodiment, a visual signal may be delivered to an external
operator display
based on the analysis. For example, the 2D camera may be a color camera and a
change in
coloration may indicate a weld defect to the operator. In one embodiment, a
perceived change
in profile may also indicate a weld defect.
[00534] In one embodiment, the inspection camera 5112 is configured to obtain
a thermal
image of (e.g., various color regions of the metal) of the weld joint/region.
This thermal
image is then analyzed to determine what temperatures the different regions of
the weld
joint/region have reached.
[00535] In one embodiment, the images provided by the inspection camera 5112
may be
color images. In one embodiment, the one or more processors 5140 that are
associated with
the inspection camera 5112 may be configured to analyze the color of each
pixel of the
received image to determine the temperature associated with that pixel.
[00536] In another embodiment, the images provided by the inspection camera
5112 may be
grayscale images. In one embodiment, the one or more processors 5140 that are
associated
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with the inspection camera 5112 may be configured to analyze the intensity or
brightness of
each pixel of the received image to determine the temperature associated with
that pixel. In
one embodiment, the one or more processors 5140 that are associated with the
inspection
camera 5112 may be configured to analyze the properties of the pixels of the
received image
to determine if the temperature is outside the threshold or predetermined
temperature range
(and is a relatively very high or relatively very low) and or if there is a
large temperature
difference between adjacent pixels. In one embodiment, the abnormal
temperature(s) or
temperature differences may be an indication of the occurrence of a weld
defect.
[00537] For example, in one embodiment, the image may be analyzed to determine
whether
a region or regions of the weld joint/region have reached a relatively very
high or relatively
very low temperature. In one embodiment, the image may be analyzed to
determine whether
a region or regions of the weld joint/region have temperature
differential/changes. In one
embodiment, a temperature of each region of the weld joint/region is
determined, and the
determined temperature of each region of the weld joint/region is compared
with a threshold
or predetermined temperature range to determine whether a region or regions of
the weld
joint/region have reached a relatively very high temperature, and/or a region
or regions of the
weld joint/region have temperature differential/changes.
[00538] In one embodiment, the inspection camera 5112 is configured to follow
the weld
torch 5502 so that an operator can inspect the weld as soon as the weld is
created by the weld
torch 5502.
[00539] In various embodiments, the inspection detector comprises a laser, 3D
camera,
ultrasound, and an electric capacitive probe. Where a laser is used, the type
of laser can be a
Laser Displacement Sensor. In one embodiment, the laser can be LK-G5000 series
Ultra
High-Speed/High-Accuracy Laser Displacement Sensor manufactured by Keyence. In
one
embodiment, the laser can be a smart laser sensor, such as, Smart Laser Sensor
SLS-050
manufactured by Meta Vision Systems Inc.
[00540] In one embodiment, the inspection detector may include an emitter for
emitting the
inspection beam of radiation, and a receiver for receiving inspection signals
from reflected
radiation. In one or more embodiments, the detector's receiver comprises a
sensor that detects
the reflected radiation and generates signals based upon the reflected
radiation. The signals
are received by the one or more processors. In one embodiment, the signals
contain data and
information corresponding to the three dimensional profile of the interface
region between
pipes to be welded and can be used to detect, for example, the relative
heights of the adjacent
pipe surfaces at the regions to be welded, the relative spacing between the
pipes, any non-
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uniformities in the adjacent surfaces to be welded (e.g., at the bevels
thereof). In addition,
because the inspector detector is scanned along the entire interface between
the pipes, it can
determine the specific interface profile at any particular region of the scan.
This information
can be used by the one or more processors to control the operation of the weld
torch to
provide a customized/tailored weld that is tailored specifically to the
structural profile of the
pipes to be welded at the interface region thereof
[00541] In one embodiment, the system 5000 may include housings 5852, 5854 (as
shown
in FIG. 31) that are configured to house and protect the inspection detector
5056 and the
inspection camera 5112, respectively from flying hot weld sparks (spatter)
and/or other debris
that may fly towards the inspection detector 5056 and/or the inspection camera
5112 during a
welding operation.
[00542] In one embodiment, the housings 5852, 5854 of the inspection detector
5056 and/or
the inspection camera 5112 may be made of polycarbonate material. In one
embodiment,
portions of the housings 5852, 5854 may be configured to be removable to
facilitate cleaning
(e.g., removal of the weld spatter or other weld debris therefrom) or repair.
In one
embodiment, the portions of the housings 5852, 5854 may include camera lens
shield or
inspection detector lens shield. In one embodiment, portions of the housings
5852, 5854 of
the inspection detector 5056 and/or the inspection camera 5112 may be
configured to be
disposable so that portions of the housings 5852, 5854 may be easily replaced
when they are
clogged with the weld spatter or other weld debris. For example, in one
embodiment, the
inspection camera 5112 may include a (rectangular) polycarbonate member in
front of its lens
that may be replaced when obstructed/blocked by the weld spatter or other weld
debris.
[00543] In one embodiment, the pre-weld inspection, the on-the-fly inspection
and the post-
weld inspection may be performed by the inspection detector 5056. In one
embodiment, the
pre-weld inspection, the on-the-fly inspection and the post-weld inspection
may be performed
by the inspection detector 5056 and the inspection camera 5112.
[00544] In one embodiment, the inspection detector 5056 includes an emitter
5180 for
emitting the beam of radiation, and a receiver 5182 for receiving inspection
signals from
reflected radiation. In one embodiment, the inspection detector 5056 transmits
radiation towards the interface region 5136. In one embodiment, the received
5182 of the
inspection detector 5136 is configured for receiving radiation reflected from
the surfaces of
the interface region 5136 and generating electronic signals based thereon. In
one embodiment,
the receiver or sensor 5182 of the inspection detector 5056 is configured to
sense the
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reflected signal to detect 3D topography of the weld joint/region. The
inspection detector
5056 may interchangeably be referred to herein as the inspection laser.
[00545] In one embodiment, the inspection detector 5136 includes a plurality
of inspection
detectors that transmit radiation towards the interface region 5136. In one
embodiment, each
inspection detector may include a receiver for receiving radiation reflected
from the surfaces
of the interface region 5136 and generating electronic signals based thereon.
[00546] In one embodiment, the inspection detector 5056 may include a Laser
Displacement Sensor. In one embodiment, the inspection detector 5056 may
include a
Complementary metal¨oxide¨semiconductor (CMOS) sensor. In one embodiment, the
inspection detector 5056 may include High Definition Ernostar type lens. In
one embodiment,
the one or more processors 5140 that are associated with the inspection
detector 5056 are
configured to use triangulation to detect the position of the reflected light
on the RS-CMOS
sensor.
[00547] In one embodiment, the inspection detector 5056 may receive its power
from the
wire feed electronics module 5046. In one embodiment, the wire feed
electronics module
5046 is configured to receive its power from the batteries 5116 in the drive
section 5010 via
the rear slip ring 5080. Thus, the inspection detector 5056 receives its power
from the
batteries 5116 in the drive section 5010 via the rear slip ring 5080 and the
wire feed
electronics module 5046. This may be the case when the cables, hoses, and/or
wires to the
reach rod/umbilical 5034 are disconnected from the system 5004, for example,
when the
system 5004 is traveling from one weld joint to the next weld joint.
[00548] In another embodiment, the inspection detector 5056 may receive its
power directly
from the umbilical/reach rod 5034. For example, when the cables, hoses, and/or
wires to the
reach rod/umbilical 5034 are connected from the system 5004, the inspection
detector 5056
may receive its power directly from the umbilical/reach rod 5034.
[00549] It should be appreciated that, in some embodiments, power to and
communication
from the inspection detector 5056 and/or camera 5112 may be desired. Such
power and/or
communication of the inspection detector 5056 and/or camera 5112 may take
place with
components, such as the one or more processors 5140 and/or a power source,
that are outside
of the pipe engagement structures (e.g., outside of the clamps 5142, 5144
and/or seals 5146,
5148). In some embodiments, where the power and/or communication takes place
through a
hardwired (as opposed to wireless) communication and/or power line, such
hardwired line
may take into account rotation by the rotatable hub 5078, for example, to
reduce or prevent
twisting and/or tangling of the hardwired line. As such, in one example as
described herein,
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the hardwired line (which can transmit information and/or power) can be
provided with (i) a
movable portion that moves with inspection detector 5056 while the inspection
detector 5056
directs the inspection beam along the interface region under the rotational
force of the one or
more orientation motors, and (ii) a stationary portion that remains fixed
during movement of
the movable portion. The stationary and rotational portions of the hardwired
line can be
connected via the described slip ring that provides the interface between the
movable and
fixed portions of the hardwired line to enable the signals to pass from the
movable portion to
the stationary portion. It should be appreciated that either a single
hardwired line (e.g., with
multiple, discreet wires) can be used, or a plurality of hardwired lines
(separate lines for
power and communication). In addition, if on-board power is provided to the
inspection
detector, then only a communication line may pass through the slip ring. If
wireless
communication with the inspection detector is provided, then only a power line
may pass
through the slip ring. If on-board power and wireless communication is
provided, then a
hardwired communication need not be provided.
[00550] Similarly to what has been described with respect to the hardwired
communication
line, it may also be desirable to provide the inert gas to an axial location
between the pipe
engagement structures (e.g., between clamps and/or seals) through a pneumatic
line or tube
for carrying pressurized inert gas. There may also be a desire to reduce
twisting and/or
tangling of the pneumatic line which might otherwise take place during
rotation of the
rotatable hub 5078. As such, the pneumatic line can be provided with the
stationary portion
connected with the inert gas source and the movable portion that extends into
the rotatable
hub , the movable portion being coupled to the stationary portion through the
rotary union.
The rotary union permits relative rotation between the stationary and movable
pneumatic
portions.
[00551] In one embodiment, the inspection detector 5056 may be operatively
associated
with the inspection motor to direct a beam of radiation along the interface
region 5136
between the pipes 1022a and 1022b. In one embodiment, the inspection detector
5056 and the
inspection motor may be operatively associated with one or more processors
5140. In one
embodiment, the first and second rotation motors 5030 and 5074 together may be
interchangeably referred to as the inspection motor.
[00552] In one embodiment, the inspection detector 5056 is configured to
detect a
characteristic of the interface region 5136 between the pipes 1022a, 1022b. In
one
embodiment, the characteristic of the interface region 5136 may include a gap
between the
pipes 1022a, 1022b. In one embodiment, the characteristic of the interface
region 5136 may
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include a radial offset (e.g., high/low) between the pipes 1022a, 1022b. In
one embodiment,
the characteristic of the interface region 5136 may include geometry at each
weld location. In
one embodiment, the characteristic of the interface region 5136 may include
chips, gauges, or
any irregularities in the pipes 1022a, 1022b. In one embodiment, the
characteristic of the
interface region 5136 may include roundness of the pipes 1022a, 1022b. In one
embodiment,
the characteristic of the interface region 5136 may include contours of bevels
of the pipes
1022a, 1022b (after pipe alignment). In one embodiment, the characteristic of
the interface
region 5136 may include various color regions of the metal of the weld
joint/region. For
example, these color regions are analyzed to determine what temperatures the
different
regions of the weld joint/region have reached.
[00553] In one embodiment, the inspection detector 5056 may be configured to
detect the
characteristic of the interface region 5136 between the pipes 1022a, 1022b,
for example,
before the weld torch 5502 has been activated to commence securing/welding the
pipes
1022a, 1022b to one another. For example, the characteristic of the interface
region 5136 may
include a pipe bevel geometry, a gap between internal adjoining ends of the
pipes 1022a,
1022b (after pipe alignment), a gap between bevels of the pipes 1022a, 1022b
(after pipe
alignment), etc. In one embodiment, the inspection detector 5056 may be
configured to detect
the characteristic of the interface region 5136 between the pipes 1022a,
1022b, for example,
1022b during a welding operation, at a region of the interface prior to weld
material being
deposited thereon. For example, the characteristic of the interface region
5136 may include a
height difference between the bevel edges of the pipes after their alignment.
In one
embodiment, the characteristic of the interface region 5136 may include high-
low differences
between the adjacent edges of the pipes (e.g., at the interior beveled
portions thereof). In one
embodiment, the inspection detector 5056 may be configured to detect the
characteristic of
the interface region 5136 between the pipes 1022a, 1022b, for example,
subsequent to a
welding operation. For example, the characteristic of the interface region
5136 may include a
characteristic of the formed weld beads, weld shape parameters such as
mismatch, bead
concavity, the re-entrant angle.
[00554] In one embodiment, the one or more processors 5140 are configured to
operate the
inspection detector 5056 and the motor 5030, 5074 to scan the interface region
5136 between
the pipes 1022a, 1022b.
[00555] In one embodiment, the one or more processors 5140 are configured to
interact
with the inspection detector 5056 to scan the interface region 5136 between
the pipes 1022a
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and 1022b to determine a profile of the interface region 5136 between the
pipes 1022a and
1022b prior to a welding procedure and generate pre-weld profile data based
thereon.
[00556] The term "profile" as used herein is a generic term in referring to
physical attributes
of the interface region to be welded between the pipes. The term "profile
data" refers to data,
corresponding to the profile, that can be derived from the interface region.
For example, such
data can be obtained by scanning the interface region with an inspection
detector, such as a
laser. The profile data can contain numerous types of information about the
profile, such
different types of information are referred to herein as "characteristics."
[00557] In one embodiment, the one or more processors 5140 are configured to
interact
with the inspection detector 5056 to scan the interface region 5136 between
the pipes 1022a,
1022b to determine the profile of the interface region 5136 between the pipes
1022a and
1022b during a welding procedure, at a region of the interface 5136 prior to
weld material
being deposited thereon, and generate on-the-fly profile data. In one
embodiment, the one or
more processors 5140 are configured to generate weld signals to control the
weld torch 5502
based on the on-the-fly profile data. The on-the-fly profile data is described
in detail below.
The term "on-the-fly" as used herein also means or refers to "real-time,"
meaning that the
sensing or detection is used by the one or more processors during a current
welding operation
to control the welder. Of course, because the inspection detector, weld torch
trails the
inspection detector/inspection laser be a defined amount, some buffering (or
slight time delay)
takes place between the receipt of the profile data, and the use of such by
the one or more
processors to control the weld torch.
[00558] In one embodiment, the one or more processors 5140 are configured to
interact
with the inspection detector 5056 to scan the interface region 5136 between
the pipes 1022a,
1022b to determine the profile of the interface region 5136 between the pipes
1022a and
1022b subsequent to a welding procedure and generate post-weld profile data
based thereon.
The post-weld profile data is described in detail below.
[00559] In one embodiment, the inspection detector 5056 is configured to work
in
conjunction with the weld torch 5502 of the weld system 5004 to sense
interface joint profile
or/and weld material profile to apply weld material to the edge joint in the
appropriate
location and amount. In one embodiment, the inspection detector 5056 is
configured to
survey the weld and send a signal to the one or more processors 5140 of the
articulating weld
head 5502 to control movement of the weld head 5502 around the entire edge
joint.
Specifically, the weld torch 5502 is configured to follow the inspection
detector as the weld
head control system continuously receives weld profile information from the
edge joint. The
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information is then used to continuously adjust the weld torch 5502 to achieve
the desired
weld structure/profile.
[00560] In one embodiment, the internal weld system 5004 may include one
inspection
detector per weld torch 5502. In one embodiment, the internal weld system 5004
includes
three weld torches 5502 and three associated inspection detectors 5056. In
another
embodiment, the internal weld system 5004 may include two inspection detectors
per weld
torch 5502. In one embodiment, the number of inspection detectors used in the
internal weld
system 5004 may vary.
[00561] In one embodiment, the field system 5000 of the present patent
application is an
intelligent internal inspection system that places the internal automation,
including the
inspection camera 5112, the inspection detector 5056, and the weld head or
torch 5502
between the spaced clamps 5142, 5144 and the sealed structure 5146, 5148. In
one
embodiment, the field system 5000 of the present patent application is an
intelligent internal
inspection system that places the inspection camera 5112 and the inspection
detector 5056
between the spaced clamps 5142, 5144 and the sealed structure 5146, 5148. In
one
embodiment, the field system 5000 of the present patent application is an
intelligent internal
inspection system that places the internal automation, including the
inspection camera 5112,
the inspection detector 5056, and the weld head or torch 5502 between the
spaced clamps
5142, 5144.
[00562] In one embodiment, the weld system is attached to the rear of the line-
up clamp,
becoming an inline analytical tool that minimizes the downtime associated with
using a third-
party tool. In one embodiment, both the inspection camera 5112 and the
inspection detector
5056 are used for inspecting the weld. In one embodiment, the inspection
camera 5112 is
configured to capture a two-dimensional image of the weld and analyze the
color of the weld.
Since the color of the weld is indicative of what temperature the material was
raised to during
the welding procedure, the information obtained by the inspection camera 5112
helps
determine whether the weld was done correctly. In one embodiment, the
inspection detector
5056 is configured to analyze the profile of the weld. In one embodiment, the
inspection
detector 5056 in conjunction with the two-dimensional (2D) charge-coupled
device (CCD)
color camera 5112 is configured to perform a root inspection directly after
the root and hot
pass weld procedures. In one embodiment, the weld system 5004 is configured to
provide the
root pass weld layer profile and the 2D raw color image that show the
discoloration and any
geometrical defects of the root pass weld layer. In one embodiment, the weld
system 5004 is
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configured to create a permanent record of the root pass weld layer profile
and visual image
that can be stored and replayed in the user's electronic device (e.g.,
laptop).
[00563] In one embodiment, the inspection performed by the inspection detector
5056 in
conjunction with the color camera 5112 may be used as a reference for the AUT
weld
inspection. In one embodiment, the inspection performed by the inspection
detector 5056 in
conjunction with the color camera 5112 may be used as a "go, no-go" (pass/fail
test (or
check)) for the root and hot pass welds. In one embodiment, if a root defect
is found, the weld
joint can be cut and prepped in the same station, far before the defect
callout would happen
after all the passes had been deposited, so a significant waste of production
time can be
avoided.
[00564] In one embodiment, the internal weld system 5004 includes a feedback
system that
is configured to be operatively connected to a plurality of sensors and the
one or more
processors 5140. In one embodiment, the one or more processors 5140 are
configured to
analyze the data provided by the plurality of sensors. In one embodiment, one
of the plurality
of sensors include a temperature sensor that is configured to provide an
indication of the
temperature(s) of the weld joint and/or monitor the temperature during the
welding procedure.
In one embodiment, one of the plurality of sensors includes a weld material
sensor that is
configured to monitor the weld material usage during the welding procedure. In
one
embodiment, one of the plurality of sensors may include sensors that are
configured to
monitor speed and time of the welding procedure.
[00565] FIG. 41 shows a front perspective view of the weld head assembly 5500,
while
FIGS 42 and 43 show rear perspective view of the weld head assembly 5500.
FIGS. 44-46
show a left side perspective view, a right side perspective view and a cross-
sectional view of
the weld head assembly 5500, where some components of the weld head assembly
5500 are
not shown for sake of clarity.
[00566] In one embodiment, in the illustrated embodiment, the center section
5008 may
have three weld torches 5502. In another embodiment, the center section 5008
may have two
weld torches 5502. In yet another embodiment, the center section 5008 may have
only one
weld torch 5502. In one embodiment, the number of weld torches may vary.
[00567] In one embodiment, the weld head assembly 5500 includes the weld torch
5502 and
a weld torch housing assembly 5504. In one embodiment, the weld torch 5502
includes a
weld tip 5503. In one embodiment, the weld head assembly 5500 (the weld torch
5502 and
the weld torch housing assembly 5504) is carried by the frame or frame
assembly of the
internal weld system 5004.
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[00568] In one embodiment, the weld torch 5502 is constructed and arranged to
feed or
guide a consumable electrode wire 5507 into the weld area/zone. The consumable
electrode
wire 5507 is supplied from a source (e.g., a wire reel or spool) through the
wire feed system
5044. In one embodiment, the weld torch 5502 is constructed and arranged to be
connected to
a power supply (e.g., a constant voltage power supply). In one embodiment, an
electric arc
forms between a consumable electrode wire 5507 and the pipes 1022a, 1022b,
which heats
the pipes 1022a, 1022b, causing them to melt, and join. In one embodiment,
along with the
consumable electrode wire 5507, a shield gas is fed through the weld torch
5502, which
shields the weld procedure from contaminants in the air. In one embodiment,
the shield gas is
fed to the weld area/zone through the weld torch nozzle that may include a gas
cup 5505. In
one embodiment, the electrode 5507 may extend beyond the end of the gas cup
5505.
[00569] In one embodiment, the shield gas stored in the drive section 5010 is
brought to the
wire feed assembly 5020 by a hose/shield gas line for distribution to the one
or more weld
torches 5502. In one embodiment, the shield gas control valve 5042 is
configured to receive
the shield gas from the rear rotary union 5072 (e.g., via the rear slip ring
5080, the rotatable
hub 5078 and the front slip ring 5016). In one embodiment, the shield gas
control valve 5042
is configured to control the flow of the shield gas to the weld torch 5502
through a shield gas
line. In one embodiment, each weld torch 5502 has a corresponding shield gas
control valve
5042 connected to it. In one embodiment, the shield gas control valve 5042 is
configured to
supply the shield gas to the corresponding weld torch 5502, when it receives
signals from the
wire feed electronics module 5046.
[00570] In one embodiment, the weld torch 5502 is configured to be carried by
the frame
assembly of the internal weld system 5004 and configured to create a weld at
the end of the
second end of the first pipe 1022a. In one embodiment, the weld torch 5502 is
configured to
be positioned internally within to the first pipe 1022a and/or second pipe
1022b to provide an
internal welding operation. In one embodiment, the internally positioned weld
torch 5502 is
mounted to (positioned on) and connected to the rotatable hub 5078.
[00571] In one embodiment, the weld torch 5502 may have at least three degrees
of
freedom. In one embodiment, the degrees of freedom of articulation allow the
weld torch
5502 to be very effective and efficient in filling in interface profiles
optimally and where
necessary.
[00572] The degree of freedom generally refers to the freedom of movement of
the weld
torch 5502 in the three-dimensional space. The translational movement or
displacement
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generally refers to linear movement or displacement along the three mutually
perpendicular X,
Y and Z axes.
[00573] In one embodiment, the term position as used herein generally refers
to the
translational movement or displacement. In one embodiment, position may be
relative or
absolute.
[00574] In one embodiment, the coordinate system may include: a Y axis, which
is aligned
substantially parallel to the longitudinal axis A-A (as shown in FIG. 8) of
the pipes 1022a,
1022b; a X axis, which is perpendicular to the Y axis; and a Z axis, which is
perpendicular to
the Y axis and is aligned substantially parallel to a radial axis R-R (as
shown in FIG. 8) of the
pipes 1022a, 1022b. For example, the translational movement along the X axis
generally
refers to a forward and backward movement. The translational movement along
the Y axis
generally refers to a left to right side movement. The translational movement
along the Z axis
generally refers to an up and down movement.
[00575] The rotational movement or displacement generally refers to rotation
about these
same three mutually perpendicular X, Y and Z axes. The rotation about the
three mutually
perpendicular X, Y and Z axes is generally referred to as yaw (Z-axis), pitch
(Y-axis) and roll
(X-axis). For example, the rotational movement about the X axis generally
refers to a left or
right side tilting movement. The rotational movement about the Y axis
generally refers to a
forward or (rearward) backward tilting movement. The rotational movement about
the Z axis
generally refers to a left or right turning movement.
[00576] In one embodiment, the term orientation as used herein generally
refers to the
rotational movement or displacement. In one embodiment, orientation may be
relative or
absolute.
[00577] In one embodiment, the at least three degrees of freedom may include
two
translational movements of the weld torch 5502 along two of the three mutually
perpendicular X, Y and Z axes and one rotational movement of the weld torch
5502 about
one of the same three mutually perpendicular X, Y and Z axes.
[00578] In one embodiment, the two translational movements of the weld torch
5502 along
two of the three mutually perpendicular X, Y and Z axes may include an up and
down
movement of the weld torch 5502 and a side to side (e.g., left to right)
movement of the weld
torch 5502. In one embodiment, the up and down movement of the weld torch 5502
may be
referred to as a radial movement (i.e., substantially parallel to the radial
axis R-R of the pipes
1022a, 1022b) of the weld torch 5502, and the side to side (left to right)
movement of the
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weld torch 5502 may be referred to as an axial movement (i.e., substantially
parallel to the
longitudinal axis A-A of the pipes 1022a, 1022b) of the weld torch 5502.
[00579] In one embodiment, the one rotational movement of the weld torch 5502
about one
of the same three mutually perpendicular X, Y and Z axes may include a forward
or
(rearward) backward tilting movement of the weld torch 5502.
[00580] In one embodiment, the weld torch 5502 is mounted for movement about a
pivot
point P (as shown in the FIGS. 54, 56 and 58) at or adjacent to the weld tip
5503 of the weld
torch 5502 such that a weld pool created at the weld tip 5503 generally
coincides with the
pivot point P. In one embodiment, the pivot point P is positioned forwardly of
the weld tip
5503. For example, in one embodiment, the weld torch 5502 has been designed to
pivot about
the pivot point P (as shown in the FIGS. 54, 56 and 58) where the electrode
wire 5507 makes
contact with the pipe 1022a, 1022b. In one embodiment, the weld torch 5502 is
mounted for
movement such that it articulates about an axis that is proximate to the weld
torch tip 5503. In
one embodiment, the axis passes through the pivot point P and is substantially
parallel to the
longitudinal axis A-A of the pipes 1022a, 1022b.
[00581] In one embodiment, the weld torch 5502 is operatively connected to one
or more
weld torch motors 5596. In one embodiment, the one or more weld torch motors
5596 and the
weld torch 5502 are configured to be positioned within an interior of the
first and/or second
pipes 1022a, 1022b. In one embodiment, one or more weld torch motors 5596 are
configured
to move the weld torch 5502 relative to the first and second pipe engagement
structures 5052,
5054 after they are fixed relative to the first pipe and second pipe 1022a,
1022b respectively.
[00582] In one embodiment, the one or more processors 5140 are configured to
control the
one or more weld torch motors 5596 to control a position and orientation of
the weld torch
5502. For example, as will be described in detail below, the one or more weld
torch motors
5596 may include the radial weld torch motor 5512 that is configured to
control the radial
position and orientation of the weld torch 5502, the axial weld torch motor
5550 that is
configured to control the axial position and orientation of the weld torch
5502 and the tilt
weld torch motor 5588 that is configured to control the tilt position and
orientation of the
weld torch 5502.
[00583] In one embodiment, the motors 5030 and 5074 are configured for moving
the weld
torch 5502 circumferentially about the interface region 5136 and also to move
the inspection
detector 5056 about the interface region 5136 simultaneously with the weld
torch 5502. In
one embodiment, the weld torch 5502 is trailing the inspection detector 5056.
In one
embodiment, the front and rear rotation motors 5030 and 5074 are configured to
rotate the
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rotatable hub 5078 and to rotate the weld torches 5502, the inspection
detector 5056 and the
inspection camera 5112 all positioned on and connected to the rotatable hub
5078. In one
embodiment, the front and rear rotation motors 5030 and 5074 may be
interchangeably
referred to as the circumferential weld torch motors.
[00584] In one embodiment, the one or more processors 5140 are operatively
connected
with the one or more orientation motors 5030 and 5074 to rotate the first
clamp 5142 relative
to the second clamp 5144, so as to rotate the first pipe 1022a relative to the
second pipe
1022b, based on the instructions from the one or more processors 5140.
[00585] In one embodiment, the motors 5030 and 5074 are configured to move the
weld
torch 5502 circumferentially about the interface region 5136 and are also
configured to move
the inspection camera 5112 about the interface region 5136 simultaneously with
the weld
torch 5502. In one embodiment, the weld torch 5502 is trailing the inspection
camera 5112.
In one embodiment, the inspection camera 5112 is trailing the weld torch 5502.
[00586] In one embodiment, the motors 5030 and 5074 are configured to move the
weld
torch 5502 circumferentially about the interface region 5136 and are also
configured to move
both the inspection camera 5112 and the inspection detector 5056 about the
interface region
5136 simultaneously with the weld torch 5502. In one embodiment, the weld
torch 5502 is
trailing both the inspection detector 5056 and the inspection camera 5112. In
one
embodiment, the weld torch 5502 is trailing the inspection detector 5056 and
is leading the
inspection camera 5112.
[00587] In one embodiment, the motors 5030 and 5074 are configured to drive
the weld
torch 5502 in a first rotational direction during the root pass weld and to
drive the weld torch
5502 in a second direction, opposite the first direction, during the hot pass
weld.
[00588] In one embodiment, the motors 5030 and 5074 are configured to drive
the weld
torch 5502 at least 360 relative to the pipe axis A-A (as shown in FIG. 8) so
as to complete a
rotationally continuous root pass weld. In one embodiment, 3600 rotation of
the weld torch
5502 relative to the pipe axis A-A (around the interior surface of the pipe)
is possible because
the weld torch 5502 is mounted on the rotatable hub 5078 (i.e., configured to
be axial
rotation).
[00589] In one embodiment, one or more weld torch motors 5596 are configured
to move
the weld torch 5502 longitudinally (as shown in FIGS. 48 and 49) within the
pipes 1022a,
1022b, toward and away from the inner surface 5130, 5132 (as shown in FIG. 33)
of the pipes
1022a, 1022b. In one embodiment, one or more weld torch motors 5596 are
configured to
move the weld torch 5502 angularly relative to the weld (as shown in FIGS. 56
and 58). In
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one embodiment, the motors 5030 and 5074 are configured to move the weld torch
5502
circumferentially along the interface region 5136.
[00590] In one embodiment, the weld head assembly 5500 includes a radial
positioning
system 5506 that is configured to enable the radial movement of the weld torch
5502, an axial
positioning system 5508 that is configured to enable the axial movement of the
weld torch
5502. and a tilt positioning system 5510 that is configured to enable the tilt
movement of the
weld torch 5502.
[00591] In one embodiment, the torch housing assembly 5504 is constructed and
arranged
to enclose the weld torch 5502, the radial positioning system 5506, the axial
positioning
system 5508 and the tilt positioning system 5510 therein. In one embodiment,
the torch
housing assembly 5504 is configured to protect the components of the weld
torch 5502 and
various components of its positioning systems 5506, 5508, and 5510 from the
welding heat
and spatter.
[00592] In one embodiment, the torch housing assembly 5504 may include a base
member
5509 and two side housing members 5511 and 5513. For example, the base member
5509
may be connected to the side housing members 5511 and 5513 using any suitable
fastening
mechanism (e.g., fastener members 5527). In one embodiment, the torch housing
assembly
5504 may include a first transverse housing member 5522 and an opposing,
second transverse
housing member 5523 that are constructed and arranged to connect the side
housing members
5511 and 5513 to each other at their top end portions. For example, the first
and second
transverse housing members 5522, 5523 may be connected to the side housing
members 5511
and 5513 using any suitable fastening mechanism (e.g., fastener members 5525).
[00593] In one embodiment, referring to FIGS. 41-46, the weld torch 5502 is
mounted for
movement, by the radial positioning system 5506, such that the weld tip 5503
is configured to
move towards and away from the weld surface 5130, 5132 of the pipes 1022a,
1022b. In one
embodiment, the one or more processors 5140 are configured to control the one
or more weld
torch motors 5512 to adjust a radial distance of the weld tip 5503 from within
the pipes 1022a,
1022b to the interface region 5136.
[00594] In one embodiment, the one or more processors 5140 are configured to
control the
one or more weld torch motors 5512 to move the weld tip 5503 radially away
from the
interface region 5136 after the root pass weld so as to accommodate the weld
material
deposited in the root pass weld and provide a hot pass weld on top of the root
pass weld from
within the pipes 1022a, 1022b (closer to the longitudinal axis A-A).
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[00595] In one embodiment, the one or more processors 5140 that are configured
to control
the one or more weld torch motors may be part of the wire feed electronics
module 5046.
[00596] In one embodiment, the radial positioning system 5506 is configured to
enable the
weld torch 5502 to move radially to track variations in the pipe shape, to
adjust the weld tip-
to-work piece (e.g., pipe) distance for multiple passes (e.g., root and hot
pass weld
procedures), and to retract away from the pipes 1022a, 1022b when the internal
weld system
is travelling.
[00597] In one embodiment, the radial positioning system 5506 is configured to
provide the
weld torch 5502 with a 1.25 inch radial travel. In one embodiment, the weld
torch 5502 is
moveable by the radial positioning system 5506 between a normal, non-raised
configuration
and a raised configuration. As shown in FIG. 43, the weld torch 5502 has been
raised (to its
raised configuration) by the radial positioning system 5506 so that the weld
torch 5502 is
positioned at the correct/desired/predetermined distance from the pipes 1022a,
1022b for the
welding procedure.
[00598] In one embodiment, the radial positioning system 5506 may include a
linear
actuator. In one embodiment, the radial positioning system 5506 may include
the radial weld
torch (electric) motor 5512, a lead screw 5514, and a lead nut 5516. In one
embodiment, the
motor 5512 is configured (e.g., mechanically connected) to rotate the lead
screw 5514. In one
embodiment, the motor 5512 is configured to rotate either clockwise or counter
clockwise
direction so as to cause the raising or lowering of the weld torch 5502
substantially parallel to
the radial axis R-R (as shown in FIG. 8) of the pipes 1022a, 1022b. In one
embodiment, the
motor 5512 is configured to be directly connected to rotate the lead screw
5514. In another
embodiment, the motor 5512 is configured to be indirectly connected, e.g.,
through a series of
gears or a gearbox, to rotate the lead screw 5514.
[00599] In one embodiment, the lead screw 5514 includes threads machined on
its outer
surface and extending along its length. In one embodiment, the lead nut 5516
is constructed
and arranged to be threaded onto the lead screw 5514 and includes
complimentary threads
machined on its inner surface.
[00600] In one embodiment, the radial positioning system 5506 includes two
front vertical
guide rod members 5518 and 5520 that are positioned parallel to and on both
sides of the lead
screw 5514. In one embodiment, the front vertical guide rod members 5518 and
5520 are
each connected to the base member 5509 of the torch housing assembly 5504 on
one end
thereof and connected to the first transverse housing member 5522 on the other
end thereof.
In one embodiment, the end portions of the front vertical guide rod members
5518 and 5520
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are received in openings formed in the base member 5509 of the torch housing
assembly
5504 to connect the front vertical guide rod members 5518 and 5520 to the base
member
5509 of the torch housing assembly 5504. In one embodiment, the end portions
of the front
vertical guide rod members 5518 and 5520 are received in openings formed in
the first
transverse housing member 5522 to connect the front vertical guide rod members
5518 and
5520 to the first transverse housing member 5522.
[00601] In one embodiment, an end portion of the lead screw 5514 (that is
opposite to its
end portion connected to the motor 5512) is constructed and arranged to pass
through an
opening 5534 in the first transverse housing member 5522.
[00602] In one embodiment, the radial positioning system 5506 includes two
rear vertical
guide rod members 5600 and 5602 that are positioned parallel to the lead screw
5514 and the
two front vertical guide rod members 5518 and 5520. In one embodiment, the
rear vertical
guide rod members 5600 and 5602 are each connected to the base member 5509 of
the torch
housing assembly 5504 on one end thereof and connected to the second
transverse housing
member 5523 on the other end thereof. In one embodiment, the end portions of
the rear
vertical guide rod members 5600 and 5602 are received in openings formed in
the base
member 5509 of the torch housing assembly 5504 to connect the rear vertical
guide rod
members 5600 and 5602 to the base member 5509 of the torch housing assembly
5504. In
one embodiment, the end portions of the rear vertical guide rod members 5600
and 5602 are
received in openings formed in the second transverse housing member 5523 to
connect the
rear vertical guide rod members 5600 and 5602 to the second transverse housing
member
5523.
[00603] In one embodiment, the radial positioning system 5506 also includes a
transverse
radial positioning member 5524 and two vertical radial positioning members
5526. In one
embodiment, the two vertical radial positioning members 5526 are connected to
both end
portions of the transverse radial positioning member 5524. In one embodiment,
the transverse
radial positioning member 5524 and the two vertical radial positioning members
5526 of the
radial positioning system 5506 are configured to be movable during the radial
movement of
the weld torch 5502.
[00604] In one embodiment, the transverse radial positioning member 5524 may
have
protruding end portions 5528 that are configured to engage with notches or
protruding end
portions receiving openings 5530 of the two vertical radial positioning
members 5526. In one
embodiment, after the protruding end portions 5528 of the transverse radial
positioning
member 5524 are received in the notches or protruding end portions receiving
openings 5530
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of the two vertical radial positioning members 5526, the transverse radial
positioning member
5524 and the two vertical radial positioning members 5526 may then be securely
connected
to each other using any suitable fastening mechanism (e.g., fastener members
5532).
[00605] In one embodiment, the transverse radial positioning member 5524
includes
openings to receive the front vertical guide rod members 5518 and 5520
threrethrough. This
configuration enables the transverse radial positioning member 5524 to be
slidable to
adjusted positions on the front vertical guide rod members 5518 and 5520. In
one
embodiment, the lead screw 5514 is configured to pass through a central
opening 5536 of the
transverse radial positioning member 5524.
[00606] In one embodiment, the radial positioning system 5506 also includes
two rear radial
positioning members 5604 and 5606. In one embodiment, the two vertical radial
positioning
members 5526 are connected to the two rear radial positioning members 5604 and
5606. In
one embodiment, the two rear radial positioning members 5604 and 5606 and the
two vertical
radial positioning members 5526 of the radial positioning system 5506 are
configured to be
movable during the radial movement of the weld torch 5502.
[00607] In one embodiment, each rear radial positioning members 5604 and 5606
have end
portions that are configured to engage with end portions of its corresponding
vertical radial
positioning member 5526. In one embodiment, after the end portions of the rear
radial
positioning members 5604 and 5606 are engaged with end portions of the two
vertical radial
positioning members 5526, each rear radial positioning member 5604 and 5606
may then be
securely connected to its corresponding vertical radial positioning member
5526 using any
suitable fastening mechanism (e.g., fastener members 5608).
[00608] In one embodiment, the rear radial positioning members 5604 and 5606
include
openings to receive the rear vertical guide rod members 5600 and 5602,
respectively
threrethrough. This configuration enables the rear radial positioning members
5604 and 5606
to be slidable to adjusted positions on the rear vertical guide rod members
5600 and 5602.
[00609] In one embodiment, the lead nut 5516 is configured to interlock with a
portion of
the transverse radial positioning member 5524 so that the rotation of the lead
nut 5516 is
prevented along with the lead screw 5514. That is, the lead nut 5516 is
restrained from
rotating along with the lead screw 5514, therefore the lead nut 5516 is
configured to travel up
and down the lead screw 5514. In one embodiment, the lead nut 5516 is
interlocked and
positioned in the central opening 5536 of the transverse radial positioning
member 5524. In
one embodiment, the lead screw 5514 is configured to pass through an opening
of the
interlocked lead nut 5516.
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[00610] In one embodiment, the two vertical radial positioning members 5526
are
connected to each other using a front and a rear transverse support members
5610 and 5612.
For example, the front transverse support member 5610 is constructed and
arranged to be
connected to the front, and bottom portions of the two vertical radial
positioning members
5526 using any suitable fastening mechanism (e.g., fastener members 5614). The
rear
transverse support member 5612 is constructed and arranged to be connected to
the rear and
bottom portions of the two vertical radial positioning members 5526 using any
suitable
fastening mechanism (e.g., fastener members 5616).
[00611] In one embodiment, the weld assembly 5500 also includes two vertical
positioning
members 5538 and a top positioning member 5540. In one embodiment, the two
vertical
positioning members 5538 are each connected to end portions of the top
positioning member
5540. In one embodiment, the end portions of the top positioning member 5540
each may
have a L-shaped configuration. In one embodiment, corresponding connection
portions of the
two vertical positioning members 5538 may include complementary shaped
configurations
that are configured to engage with the L-shaped configurations of the end
portions of the top
positioning member 5540. In one embodiment, after the L-shaped configurations
of the end
portions of the top positioning member 5540 are engaged with the complementary
shaped
configurations of corresponding connection portions of the two vertical
positioning members
5538, the top positioning member 5540 and the two vertical positioning members
5538 may
then be securely connected to each other using any suitable fastening
mechanism (e.g.,
fastener members 5542).
[00612] In one embodiment, the axial positioning system 5508 is configured to
enable the
weld torch 5502 to move axially to keep the weld torch 5502 in the weld bevel
as the weld
torch 5502 travels around the pipe and to allow the weld torch 5502 to
oscillate within the
weld bevel if needed to completely fill the bevel.
[00613] FIG. 47 shows the weld torch 5502 positioned in a normal, centered
axial position.
In one embodiment, the axial positioning system 5508 is configured to provide
the weld torch
5502 with a +/- 1 inch axial travel. For example, as shown in FIGS. 48 and 49,
the weld torch
5502 has been moved by the axial positioning system 5508 to +1 inch of axial
travel and -1
inch of axial travel, respectively so that the weld torch 5502 is positioned
at the
correct/desired/predetermined distance from the pipe for welding.
[00614] FIGS. 50 and 51 show a left side perspective view and an exploded view
of the
weld head assembly 5500, where some components of the weld head assembly 5500
are not
shown for sake of clarity. FIG. 52 shows a bottom perspective view of the top
positioning
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member 5540 of the weld head assembly. FIG. 53 shows a top elevational view of
the weld
head assembly 5500, where some components of the weld head assembly 5500 are
not shown
for sake of clarity.
[00615] In one embodiment, referring to FIGS. 50-53, the axial positioning
system 5508
may be a linear actuator. In one embodiment, the axial positioning system 5508
may include
the axial weld torch (electric) motor 5550, a lead screw 5552, and a lead nut
5554. In one
embodiment, the structure, the configuration and the operation of each of the
motor 5550, the
lead screw 5552 and the lead nut 5554 of the axial positioning system 5508 is
similar to the
motor 5512, the lead screw 5514 and the lead nut 5516 of the radial
positioning system 5506
and, hence, will not be described in great detail here. In one embodiment,
when the lead
screw 5552 is rotated by the motor 5550, the lead nut 5554 is driven along the
threads.
[00616] In one embodiment, the axial positioning system 5508 includes two
horizontal
guide rod members 5556 and 5558 that are positioned parallel to and on both
sides of the
horizontally positioned lead screw 5552. In one embodiment, each of the
horizontal guide rod
members 5556 and 5558 are connected to the top positioning member 5540 at both
of their
ends. In one embodiment, the end portions of the horizontal guide rod members
5556 and
5558 are received in openings formed in the top positioning member 5540 to
connect the
horizontal guide rod members 5556 and 5558 with the top positioning member
5540. In one
embodiment, at least one end portion of each of the horizontal guide rod
members 5556 and
5558 includes a protruding member 5560 that is configured to be received in a
corresponding
protruding member receiving portion 5562 formed in the opening of the top
positioning
member 5540 to secure the horizontal guide rod members 5556 and 5558 with the
top
positioning member 5540.
[00617] In one embodiment, the weld head assembly 5500 includes a weld torch
frame
5564 that is configured to receive the weld torch 5502 therein. In one
embodiment, the weld
torch frame 5564 includes three horizontally extending openings 5566, 5568,
and 5570 and a
vertically extending opening 5572 formed therein. In one embodiment, the
horizontal guide
rod members 5556 and 5558 are configured to pass through the openings 5566 and
5570 of
the weld torch frame 5564, respectively. In one embodiment, the horizontally
positioned lead
screw 5552 is configured to pass through the opening 5568 of the weld torch
frame 5564. In
one embodiment, the weld torch 5502 is configured to pass through the opening
5572 of the
weld torch frame 5564. In one embodiment, the weld torch frame 5564 may
include a support
portion 5574 that is configured to support portions of the weld torch 5502,
when the weld
torch 5502 is received in the opening 5572 of the weld torch frame 5564.
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[00618] In one embodiment, a portion 5584 of the weld torch frame 5564 is
configured to
engage with a portion 5586 of the weld torch 5502 so as to prevent any
rotation of the weld
torch 5502, when the weld torch 5502 is received in the opening 5572 of the
weld torch frame
5564.
[00619] In one embodiment, the motor 5550 is configured (e.g., mechanically
connected) to
rotate the lead screw 5552. In one embodiment, the motor 5512 is configured to
rotate either
clockwise or counter clockwise direction so as to cause the left or right side
movement of
weld torch 5502 substantially parallel to the axial axis A-A (as shown in FIG.
8) of the pipes
1022a, 1022b. In one embodiment, the motor 5550 is configured to be indirectly
connected,
e.g., through a series of gears 5576, 5578, and 5580, to rotate the lead screw
5552. That is,
the motor 5550 comprises an output shaft 5582 and the motor 5550 is operably
connected to
the lead screw 5552 through the gears 5576, 5578, and 5580 engaging the output
shaft 5582
of the motor 5550. In one embodiment, the gear 5576 is connected to the output
shaft 5582 of
the motor 5550, the gear 5580 is connected or attached to the lead screw 5552,
and the gears
5576 and 5580 are coupled to each other via the gear 5578. By connecting the
motor 5550 to
the lead screw 5552 through the gears 5576, 5578, and 5580, the lead screw
5552 turns when
the motor 5550 operates. In another embodiment, the motor 5550 is configured
to be directly
connected (i.e., without the gear arrangement) to rotate the lead screw 5552.
[00620] In one embodiment, the lead nut 5554 is configured to interlock with a
portion of
the weld torch frame 5564 so that the lead nut 5554 is prevented from rotation
along with the
lead screw 5552. That is, the lead nut 5554 is restrained from rotating along
with the lead
screw 5552, therefore the lead nut 5554 is configured to travel/move side to
side (i.e.,
substantially parallel to the axial direction Y-Y as shown in FIG. 53) with
the lead screw
5552. In one embodiment, the lead nut 5554 is interlocked and positioned in
the opening
5568 of the weld torch frame 5564. In one embodiment, the lead screw 5552 is
configured to
pass through an opening of the interlocked lead nut 5554.
[00621] In one embodiment, the tilt positioning system 5510 is configured to
enable the
weld torch 5502 to change its tilt angle in the plane of travel to account for
changes in the
direction of welding relative to the direction of gravity. In one embodiment,
the tilt angle of
the weld torch 5502 may be changed to accommodate the force of gravity. In one
embodiment, the tilt angle of the weld torch 5502 may be adjusted to
compensate for
different orientation due to gravity. In one embodiment, the angular
orientation of the weld
torch 5502 is controlled based upon the profile of the interface region. In
one embodiment,
the tilt angle of the weld torch 5502 may be adjusted based on the on-the-fly
weld profile data.
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In one embodiment, the tilt angle of the weld torch 5502 may be adjusted based
on the on-
the-fly weld profile data to accommodate and/or compensate for other weld
conditions (i.e.,
not just the force of gravity).
[00622] Because the weld torch is able to articulate during the weld
operation, it is able to
take into account gravitational forces acting on the weld pool, as the weld
torch rotates about
the fixed pipe. Specifically, the angle of the weld torch can change by being
operated by the
at least one weld torch motor (i.e., the tilt weld torch motor 5588), based
upon whether the
weld is torch it traveling upwardly against the force of gravity, or
downwardly with the force
of gravity. The one or more motors (e.g., tilt weld torch motor 5588) can also
change the
weld angle within to rotational plane based up the specific location within
the upwards or
downwards travel of the weld torch. It should be appreciated that because the
weld torch can
be articulated for some embodiments, it can be better angled to accommodate
the force of
gravity, and need not be set in a fixed position under the assumption, for
example, that it
would only be traveling downwardly, with the force of gravity. In some
embodiments, as
noted above, the present application contemplates that welding can be
accomplished while
the weld torch is moving upwardly (against the force of gravity) or downwardly
(with the
force of gravity). In addition, the weld torch can be articulated based on the
different
rotational position (e.g., a welding operation conducted at 10 degrees from
top dead center
may ideally slightly different requirements than a weld conducted at 90
degrees from top
dead center, due to (for example) gravitational forces applied to the weld
pool, as well as the
tendency for the weld pool to adhere to the interior surface of the pipe
differently at different
positions on the pipe to be welded.
[00623] In one embodiment, the motors 5030 and 5074 that direct the inspection
detector
5056 also rotates the weld torch 5502 circumferentially about a rotational
plane to create the
weld along the interface region 5136. In one embodiment, the tilt positioning
motor 5588 that
angularly articulates the weld torch 5502 generally within the rotational
plane. In one
embodiment, the angular orientation of the weld torch 5502 is controlled based
upon the
position of the torch. In one embodiment, the weld torch 5502 is configured to
pivot along the
weld seam about the rotational plane.
[00624] In one embodiment, the weld torch 5502 may be configured such that the
weld
torch 5502 may include a different torch tilt angle for each 90 of rotation.
For example, in
one embodiment, the weld torch 5502 may include a tilt angle 1 when performing
the weld
procedure in a section boundary 1 from 2 o'clock position to 5 o'clock
position, the weld
torch 5502 may include a tilt angle 2 when performing the weld procedure in a
section
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boundary 2 from 5 o'clock position to 8 o'clock position, the weld torch 5502
may include a
tilt angle 3 when performing the weld procedure in a section boundary 3 from 8
o'clock
position to 11 o'clock position, and the weld torch 5502 may include a tilt
angle 4 when
performing the weld procedure in a section boundary 4 from 11 o'clock position
to 2 o'clock
position. In one embodiment, the weld torch 5502 may be configured such that
the weld torch
5502 may include a different torch tilt angle for each 300 of rotation. In one
embodiment, the
weld torch 5502 may be configured such that the weld torch 5502 may include a
different
torch tilt angle for each 60 of rotation. In one embodiment, the weld torch
5502 may be
configured such that the weld torch 5502 may include a different torch tilt
angle for each 120
of rotation. In one embodiment, the weld torch 5502 may be configured such
that the weld
torch 5502 may include a different torch tilt angle for any desired degrees of
rotation.
[00625] In one embodiment, the weld torch 5502 may be configured to have a
continuously
variable torch tilt angle to compensate for or accommodate the continuously
changing
orientation of the weld torch due to gravity. In one embodiment, the weld
torch 5502 may be
configured to progressively change the torch tilt angle based upon the
position at which the
weld torch is (i.e., the position of the weld troch along the circumferential
weld).
[00626] FIG. 54 shows the weld torch 5502 is positioned in a normal, non-
tilted position. In
one embodiment, the tilt positioning system 5510 is configured to provide the
weld torch
5502 with a +/- 5 of angular tilt. For example, as shown in FIGS. 55 and 56,
the weld torch
5502 has been moved by the tilt positioning system 5510 to +5 of angular tilt
so that the weld
torch 5502 is positioned at the correct/desired/predetermined distance from
the pipe for
welding. As shown in FIGS. 57 and 58, the weld torch 5502 has been moved by
the tilt
positioning system 5510 to ¨ 5 of angular tilt, respectively so that the weld
torch 5502 is
positioned at the correct/desired/predetermined distance from the pipe for
welding. In another
embodiment, the tilt positioning system 5510 is configured to provide the weld
torch 5502
with a +/- 7 of angular tilt. In one embodiment, the tilt positioning system
5510 is configured
to provide the weld torch 5502 with less than +/- 5 of angular tilt.
[00627] In one embodiment, a circumferential arc between the pivot point P and
a point of
impingement PI (as shown in FIGS. 56 and 58) of the inspection beam of
radiation upon the
interface region remains generally constant during a welding procedure. In one
embodiment,
the one or more processors 5140 have knowledge of a constant arcuate distance
between the
pivot point P (e.g., weld tip) and the point of inspection PI, so that the one
or more processors
5140 are configured to control the articulation and pivoting movement of the
weld torch 5502
based on the pre-weld profile inspection data.
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[00628] The configuration of the weld torch 5502 that enables the weld torch
5502 to pivot
about the pivot point P allows the angle of the weld torch 5502 to be changed
while welding
without affecting the speed at which the weld torch 5502 is travelling. For
example, this is
especially useful for weld systems with multiple weld torches. In one
embodiment, the weld
torches will not have their angles changed at the same time, in which case it
would be
beneficial for a torch's angle to be changed without any adverse effects on
the other weld
torches.
[00629] In one embodiment, the tilt positioning system 5510 includes the tilt
weld torch
motor 5588, guide rail members 5544, and guide rollers 5546. In one
embodiment, the guide
rail members 5544 are configured to be engaged with the guide rollers 5546 to
facilitate the
tilt positioning of the weld torch 5502. In the illustrated embodiment, the
guide rollers 5546
may include two upper and two lower guide rollers. In one embodiment, the tilt
positioning
system 5510 includes one guide rail member 5544 and its four associated guide
rollers 5546
positioned on opposing sides of the weld torch assembly 5500.
[00630] In one embodiment, the guide rollers 5546 are constructed and arranged
to be
connected to their corresponding vertical positioning members 5538. In one
embodiment,
each vertical radial positioning member 5526 is configured to be connected
with a
corresponding guide rail member 5544 using any suitable fastening mechanism
(e.g., fastener
members 5548). This configuration enables each vertical radial positioning
member 5526 to
be connected to the corresponding vertical positioning members 5538 through
the
engagement of the corresponding guide rail member 5544 and the guide rollers
5546.
[00631] In one embodiment, the motor 5588 is configured (e.g., mechanically
connected) to
rotate a gear 5590. In one embodiment, the motor 5588 is configured to rotate
either
clockwise or counter clockwise direction so as to cause the forward or
rearward tilt
movement of weld torch 5502. In one embodiment, the motor 5588 is configured
to be
connected, e.g., through the gear 5590, to the guide rail member 5544. That
is, the motor
5588 comprises an output shaft 5592, and the gear 5590 is connected to the
output shaft 5592
of the motor 5588. By connecting the motor 5588 to the guide rail member 5544
through the
gear 5590, the guide rail 5544 moves when the motor 5588 operates.
[00632] In one embodiment, the guide rail member 5544 is configured to guide
the upper
and lower guide rollers 5546. In one embodiment, the upper and lower guide
rollers 5546 are
biased against the guide rail member 5544 such that the upper and lower guide
rollers 5546
are configured to cause the corresponding vertical positioning member 5538
(connected
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thereto) to move and thereby enable the weld torch 5502 to change its tilt
angle in the plane
of travel.
[00633] In one embodiment, the two opposing vertical positioning members 5538
are
connected to each other via the top positioning member 5540 such that the
movement in one
of the vertical positioning members 5538 (i.e., caused by the motor 5588)
causes a similar
movement in the other of the vertical positioning members 5538. The
configuration of the
two horizontal guide rod members 5556 and 5558 being connected to the top
positioning
member 5540 at both of their ends also facilitates the translation of the
movement from one
of the vertical positioning members 5538 to the other.
[00634] The operation of the radial positioning system 5506 is discussed in
detail below.
When the lead screw 5514 is rotated by the motor 5512, the lead nut 5516 is
driven along the
threads. In one embodiment, the direction of motion of the lead nut 5516
depends on the
direction of rotation of the lead screw 5514 by the motor 5512.
[00635] As the lead nut 5516 is interlocked in the opening 5536 of the
transverse radial
positioning member 5524, the transverse radial positioning member 5524 is
configured to
travel/move (up or down) the lead screw 5514 along with the lead nut 5516. The
slidable
engagement between the transverse radial positioning member 5524 and the front
vertical
guide rod members 5518 and 5520 also facilitate this (up or down)
travel/movement of the
transverse radial positioning member 5524.
[00636] Also, as the transverse radial positioning member 5524 is connected to
the two
vertical radial positioning members 5526, the (up or down) movement of the
transverse radial
positioning member 5524 causes the (up or down) movement of the two vertical
radial
positioning members 5526.
[00637] The two vertical radial positioning members 5526 are also connected to
the two
rear radial positioning members 5604 and 5606. The (up or down) movement of
the two
vertical radial positioning members 5526 causes the (up or down) movement of
the two rear
radial positioning members 5604 and 5606 on the rear vertical guide rod
members 5600 and
5602. The slidable engagement between the rear radial positioning members 5604
and 5606
and the rear vertical guide rod members 5600 and 5602 also aid the (up or
down)
travel/movement of the two vertical radial positioning members 5526.
[00638] As discussed above, each vertical radial positioning member 5526 is
connected
with the corresponding vertical positioning members 5538 through the
engagement of the
corresponding guide rail member 5544 and guide rollers 5546. Thus, the (up or
down)
movement of each vertical radial positioning member 5526 also causes the (up
or down)
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movement of its corresponding vertical positioning member 5538. As the two
vertical
positioning members 5538 are securely connected to the top positioning member
5540, the
(up or down) movement of the two vertical positioning members 5538 causes the
(up or
down) movement of the top positioning member 5540.
[00639] As the weld torch 5502 is connected to the top positioning member 5540
via the
horizontal lead screw 5552, the two horizontal guide rod members 5556 and 5558
and the
weld torch frame 5564, the (up or down) movement of the top positioning member
5540 also
causes the (up or down) movement of the weld torch 5502. Thus, the weld torch
5502 is
mounted for movement, by the radial positioning system 5506, such that the
weld tip 5503 is
configured to move towards and away from the weld surface of the pipes 1022a,
1022b.
[00640] The operation of the axial positioning system 5508 is discussed in
detail below.
When the lead screw 5552 is rotated by the motor 5550 via the gears 5576, 5578
and 5580,
the lead nut 5554 is driven along the threads. In one embodiment, the
direction of motion of
the lead nut 5554 depends on the direction of rotation of the lead screw 5552
by the motor
5550.
[00641] As the lead nut 5554 is interlocked in the opening 5568 of the weld
torch frame
5564, the weld torch frame 5564 is configured to travel/move (side to side)
along with the
lead nut 5554. The slidable engagement between the weld torch frame 5564 and
the
horizontal guide rod members 5556 and 5558 also facilitate this (side to side)
travel/movement of the weld torch frame 5564. The slidable engagement between
the two
horizontal guide rod members 5556 and 5558 and the weld torch frame 5564 also
aid the
(side to side) travel/movement of the weld torch frame 5564 (and the weld
torch 5502). In
one embodiment, the amount of the axial movement of the weld torch frame 5564
is
restricted by an elongated opening 5594 in the top positioning member 5540.
[00642] The operation of the tilt positioning system 5510 is discussed in
detail below. When
the gear 5590 is rotated by the motor 5588, the guide rail member 5544 is
driven along the
teeth. In one embodiment, the direction of motion of the guide rail member
5544 depends on
the direction of rotation of the gear 5590 by the motor 5588.
[00643] In one embodiment, the upper and lower guide rollers 5546 that are
biased against
the guide rail 5544 are configured to cause the corresponding vertical
positioning member
5538 (connected to the guide rollers 5546) to move/tilt.
[00644] In one embodiment, the configuration of the two opposing vertical
positioning
members 5538 being connected to each other via the top positioning member 5540
is such
that the movement in one of the vertical positioning members 5538 (i.e.,
caused by the motor
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5588) causes a similar movement in the other of the vertical positioning
members 5538. The
configuration of the two horizontal guide rod members 5556 and 5558 being
connected to the
top positioning member 5540 at both of their ends also facilitates the
translation of the
movement from one of the vertical positioning members 5538 to the other.
[00645] When the vertical positioning members 5538 and the top positioning
member 5540
(along with the two horizontal guide rod members 5556 and 5558) are
moved/titled, this
movement enables the weld torch 5502 (connected to the two horizontal guide
rod members
5556 and 5558 via the weld torch frame 5564) to change the tilt angle of the
weld torch 5502
in the plane of travel.
[00646] As noted herein, the weld torch is mounted for movement in a manner
such that
when it is driven by the tilt weld torch motor 5588, it is articulated or
pivoted about a point
that is at, or slightly in front, the weld torch tip. For example, the weld
torch tip may
articulate about a point that sits in the weld pool that it creates during a
welding operation. As
a result, the position of the weld pool will not change relative to a radius
drawn to the weld
pool, irrespective of the fact that the weld torch may be articulated by the
tilt weld torch
motor. Thus, arc length between the weld pool and the point at which the
radiation beam
emitted from the inspection laser impinges upon the inner surface of the pipes
to be welded
(e.g., at the interface region) remains constant as the orientation motors
rotate the weld torch
and the inspection laser, irrespective of the articulation of the weld torch
by the tilt weld torch
motor. And because the speed and the orientation motors are also controlled
and known by
the one or more processors, the one or more processors can control weld
parameters at a
particular region of the interface region, knowing the fixed arc length and
based on the
processor calculating the detected weld profile at the upcoming region in
front of the weld tip.
In one embodiment, the orientation motors are provided with angular encoders
operatively
connected to the one or more processors to enable the one or more processors
to determine
the rotational position of the motors and hence the clamps and pipes as well.
In another
embodiment, signals from the inspection detector (e.g., inspection laser) are
be used to detect
movement of the pipe being welded, with such signals being used by the one or
more
processors, knowing the fixed arc length, to control the torch at the
appropriate location
corresponding to the determined position of the weld torch. In another
embodiment, the point
to articulation of the weld torch need not be at the position in front of, or
at, the weld tip, and
arc length between the weld pool and point of inspection laser beam
impingement upon the
interface regions need not remain constant. Instead, the one or more
processors, receiving
positional information of the weld torch tip from the one or more weld torch
motors and/or
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the inspection detector is used to calculate the actual position of the weld
tip relative to the
pipe in real time ("on the fly") in order to control the one or more weld
torch motors to
position the weld torch tip in the desired location based upon the profile
data received from
the inspection detector.
[00647] As noted herein, the weld torch is mounted to be moved or driven by
the one or
more motors in a generally radial direction, along the longitudinal axis of
the weld torch tip,
either towards or away from the interior surface of the pipe being welded. It
should be
appreciated that because the longitudinal axis of the weld torch (e.g.,
through its weld torch
tip) is likely not aligned with the radius of the pipe being welded (taken
from the central axis)
or the radius of the rotatable central hub, due to the fact that the weld
torch is typically angled
in a forward weld direction (and articulated by the tilt weld torch motor
5588, when referring
to the "radial" movement of the weld torch and its tip towards and away from
the interior
surface of the pipe (e.g., the interface region), such radial movement is
being used in the
context described above. For example, such radial movement of the weld torch
can be
considered to refer to longitudinal movement of the weld torch along the weld
torch tip axis.
Because the weld torch is mounted for movement by the at least one weld torch
motor, and
specifically the radial weld torch motor 5512 to enable the torch tip is to
move towards and
away from the weld surface, the weld tip can be moved further away from the
interface
region after each weld pass to accommodate for weld material build-up. After
the first and
second pipe engagement structures are fixed relative to the pipes, the weld
torch can be used
to complete a full root weld pass, the "root" weld pass being the first weld
applied between
the pipe ends (e.g., one full 360 degree weld). After the root weld pass is
completed, the weld
tip can be moved (retracted) slight away from interior surface of the pipes
(and in particular
away from the weld material of the applied root pass weld) so that the second
weld pass (also
referred to as the "hot" pass weld can be conducted with the weld tip at an
appropriate
distance from the root pass weld material.
[00648] In one embodiment, the one or more processors 5140 operating the
motors 5030
and 5074 and the one or more weld torches 5502 to generate a complete
circumferential weld
along the interface region 5136 by rotating the one or more weld torches 5502
along the
interface region 5502 in a single rotational direction until the complete
circumferential weld
is completed.
[00649] In one embodiment, the one or more weld torches 5502 include a
plurality of weld
torches. In one embodiment, at least one of the plurality of weld torches weld
in an upwards
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rotational direction while at least another of the plurality of weld torches
and weld in an
downwards rotational direction.
[00650] In one embodiment, the weld tip is configured to be pointing in the
weld direction.
In one embodiment, the weld torch is always pointing into the direction of
travel. That is,
basically, the weld tip is pointing generally in the direction of travel. In
one embodiment, the
weld torch tilt angle is slightly higher when the weld torch 5502 is
performing an uphill weld
procedure (where the weld torch 5502 is welding in an upwards rotational
direction) and the
weld torch tilt angle is slightly less performing a downhill weld procedure
(where the weld
torch 5502 is welding in a downwards rotational direction).
[00651] In one embodiment, the internal weld system is configured to perform
the downhill
weld procedure (i.e., weld in the downwards rotational direction) when using a
short-arc weld
procedure.
[00652] In one embodiment, when the internal weld system is configured to
perform the
uphill weld procedure (i.e., weld in the upwards rotational direction), the
productivity and the
quality of the weld may be improved. In one embodiment, the uphill weld
procedure is
configured to provide an option to weld both sides of the pipe at the same
time instead of the
downhill weld procedure being performed on each side in succession. For
example, this may
a multi-weld torch operation and having multiple weld overlaps. Alternatively,
this may
provide an option to weld 3600 in one, continuous pass to produce a weld with
only one
overlap. In one embodiment, the requirements of the customer and the size of
the pipe may
dictate which approach would be used.
[00653] In one embodiment, unless there is a quality requirement for only
having one weld
overlap joint, the weld may be performed with as many weld torches as they fit
inside the
pipe. In one embodiment, the internal weld system 5004 may include four weld
torches, six
weld torches, or eight weld torches with half of those weld torches performing
the weld in the
downwards rotational direction and the other half of the weld torches
performing the weld in
the upwards rotational direction. In one embodiment, the half of those weld
torches are
configured to perform the clockwise weld procedure and the other half of the
weld torches
are configured to perform the counterclockwise weld procedure. In one
embodiment, four
weld torches of the internal weld system 5004 may be positioned 90 apart from
each other
and are configured to rotate 900 each. In one embodiment, six weld torches of
the internal
weld system 5004 may be positioned 600 apart from each other and are
configured to rotate
60 each. In one embodiment, eight weld torches of the internal weld system
5004 may be
positioned 450 apart from each other and are configured to rotate 450 each. In
one
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embodiment, the internal weld system 5004 may include two weld torches
positioned 1800
apart from each other and are configured to rotate 1800 each. In one
embodiment, the internal
weld system 5004 may include one weld torch that is configured to rotate 360 .
[00654] The ability to weld upwards as well as in the downwards direction may
improve
weld operation speed (weld throughput time) and also improve weld quality (by
taking into
account the gravitational forces at different locations). Also, where multiple
weld torches are
provided, welding can take place both upwardly and downwardly at the same time
(e.g.,
plural, circumferentially spaced weld torches, moving in the same rotational
direction and
simultaneously applying weld material), with at least one weld torch moving
upwards while
at least another moves downwards. This is time efficient, for example, in
comparison with
welding downhill on each side of the pipe in sequence. Alternatively, in one
embodiment, a
single weld torch can be used to conduct a single 360-degree weld to provide a
continuous
weld, with no overlap of weld portions. Such overlap would occur when more
than one weld
torch is used and the end of each weld seam portion from a trailing weld torch
needs to
connect with and slightly overlap with the beginning of the weld seam portion
applied by a
weld torch in front of the trailing weld torch. As a result, for some
applications where it may
be desired to avoid portions of weld overlap (which make weld pass slightly
less uniform at
the points of overlap), the continuous 360-degree internal weld can be useful.
[00655] In one embodiment, the weld torches all point in a forward weld
direction. In other
words, they are pointed slightly in the weld direction so that the weld torch
tip "pushes" the
weld, rather than trailing the weld. This is true whether the weld torch is
positioned internally,
as in some embodiments, or externally as in other embodiments described
herein. This is
illustrated with respect to internal welder, as shown in FIG. 56A. In one
embodiment, the
weld torch tips are pointing at an angle 0 (e.g., a "lead angle") of between 3
degrees to 7
degrees. The lead angle 0 is defined as an angle measured between a line
(radius) R from the
axial center of the pipes being welded to weld torch tip (or the weld pool) as
shown in FIG.
56A (the line R can also be considered the radius taken from the axial center
of the rotational
hub 5078 to the torch tip or weld pool), and a line passing through the
longitudinal axis A of
the weld torch tip. In the illustration of FIG. 56A, the weld torch is being
rotationally moved
in a counterclockwise direction, as depicted by the arrow D. That lead angle 0
can be
changed by operation of the tilt weld torch motor 5588 as the weld torch is
moved
circumferentially around the interior of pipes by the orientation motor. It is
contemplated
that the lead angle 0 will be slightly higher (e.g., 6 degrees) when the weld
torch is traveling
upwardly, and slightly lower (e.g., 4 degrees) when traveling downwardly. In
addition, in one
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embodiment, the lead angle 0 can change continuously throughout the travel of
a particular
weld torch. In another embodiment, the pipe can be divided into sectors, with
the weld angle
0 being changed based on the sector. For example, in considering the full 360
degrees or
movement to correspond to the hour hand on a clock, the pipe can be divided
into the various
o'clock sectors: 2-5, 5-8, 8-11, 11-2. The one or more motors can be operated
by the one or
more processors to change at the sector boundaries.
[00656] As will be appreciated from FIG. 56A, welding is being conducted in an
counterclockwise direction in the depiction shown. For welding in a clockwise
direction, the
one or more processors 5140 sends a signal to the one or more torch motors so
that the gear
5590 is rotated and the weld torch 5502 is pivoted (e.g., about point P), such
that the axis
through the torch (line A) is moved to the opposite side of the radial line R.
As such, the
angle 0 will be negative for clockwise welding. This will enable the weld
torch to point in the
forwards direction ("pushing" the weld pool) when welding in the clockwise
direction.
[00657] In one embodiment, as shown in FIGS. 60A-63, the internal weld system
5004 may
include one weld torch WT, a camera C and two inspection detectors Li and L2.
In one
embodiment, the weld torch WT and the camera C are separated by a 1800 angle.
In one
embodiment, the angle between the camera and the weld torch WT may vary.
[00658] In one embodiment, one of the two inspection detectors Li and L2 may
be a leading
inspection detector that is configured to lead the weld torch WT during the
welding procedure
and also to provide pre-weld data. In one embodiment, the other of the two
inspection
detectors Li and L2 may be a trailing inspection detector that is configured
to trail the weld
torch WT during the welding procedure and to provide post-weld data.
[00659] In one embodiment, the inspection detector Li and the weld torch WT
are separated
by a 200 angle. In one embodiment, the inspection detector L2 and the weld
torch WT are
separated by a 200 angle. In one embodiment, the angle between the inspection
detector L2
and the weld torch WT and the angle between the inspection detector Li and the
weld torch
WT may vary.
[00660] In one embodiment, the angle between the inspection detector L2 and
the weld
torch WT and the angle between the inspection detector Li and the weld torch
WT may be
adjustable. For example, in one embodiment, when Li is a leading inspection
detector, then
the angle between the inspection detector Li and the weld torch WT is 20 or
less and the
angle between the trailing inspection detector L2 and the weld torch WT is
more than 20 . In
one embodiment, when L2 is a leading inspection detector, then the angle
between the
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inspection detector L2 and the weld torch WT is 200 or less and the angle
between the trailing
inspection detector L1 and the weld torch WT is more than 20 .
[00661] In one embodiment, as shown in FIG. 60A, the inspection detector L1 is
positioned
at its start position. In one embodiment, referring to FIG. 60B, the weld
torch WT starts the
welding procedure when the weld torch WT is positioned at StartwT In one
embodiment, the
weld torch WT is configured to travel in a clockwise direction (as indicated
by arrow T1)
during the welding procedure. In one embodiment, referring to FIG. 61, the
weld torch WT
ends the welding procedure when the weld torch WT reaches StopwT In one
embodiment, a
weld bead WB1 formed by the weld torch WT as it travels from StartwT to StopwT
in the
clockwise direction indicated by the arrow T1. In one embodiment, as shown in
FIGS. 60B
and 61, the torch WT follows the inspection detector L1 during its travel from
StartwT to
StopwT in the clockwise direction indicated by the arrow Ti. After the welding
procedure, the
weld torch WT is moved in a counter clockwise direction (i.e., opposite to the
direction of the
arrow Ti) such that the inspection detector L2 is positioned back at its start
position, StartwT.
[00662] In one embodiment, referring to FIG. 62, the weld torch WT starts the
welding
procedure when the weld torch WT is positioned at StartwT In one embodiment,
the weld
torch WT is configured to travel in a counterclockwise direction (as indicated
by arrow T2)
during the welding procedure. In one embodiment, referring to FIG. 63, the
weld torch WT
ends the welding procedure when the weld torch WT reaches StopwT In one
embodiment, a
weld bead WB2 formed by the weld torch WT as it travels from StartwT to StopwT
in the
counterclockwise direction indicated by the arrow T2. In one embodiment, as
shown in FIGS.
62-63, the torch WT follows the inspection detector L2 during its travel from
StartwT to
StopwT in the counterclockwise direction indicated by the arrow T2. After the
welding
procedure, the weld torch WT is moved in a clockwise direction (i.e., opposite
to the direction
of the arrow T2) such that the laser L1 is positioned back at its start
position, StartwT.
[00663] In one embodiment, as shown in FIGS. 64-69, the internal weld system
5004 may
include two weld torches WTi and WT2, a camera C and one inspection detector
L. In one
embodiment, the inspection detector L and the weld torch WTi are separated by
a 200 angle.
In one embodiment, the inspection detector L and the weld torch WT2 are
separated by a 200
angle. In one embodiment, the inspection detector L and the camera C are
separated by a 1800
angle.
[00664] In one embodiment, as shown in FIG. 64, the inspection detector L is
positioned at
its start position. In one embodiment, referring to FIG. 65, the weld torch
WTi starts the
welding procedure when the weld torch WTi is positioned at Startwri In one
embodiment, the
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weld torch WT1 is configured to travel in a clockwise direction (as indicated
by arrow Ti)
during the welding procedure. In one embodiment, referring to FIG. 66, the
weld torch WTi
ends the welding procedure when the weld torch WTi reaches StopwTi. In one
embodiment,
as shown in FIG. 66, a weld bead WBwTi is formed by the weld torch WTi as it
travels from
StartwTi to StopwTi in the clockwise direction indicated by the arrow T1. In
one embodiment,
as shown in FIGS. 64-66, the torch WTi follows the inspection detector L
during its travel
from StartwTi to StopwTi in the clockwise direction indicated by the arrow T1.
After the
welding procedure, the weld torch WT1 is moved in a counter clockwise
direction (i.e.,
opposite to the direction of the arrow Ti) such that the inspection detector L
is positioned
back at its start position as shown in FIG. 67.
[00665] In one embodiment, referring to FIG. 68, the weld torch WT2 starts the
welding
procedure when the weld torch WT2 is positioned at StartwT2. In one
embodiment, the weld
torch WT2 is configured to travel in a counterclockwise direction (as
indicated by arrow T2)
during the welding procedure. In one embodiment, referring to FIG. 69, the
weld torch WT2
ends the welding procedure when the weld torch WT2 reaches StopwT2. In one
embodiment, a
weld bead WBwT2 is formed by the weld torch WT2 as it travels from StartwT2 to
StopwT2 in
the counterclockwise direction indicated by the arrow T2 as shown in FIG. 69.
In one
embodiment, as shown in FIGS. 68-69, the torch WT2 follows the inspection
detector L
during its travel from StartwT2 to StopwT2 in the counterclockwise direction
indicated by the
arrow T2. After the welding procedure, the weld torch WT2 is moved in a
clockwise direction
(i.e., opposite to the direction of the arrow T2) such that the inspection
detector L is
positioned back at its start position as shown in FIGS. 64 and 67.
[00666] In one embodiment, the internal weld system 5004 may include one weld
torch and
one inspection detector. In one embodiment, the angle between the inspection
detector and
the weld torch may be 200 or less. In one embodiment, the inspection detector
and the weld
torch may be separated by an arc length AL (as shown in FIG. 64) of 3 inches.
In one
embodiment, the inspection detector and the weld torch may be separated by an
arc length
AL of 4 inches. In one embodiment, the angle between the inspection detector
and the weld
torch is 190. In one embodiment, the angle between the inspection detector and
the weld torch
is 160. In one embodiment, the angle between the inspection detector and the
weld torch is
140. In one embodiment, the angle between the inspection detector and the weld
torch is 120
.
[00667] FIG. 70 shows a schematic diagram showing the flow of compressed air
through
the internal weld system 5004, where some components of the internal weld
system 5004 are
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not shown for sake of clarity and to better illustrate the other components
and/or features of
the internal weld system 5004.
[00668] Referring to FIG. 70, the compressed air tank 5128, the brake cylinder
5133, the
drive wheel cylinder 5137, brake valve 5190 and drive wheel valve 5192 are
shown in the
drive section 5010 of the internal weld system 5004. The rear rotary union
5072, the rear
clamp control valve 5062, the rear clamp 5144 and the front clamp 5142 are
shown in the
center section 5008 of the internal weld system 5004. The front rotary union
5032 and the
front clamp control valve 5018 are shown in the forward-most section 5006 of
the internal
weld system 5004.
[00669] In one embodiment, the compressed air tank 5128 has two separate fluid
communication lines connected via a valve 5113. In one embodiment, the
compressed air
tank 5128 is in fluid communication through fluid communication lines with the
brake valve
5190 (and the brake cylinder 5133), the drive wheel valve 5192 (and the drive
wheel cylinder
5137), the rear clamp control valve 5062 (and the rear clamp 5144), the rear
rotary union
5072, the front rotary union 5032, the front clamp control valve 5018 (and the
front clamp
5142), and the compressor 5029.
[00670] The compressed air stored in the compressed air tank 5128 is sent
through the fluid
line to a valve 5194. A portion of the compressed air received by the valve
5194 is sent to the
brake valve 5190 and the remaining portion of the compressed air received by
the valve 5194
is sent to a valve 5196. The brake valve 5190 is in fluid communication
through lines 5198
and 5199 with the brake cylinder 5133. In one embodiment, the brake valve 5190
is
configured to supply the compressed air to actuate the brake cylinder 5133,
when it receives
signals from the drive section electronics module 5118. The compressed air
operates the
brake cylinder 5133 which through its operation provides a brake force to the
drive rollers
5122. In one embodiment, the brake cylinder 5133 and the brake valve 5190 may
be referred
to as a brake system that is configured to secure the frame of the internal
weld system 5004
from movement at a desired location within the pipes 1022a, 1022b. In one
embodiment, the
brake system that is configured to secure the frame of the internal weld
system 5004 from
movement at a desired location within the pipes 1022a, 1022b may include a
wheel/roller
lock. In one embodiment, the wheel/roller lock is configured to prevent the
one or more of
the rollers 5122 to secure the frame of the internal weld system 5004 from
movement. In one
embodiment, the brake system may also include a motor lock. In one embodiment,
the motor
lock is configured to prevent the rotation of the drive motors 5124 that drive
the rollers 5122
for the locomotion of the frame of the internal weld system 5004.
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[00671] A portion of the compressed air received by the valve 5196 is sent to
the drive
wheel valve 5192 and the remaining portion of the compressed air received by
the valve 5196
is sent to a valve 5198. The drive wheel valve 5192 is in fluid communication
through lines
5200 and 5201 with the drive wheel cylinder 5137. In one embodiment, the drive
wheel valve
5192 is configured to supply the compressed air to actuate the drive wheel
cylinder 5137,
when it receives signals from the drive section electronics module 5118. The
compressed air
operates the drive wheel cylinder 5137 which through its operation provides a
drive force to
the drive rollers 5122. In one embodiment, the drive wheel cylinder 5137 may
be operatively
connected to an axle having the drive rollers 5122 thereon. In one embodiment,
the drive
wheel cylinder 5137 may be operatively connected to the axle via one or more
gear
arrangements.
[00672] In one embodiment, both the drive wheel cylinder 5137 and the brake
cylinder
5133 are retracted when loading the internal weld system 5004 into the pipes.
In one
embodiment, the drive wheel cylinder 5137 is retracted only when the internal
weld system
5004 is taken out of the pipes. In one embodiment, the drive wheel cylinder
5137 is extended
to accelerate or decelerate (the travel of) the internal weld system 5004 in
the pipes
[00673] A portion of the compressed air received by the valve 5198 is sent to
the rear rotary
union 5072 and the remaining portion of the compressed air received by the
valve 5198 is
sent to the rear clamp control valve 5062. The rear clamp control valve 5062
is in fluid
communication through lines 5202 and 5203 with the rear clamp 5144. In one
embodiment,
the fluid communication line 5202 is used for the extension of the clamps 5144
and the fluid
communication line 5203 is used for the retraction of the clamps 5144. In one
embodiment,
the rear clamp control valve 5062 is configured to supply the compressed air
to actuate and
operate the rear clamp 5144, when it receives signals from the center section
electronics
module 5064.
[00674] The compressed air output by the rear rotary union 5072 is sent to the
front rotary
union 5032. The compressed air output by the front rotary union 5032 is sent
to a valve 5204.
A portion of the compressed air received by the valve 5204 is sent to the
front clamp control
valve 5018 and the remaining portion of the compressed air received by the
valve 5204 is
sent to the compressor 5029. In one embodiment, the compressor 5029 is
configured to
recharge the system (e.g., fill the tank with compressed air) using the
received compressed air.
[00675] The front clamp control valve 5018 is in fluid communication through
lines 5206
and 5207 with the front clamp 5142. In one embodiment, the fluid communication
line 5206
is used for the extension of the front clamp 5142 and the fluid communication
line 5207 is
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used for the retraction of the front clamp 5142. In one embodiment, the front
clamp control
valve 5018 is configured to supply the compressed air to actuate and operate
the front clamp
5142, when it receives signals from the forward-most electronics module 5014.
[00676] FIG. 71 shows a schematic diagram showing the flow of power including
weld
power, communication data, and controls data through the internal weld system
5004, where
some components of the internal weld system 5004 are not shown for sake of
clarity and to
better illustrate the other components and/or features of the internal weld
system 5004.
[00677] Referring to FIG. 71, the forward-most electronics module 5014, the
front rotation
motor 5030, the front position sensor 5022, the front clamp control valve
5018, the front slip
ring 5016, the wire feed electronics module 5046 of the wire feed assembly
5020, the wire
feed systems 5044, and the shield gas control valve 5042 are shown in the
forward-most
section 5006 of the internal weld system 5004. The rotatable hub 5078, the
weld torches 5502,
the inspection detectors 5056, the inspection camera 5112, the front clamp
5142 and the rear
clamp 5144, the rear slip ring 5080, the center section electronics module
5064, the rear
position sensor 5076, the rear clamp control valve 5062, and the rear rotation
motor 5074 are
shown in the center section 5008 of the internal weld system 5004. The
batteries 5116, the
drive section electronics module 5118, the brake valve 5190, the drive wheel
valve 5192, and
the drive motors 5124 are shown in the drive section 5010 of the internal weld
system 5004.
[00678] In one embodiment, the weld power is received by the internal weld
system 5004
from the umbilical 5034. In one embodiment, the weld power, from the umbilical
5034, is
supplied to the weld torches 5502 via the front slip ring 5016.
[00679] In one embodiment, the batteries 5116 of the drive section 5010 are
configured to
supply the power to all the electronics modules in the internal weld system
5004, including
the forward-most electronics module 5014, the wire feed electronics module
5046, the center
section electronics module 5064 and the drive section electronics module 5118.
In one
embodiment, the batteries 5116 of the drive section 5010 are configured to
supply the power
to all the electric drive motors in the internal weld system 5004, including
the front rotation
motor 5030, the motors of the wire feed systems 5044, the rear rotation motor
5074, the drive
motors 5124, the axial weld torch motor 5550, the radial weld torch motor
5512, and the tilt
weld torch motor 5588.
[00680] In one embodiment, the power of the batteries 5116 is directly
supplied to the rear
slip ring 5080, the center section electronics module 5064 and the drive
section electronics
module 5118. In one embodiment, the power of the batteries 5116 is supplied to
the front slip
ring 5016 via the rear slip ring 5080. That is, the power of the batteries
5116 transfers from
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the rear slip ring 5080 to the front slip ring 5016. In one embodiment, the
power from the
batteries 5116 is supplied from the front slip ring 5016 to the forward-most
electronics
module 5014 and the wire feed electronics module 5046.
[00681] In one embodiment, the power of the batteries 5116 is supplied from
the forward-
most electronics module 5014 to the front rotation motor 5030 and from the
wire feed
electronics module 5046 to the motors of the wire feed systems 5044. In one
embodiment, the
power of the batteries 5116 is supplied from the center section electronics
module 5064 to the
rear rotation motor 5074. In one embodiment, the power of the batteries 5116
is supplied
from the drive section electronics module 5118 to the drive motors 5124. In
one embodiment,
the power of the batteries 5116 is supplied from the wire feed electronics
module 5046 to the
axial weld torch motor 5550, the radial weld torch motor 5512, and the tilt
weld torch motor
5588.
[00682] In one embodiment, the batteries 5116 are also configured to supply
the power to
the inspection camera 5112 and the inspection detectors 5056. For example, the
power of the
batteries 5116 is supplied from the wire feed electronics module 5046 to the
inspection
camera 5112 and the inspection detectors 5056.
[00683] In one embodiment, the batteries 5116 are also configured to supply
the power to
the front position sensor 5022 and the rear position sensor 5076. For example,
the power of
the batteries 5116 is supplied from the forward-most electronics module 5014
to the front
position sensor 5022 and from the center section electronics module 5064 to
the rear position
sensor 5076.
[00684] In one embodiment, the batteries 5116 are also configured to supply
the power to
the front clamp control valve 5018, the shield gas control valve 5042, the
rear clamp control
valve 5062, the brake valve 5190, and the drive wheel valve 5192. For example,
the power of
the batteries 5116 is supplied from the forward-most electronics module 5014
to the front
clamp control valve 5018, from the wire feed electronics module 5046 to the
shield gas
control valve 5042, from the center section electronics module 5064 to the
rear clamp control
valve 5062, and from the drive section electronics module 5118 to the brake
valve 5190, and
the drive wheel valve 5192.
[00685] In one embodiment, the internal weld system 5004 is configured to
receive and
send communication signals via the umbilical 5034 to the external computer
system (e.g.,
have one or more processors). In one embodiment, a received communication
signal may
travel from the umbilical 5034 to the forward-most electronics module 5014,
then to the wire
feed electronics module 5046 via the front slip ring 5016, then to the center
section
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electronics module 5064 via the rear slip ring 5080, and then to the drive
section electronics
module 5118.
[00686] In one embodiment, a communication signal may travel (in the opposite
direction
to the received signal) from the drive section electronics module 5118, then
to the center
section electronics module 5064, then to the wire feed electronics module 5046
via the rear
slip ring 5080, then to the forward-most electronics module 5014 via the front
slip ring 5016,
and to the umbilical (and to the external computer system having one or more
processors).
[00687] In one or more embodiments describe herein, and as may be appreciated
from FIG.
71, the one or more processors 5140 are operatively associated with inspection
detector 5056,
e.g., inspection laser (or optionally plural inspection detectors 5056 where
more than one is
provided) through a hardwired communication line or lines 5056a that transmits
signals from
the inspection laser 5056 to the one or more processors 5140. The hardwired
communication
line has (i) a movable portion 5056b that moves with inspection detector(s)
5056 while the
inspection laser directs the inspection beam along the interface region, and
(ii) a stationary
portion 5056c that remains fixed during movement of the movable portion 5056b.
The system
further comprises the previously described front slip ring 5016 (which can be,
from one
perspective, considered part of the hardwired communication line) that
provides an interface
between a section of the movable portion 5056b and a section of the fixed
portion 5056c of
the communication line to enable the signals to pass from the movable portion
5056b to the
stationary portion 5056c.
[00688] It should be appreciated that the hardwired communication line or
lines 5056a
(including the movable and stationary portions thereof) are also configured
(or alternatively
configured if wireless communications are provided for the inspection
detectors 5056 to
communicate with the one or more processors) to transmit power to the
inspection detectors
5056 through the slip ring 5016.
[00689] The slip ring 5016 comprises an outer stator 5016a and an inner rotor
5016b (see
FIG. 26). The inner rotor 5016b and stator 5016a have a bearing 5016k
therebetween. The
stator 5016a is fixedly mounted with respect to the center frame 5068 (see
FIGS. 23 and 24),
while the rotor 5016b is connected with the rotatable hub 5078 at its central
axis (e.g., see
FIG. 24). The rotor 5016b is rotated along with the rotatable hub 5078 when
the hub is driven
for rotation. The stator 5016a is connected with the stationary portion 5056c
of the hardwire
communication line, and rotor 5016b connected with the movable portion 5056b
of the
hardwire communication line, as shown in FIG. 26. As seen in FIG. 26, the
rotor 5016b of the
front slip ring 5016 has a hollow cylindrical configuration, with a central
passage 5016d
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therethrough. The passage 5016d allow the passage of other conduits or lines
therethrough,
and specifically, for example, pneumatic lines from the front rotary union
(such as external
compressed air lines that will be communicated to compressed air tank 5128).
[00690] As can be appreciated, the hardwiring between the inspection detector
5056 and the
one or more processors 5140 can, in some embodiments, travel through other
components as
well. For example, as shown in FIG. 71, the communication line from the
inspection detector
5056 may travel through the wire feed electronics 5046 before being received
by the slip ring
5016.
[00691] The slip ring 5016 permits the movable portion 5056b of the
communication line to
move with rotatable hub 5078, as the hub 5078 rotates during a scanning
operation of the
inspection detector 5056, during a pre-weld scan of the interface region
between the pipes
prior to a welding operation, as well as during the on-the-fly scan of the
interface region
between the pipes during a welding operation.
[00692] It should also be appreciated that the slip ring 5016 is further
configured to couple
the communication connection between the one or more processors 5140 and the
inspection
camera 5112, as well as provide power to the inspection camera 5112. This can
be done
through the same hardwired communication line or lines 5056a The one or more
processors
5140 are configured to receive camera inspection data from the inspection
camera 5112 prior
to, subsequent to, or during a weld operation. The movable portion 5056b moves
with the
camera (and rotatable hub 5078) while the camera scans the interface region,
and stationary
portion 5056c remains fixed during movement of the movable portion 5056b that
communicates with the camera 5112.
[00693] It should further be appreciated that the same slip ring 5016 (and/or
slip ring 5080)
are configured to communicate power to other components that may rotate with
the rotatable
hub 5078. For example, as illustrated in FIG. 35B, weld power lines 5502k for
providing
weld power to the weld torches 5502, and power and command lines 5550k for
controlling
and powering the one or more weld torch motors 5550, 5512, 5588 for
controlling the weld
torch are all lines that are configured to pass through slip ring 5016. For
example, for
illustrative purposes in FIG. 26 and 35B, the stationary portion of the
hardware power line for
the weld power line 5502k is labeled as 5112c and the movable portion of the
weld power
line is labeled as 5112b. It can be appreciated that they could alternatively
be represented by
showing additional lines into the same slip ring 5016, or shown in connection
with a separate
slip ring.
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[00694] Similarly, a hardwired communication line 5550k can be provided
through slip ring
5016 to provide command (and control), as well as power to the torch motors
5550, 5512,
5588. For sake of simplicity sake, and without the need for redundancy, the
movable portion
5550m is of this hardwired line 5550k is shown in Fig. 35B, but not shown in
FIG. 26. It
should be appreciated that this FIG. 26, as well as FIG. 71, are used to
illustrate how slip ring
5016 (or another slip ring) can be used to transmit power and communication to
the weld
torches 5502 as the weld torches are rotated with the rotatable hub 5078, and
as they are
powered and controlled to create a weld during a welding operation.
[00695] As shown in FIG. 35B (and several other figures), the rotatable hub
5078 has a
generally hollow cylindrical portion 5078a. The middle of the cylindrical
portion, at a region
that is generally axially aligned with the weld torches, lasers and camera,
has a plurality of
openings or slots 5078b therethrough. The openings 5078b allow the movable
power lines
and communication lines from the slip ring 5016 (and optionally from slip ring
5080) to pass
radially outwardly from the interior 5078c of the rotatable hub 5078 to the
exterior of the hub
5078 for connection with the weld torches, lasers, and camera.
[00696] It should be appreciated that while the rotatable hub 5078 shown and
described
herein has a generally cylindrical configuration, the hub can be of a
different shape. The
rotatable hub can be of any tubular shape (e.g., with a hollow square or
triangular
configuration, just for example). In addition, the rotatable hub can also be
interchangeably
termed a "rotatable frame."
[00697] As shown and described above, the inspection detector 5056 is mounted
on the
exterior of the tubular hub, the tubular hub having opposite ends and a radial
opening 5078b
between the ends. The movable portion 5056b of the power and communication
lines
extending from the front slip ring 5016 and wire feed electronics module 5046
extends
through the interior 5078c of the tubular hub 5078, through the radial opening
5078b, and
connected with the one or more inspection detectors 5056.
[00698] As can also be appreciated from FIGS. 24 and 35B, a pneumatic line
5032a
carrying shield gas (an inert gas) passes through the rear rotary union 5072,
through the
opening 5080d in the slip ring, and travels through the hollow interior 5078c
of the rotatable
hub 5078 to one of the shield gas valves 5042 (see FIG. 72), the valves being
mounted in the
wire feed electronics module 5046 (see FIG. 71) which is mounted on the
rotatable hub 5078
for rotation therewith. The pneumatic line 5032a, which is a movable line that
moves with the
rotation of the rotatable hub 5078, after connecting with the shield gas
valves 5042, doubles
back and again extends through the hollow interior 5078c of the rotatable hub
5078 (thus two
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lines 5032a are shown in FIG. 24). The pneumatic line 5032a passes through one
or more of
the openings 5078b so as to be directed into the vicinity of the tip of the
weld torch 5502. The
pneumatic line 5032a shown in FIG. 35B comprise movable portions of the
pneumatic line
that will rotate with rotation of the rotatable hub. 5078.
[00699] FIG. 25 is a partial sectional view of the front rotary union 5032,
which is
essentially of the same construction of the rear rotary union 5072. The front
rotary union
5032 is used to communicate compressed air from an external source 5029 to an
on-board
compressed air tank 5128. The front rotary union comprises a stator 5032d and
a rotor 5032e.
The rotor 5032e is mounted on the stator 5032d by ball bearings 5032f. The
stator 5032d is
fixed relative to the center frame 5068, and the rotor 5032e is coupled to the
movable portion
5072d of the pneumatic line, the opposite end of movable portion 5072d
connecting with the
rotor or the rear rotary union 5072. The movable portion 5072d of the
pneumatic line passes
through the central passage 5016d of the slip ring 5016 so as to be introduced
into the interior
5078c of the rotatable hub 5078 and then to the rotor of the rear rotary union
5072.
[00700] It should be appreciated that while front slip ring 5016 is
illustrated in FIG 26 and
the front rotary union 5032 is illustrated in FIG. 25, the same configurations
for each will
apply to the rear rotary union 5072 and the rear slip ring 5080.
[00701] The manner in which the movable portion of the pneumatic line passes
through the
central passage 5016d of slip ring 5016 can be further appreciated from the
cross sectional
view of FIG. 24, which illustrates this attribute in the context of how this
applies to the rear
slip ring 5080 and rear rotary union 5072. Specifically, the rear rotary union
5072 has an
outer stator 5072a and an inner rotor 5072b. The rotor 5072b receives
compressed air from a
rotatable pneumatic supply line 5072d (See FIG. 24 and 70; it should be
appreciated that FIG.
70 is a schematic drawings and the line 5072d is drawn schematically in FIG.
70, but passes
through the interior 5078c of the rotatable hub as shown in FIG. 24). The
rotatable supply
line 5072d is connected at its opposite end to the rotor of the front rotary
union 5032.
Specifically, the external supply tank 5029 first passes the compressed gas
through the stator
of the front rotary union 5032 and then exits out through the rotor of the
front rotary union
5032. The front rotary union 5032 has its rotor operatively connected with the
rotatable hub
5078 so as to be rotatable together. The rotatable supply line 5072d passes
from the rotor of
the front rotary union 5032 to the rotor 5072b of the rear rotary union 5072.
The compressed
air passed through the stator 5072a of the rear rotary union to a stationary
pneumatic supply
line 5072f extending therefrom. The fixed pneumatic supply line 5072f is
connected through
valves to the compressed air tank 5128, which receives compressed air from the
external
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supply tank 5029 periodically, when tank 5128 is depleted. As seen in FIG. 24,
the rotatable
supply line 5072d passes from the rotor 5072b through the central opening
5080d in the rear
slip ring 5080. The movable pneumatic supply line 5072d then passes through
the through
passage 5078c within the rotatable hub 5078 for connection with the front
rotary union 5032.
[00702] As can be seen in FIG. 24, the rear slip ring 5080 has an inner rotor
5080r, an outer
stator 5080s, and a bearing 5080m therebetween.
[00703] As can also be appreciated from FIGS. 24, 72, the rear rotary union
5072 also has
another stationary line 5072g that receives shield gas from the shield gas
tanks 5262 to be
described in greater detail later. The shield gas passes from the stator 5072a
to the rotor
5072b, and then out from the rotor through the movable pneumatic line 5032a.
The movable
pneumatic line 5032a passes through the opening 5080d in the slip ring and
into passage
5078c. The pneumatic line 5032a moves with the rotation of the rotatable hub
5078. The
opposite end of the pneumatic line 5032a connects with the shield gas valves
5042 and then
doubles back (hence two lines 5032a shown in FIG. 24) and passes to weld
torches 5502. In
traveling to the weld torches 5502, the movable pneumatic line 5032a passes
through the
openings 5078b in the rotatable hub 5078, as can be appreciated from FIG. 72.
[00704] Although not described in detail here, it should be appreciated that
the provision of
the shield gas through the rear rotary union 5072 will also apply to passage
of purge gas from
purge gas tanks 7070 through rear rotary union 7072 as shown in FIG. 94
described later.
[00705] In FIG. 25, the front rotary union 5032 is illustrated as having two
inlet and outlet
ports. As shown, only one of the ports for communicating compressed air
through pneumatic
line (stationary portion 5032c and movable portion 5072d) is used. The other
ports are not
functional for the front rotary union, but both ports will be used for the
rear rotary union 5072
as will be appreciated from the above description.
[00706] It should also be appreciated, that in some embodiments, wireless
communication
may be provided to/from the inspection detector, camera and/or weld torch, in
which case the
use of a slip ring for certain functionality can be by passed.
[00707] In one embodiment, the communications signals may not traverse the
entire
communication path between the umbilical 5034 and the drive section
electronics module
5118 and may travel between specific devices/modules of the communication
path.
[00708] In one embodiment, all the electronics modules in the internal weld
system 5004,
including the forward-most electronics module 5014, the wire feed electronics
module 5046,
the center section electronics module 5064 and the drive section electronics
module 5118
may each include a memory, a secondary storage device, and one or more
processors
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configured to perform system controls. In one embodiment, all the electronics
modules in the
internal weld system 5004 may be configured to receive, process, store,
retrieve and transmit
signals (sensor or control) and data. In one embodiment, these electronics
modules may
contain other components. For example, various circuitry such as, for example,
power supply
circuitry, signal conditioning circuitry, solenoid driver circuitry, and/or
any other circuitry
that is known in the art may be incorporated in the electronics modules. In
one embodiment,
all the electronics modules in the internal weld system 5004 may be configured
to transmit
control signals that are used to direct the operation of the devices
operatively connected
thereto and receive data or other signals (sensor) from the devices
operatively connected
thereto.
[00709] For example, the forward-most electronics module 5014 is operatively
coupled to
the front rotation motor 5030, the front position sensor 5022, and the front
clamp control
valve 5018. In one embodiment, the forward-most electronics module 5014 is
configured to
transmit control signals to control the operation of the front rotation motor
5030 and the front
clamp control valve 5018 and receive sensor signals from the front position
sensor 5022.
[00710] In one embodiment, the wire feed electronics module 5046 is
operatively coupled
to the shield gas control valve 5042, the motors of the wire feed systems
5044, the axial weld
torch motor 5550, the radial weld torch motor 5512, and the tilt weld torch
motor 5588. In
one embodiment, the wire feed electronics module 5046 is configured to
transmit control
signals to control the operation of the shield gas control valve 5042, the
motors of the wire
feed systems 5044, the axial weld torch motor 5550, the radial weld torch
motor 5512, and
the tilt weld torch motor 5588.
[00711] In one embodiment, the center section electronics module 5064 is
operatively
coupled to the rear rotation motor 5074, the rear position sensor 5076, and
the rear clamp
control valve 5062. In one embodiment, the center section electronics module
5064 is
configured to transmit control signals to control the operation of the rear
rotation motor 5074
and rear clamp control valve 5062, and receive sensor signals from the rear
position sensor
5076.
[00712] In one embodiment, the drive section electronics module 5118 is
operatively
coupled to the drive motors 5124, the brake valve 5190, and the drive wheel
valve 5192. In
one embodiment, the drive section electronics module 5118 is configured to
transmit control
signals to control the operation of the drive motors 5124, the brake valve
5190, and the drive
wheel valve 5192.
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[00713] FIG. 72 shows a schematic diagram showing the flow of shield gas
through the
internal weld system 5004, where some components of the internal weld system
5004are not
shown for sake of clarity and to better illustrate the other components and/or
features of the
internal weld system 5004.
[00714] In one embodiment, an inert/shield gas supply line is configured to
direct
inert/shield gas from the inert/shield gas source 5262 to a region between the
first and second
clamps 5142, 5144, and towards a region in a vicinity of the weld tip 5503 of
the weld torch
5502, to reduce oxygen in the vicinity of the weld tip 5503 during a welding
operation.
[00715] Referring to FIG. 72, the shield gas tanks 5262 are shown in the drive
section 5010
of the internal weld system 5004. In one embodiment, a high pressure regulator
5264 may be
positioned in the drive section 5010 of the internal weld system 5004. In one
embodiment,
the high pressure regulator 5264 may be positioned in the center section 5008
of the internal
weld system 5004. In one embodiment, the rear rotary union 5072, the welding
torches 5502,
the rotatable hub 5078, the front and rear clamps 5142, 5144, and the front
and rear clamps
5142 and 5144 are shown in the center section 5008 of the internal weld system
5004. In one
embodiment, the front and rear seals 5146 and 5148 may be positioned in the
center section
5008 of the internal weld system 5004. The shield gas valves 5042 are shown in
the forward-
most section 5006 of the internal weld system 5004.
[00716] In one embodiment, the shield gas tanks 5262 are configured to be
maintained at a
pressure of 500-2400 psi. The shield gas tanks 5262 are in fluid communication
through fluid
communication lines with the rear rotary union 5072. In one embodiment, the
shield gas
tanks 5262 are in fluid communication with the rear rotary union 5072 via a
valve 5266 and
the high pressure regulator 5264. In one embodiment, the high pressure
regulator 5264 is
configured to automatically cut off the flow of the purge gas at a pressure of
75 psi. That is,
the high pressure regulator 5264 is typically set to reduce the pressure in
the shield gas tanks
5262 to about 75 psi in the fluid communication line downstream of the high
pressure
regulator 5264, and from the rear rotary union 5072 to the shield gas valves
5042.
[00717] In one embodiment, the rear rotary union 5072 is in fluid
communication through
fluid communication lines with the shield valves 5042. In one embodiment, the
shield gas
stored in the shield gas tanks 5262 is sent through the fluid communication
lines to the rear
rotary union 5072, and then through the fluid communication lines from the
rear rotary union
5072 to the shield gas valves 5042. In one embodiment, each shield gas control
valve 5042 is
configured to control the flow of the shield gas to the corresponding weld
torch 5502 through
a shield gas line 5268. In one embodiment, each weld torch 5502 has a
corresponding shield
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gas control valve 5042 connected to it. In one embodiment, the shield gas
control valve 5042
is operatively connected to receive control signals from the wire feed
electronics module
5046. In one embodiment, the shield gas control valve 5042 is configured to
supply the shield
gas to the corresponding weld torch, when it receives signals from the wire
feed electronics
module 5046.
[00718] In one embodiment, the drive section 5010 of the internal weld system
5004 may
include the purge gas tanks, the shield gas tanks 5262 and the compressed air
gas tanks. In
one embodiment, the shield gas from the shield gas tanks 5262 is only used to
supply shield
gas to the weld torches 5502. In one embodiment, separate purge gas tanks may
be
configured to fill and maintain the purge gas in the purge gas chamber. In one
embodiment,
the compressed air is used to inflate the seals 5146 and 5148 and to expand
the clamps 5142
and 5144.
[00719] In one embodiment, the drive section 5010 of the internal weld system
5004 may
include the compressed air gas tanks and the purge/shield gas tanks. That is,
the shield and
purge gas tanks are one and the same. In one embodiment, the compressed air
from the
compressed air gas tanks is used to inflate the seals 5146 and 5148 and to
expand the clamps
5142 and 5144. In one embodiment, the seals 5146 and 5148 are optional in the
internal weld
system 5004. In one embodiment, the shield gas to the weld torches 5502 and
the purge gas
to the purge gas chamber are supplied by the same gas tank having purge/shield
gas. In one
embodiment, the supply of the purge gas to the purge gas chamber is optional.
[00720] In one embodiment, the drive section 5010 of the internal weld system
5004 may
only include the purge/shield gas tanks (i.e., no compressed air gas tanks).
This may be the
case for small internal weld systems. In one embodiment, the purge/shield gas
tanks are
configured to supply the purge/shield gas to the weld torches 5502, the
purge/shield gas to the
purge gas chamber, and the purge/shield gas to inflate the seals 5146 and 5148
and to expand
the clamps 5142 and 5144. In one embodiment, the seals 5146 and 5148 are
optional in the
internal weld system 5004. In one embodiment, the supply of the purge gas to
the purge gas
chamber is optional.
[00721] FIGS. 72A, 72B and 72C show close-up views of the internal weld torch
used in a
prior art system and the internal weld system 5004, respectively, where the
pipes have a gap
and radial offset (Hi-Lo) alignment. For example, as shown in FIG. 72A, the
pipes 1022a,
1022b have a 1 millimeter gap and radial offset (Hi-Lo).
[00722] As shown in FIG. 72B, in the prior art system, the raised edge of the
pipe shields
the left side of the weld groove causing reduced weld penetration. As shown in
FIG. 72C, the
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one or more processors 5140 associated with the internal weld system 5004 are
configured to
receive weld profile data (e.g., prior to, during and subsequent to the
welding procedure) and
are configured, based on the received weld profile data, to shift its internal
weld torch 5502
and/or to tilt its external weld torch 5502 to achieve a full weld
penetration. Thus, the weld
profile data from the internal weld system 5004 may be used to make better
weld.
[00723] In one embodiment, the one or more processors 5140 are configured to
receive
profile data related to welding of the interface region 5136 between the first
pipe 1022a and
the second pipe 1022b from the field system 5000. In one embodiment, the
related profile
data is based on a scan of the interface region 5136 between the pipes 1022a,
1022b. In one
embodiment, the one or more processors 5140 are configured to compare one or
more
characteristics of the related profile data with one or more predefined
profile characteristics
to generate a response to the field system 5000. In one embodiment, the one or
more
processors 5140 are configured to transmit the response to the field system
5000 to cause the
field system 5000 to perform one or more operations based on the response. In
one
embodiment, the one or more processors 5140 are configured to transmit a
signal to the field
system 5000 to stop welding-related procedure, change or develop a welding
protocol, save
or further analyze profile data of the interface region 5136, save or further
analyze pre-weld
profile data, save or further analyze post-weld profile data, affirm or modify
a version thereof,
etc.
[00724] In one embodiment, the one or more processors 5140 are operatively
associated
with the inspection detector 5056 to determine a profile of the interface
region 5136 between
the pipes 1022a, 1022b. In one embodiment, the weld torch 5502 is configured
to create a
weld at the interface region 5136 between the pipes 1022a, 1022b based on the
profile of the
interface region 5136 between the pipes 1022a, 1022b. In one embodiment, the
weld torch
(e.g., of the external weld system 7500) is configured to create a weld
between the pipes
1022a, 1022b based on the profile of the interface region 5136 between the
pipes 1022a,
1022b.
[00725] In one embodiment, the one or more processors 5140 are configured to
receive
inspection data from the inspection detector 5056 prior to, subsequent to, or
during a weld
operation. In one embodiment, the one or more processors 5140 are configured
to receive
camera inspection data from the inspection camera 5112 prior to, subsequent
to, or during a
weld operation. In one embodiment, the one or more processors 5140 are
configured to
receive inspection data from the inspection detector 5056 and the camera
inspection data
from the inspection camera 5112 prior to, subsequent to, or during a weld
operation.
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[00726] In one embodiment, the inspection camera 5112 is configured to scan
the welded
interface region 5136 after a welding operation. In one embodiment, the
inspection camera
5112 is configured to send signals to the one or more processors 5140 based on
the scan. In
one embodiment, the one or more processors 5140 are configured to determine a
characteristic of the welded interface region 5136 based on the signals from
the inspection
camera 5112.
[00727] In one embodiment, the one or more processors 5140 are configured to
analyze the
data to automatically detect undercuts or other shape deviations.
[00728] In one embodiment, if a characteristic of the interface region 5136 is
greater than a
predetermined threshold, it may be referred to as an undesirable
characteristic of the interface
region 5136. In one embodiment, if a characteristic of the interface region
5136 is greater
than a predetermined threshold and a difference between the characteristic and
the
predetermined threshold is falling within a predetermined acceptable/allowable
range, it is
determined that the undesirable characteristic of the interface region 5136
does not need
correction. In one embodiment, if a characteristic of the interface region
5136 is greater than
a predetermined threshold and a difference between the characteristic and the
predetermined
threshold is not falling within a predetermined acceptable/allowable range, it
is determined
that the undesirable characteristic of the interface region 5136 needs
correction.
[00729] In one embodiment, if a characteristic of the interface region 5136 is
less than a
predetermined threshold, it may be referred to as undesirable characteristic
of the interface
region 5136. In one embodiment, if a characteristic of the interface region
5136 is less than a
predetermined threshold and a difference between the characteristic and the
predetermined
threshold is falling within a predetermined acceptable/allowable range, it is
determined that
the undesirable characteristic of the interface region 5136 does not need
correction. In one
embodiment, if a characteristic of the interface region 5136 is less than a
predetermined
threshold and a difference between the characteristic and the predetermined
threshold is not
falling within a predetermined acceptable/allowable range, it is determined
that the
undesirable characteristic of the interface region 5136 needs correction.
[00730] In one embodiment, if a characteristic of the interface region 5136 is
not within a
predetermined range, it may be referred to as undesirable characteristic of
the interface region
5136. In one embodiment, if a characteristic of the interface region 5136 is
not within a
predetermined range and is falling within an acceptable/allowable range, it is
determined that
the undesirable characteristic of the interface region 5136 does not need
correction. In one
embodiment, if a characteristic of the interface region 5136 is not within a
predetermined
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range and is not falling within the acceptable/allowable range, it is
determined that the
undesirable characteristic of the interface region 5136 does not need
correction.
[00731] In one embodiment, the one or more processors 5140 are configured to
receive the
electronic signals (e.g., generated by the receiver of the inspection detector
5136) to
determine whether the undesirable characteristic of the interface region 5136
should be
corrected. In one embodiment, in response to detecting one or more undesirable
characteristics of the interface region 5136, the one or more processors 5140
are configured
to send instructions to the motor 5030, 5074 controlling an axially rotational
position of one
of the pipes to cause the motor 5030, 5074 to rotate the one of the pipes
1022a, 1022b relative
to the other of the pipes 1022a, 1022b to correct the undesirable
characteristic. In one
embodiment, the motor 5030, 5074 is configured for moving a radially extending
clamp 5142,
5144.
[00732] In one embodiment, the weld torch 5502, operatively connected with the
one or
more processors 5140, is configured to perform a weld operation to weld the
pipes 1022a,
1022b together in response to the one or more processors 5140 detecting that
no undesirable
characteristics exist.
[00733] In one embodiment, the one or more processors 5140 are configured to
interact
with the inspection detector 5056 to scan the interface region 5136 between
the pipes 1022a,
1022b to determine the profile of the interface region 5136 between the pipes
1022a, 1022b
prior to a welding operation and generate pre-weld profile data based thereon.
In one
embodiment, the one or more processors 5140 are configured to interact with
the inspection
detector 5056 to scan the entire interface region 5136 between the pipes
1022a, 1022b to
generate the pre-weld profile data prior to weld material being applied to
weld the two pipes
1022a, 1022b together. In one embodiment, the one or more processors 5140 are
configured
to interact with the inspection detector 5056 to scan the interface region
5136 to obtain the
pre-weld profile data subsequent to the first clamp 5142 and the second clamp
5144 engaging
with the first pipe and second pipe 1022a, 1022b, respectively.
[00734] Additionally, or alternatively, the one or more processors 5140 are
configured to
interact with the inspection camera 5112, x-ray radiography inspection device,
gamma ray
inspection device, ultrasonic inspection device, magnetic particle inspection
device, eddy
current inspection device or other inspection devices to scan the interface
region 5136
between the pipes 1022a, 1022b to determine the profile of the interface
region 5136 prior to
the welding operation.
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[00735] The pre-weld scan/inspection procedure is the same for the tie-in
internal weld
system 3001 and the purge and inspection system 7001, and, therefore, will not
be described
again with reference to the tie-in internal weld system 3001 and the purge and
inspection
system 7001.
[00736] In various embodiments, the "pre-weld" profile data described herein
refers to data
obtained from the inspection detector (e.g., such as by an inspection laser)
that has scanned
the interface region between two pipes to be welded before the weld torch has
been activated
to commence securing the pipes to one another. This pre-weld profile data is
communicated
to the one or more processors to determine whether the pipes are sufficiently
aligned prior to
any weld material being deposited to the interface region. In one embodiment,
if
misalignment is detected, e.g., by a determination by the one or more
processors that the
misalignment is outside an acceptable misalignment value, the one or more
processors are
configured to send signals to the cradles that engage with the exterior
surfaces of the pipes.
One or both of the cradles can be adjusted based on output signals from the
pre-weld profile
data to adjust relative positioning between the pipes to bring the alignment
of the interface
region within an acceptable misalignment value.
[00737] It should be appreciated that, given slight inconsistencies in the
pipe structures,
absolutely perfect alignment is often (and typically) not achieved.
Nevertheless, such perfect
alignment is unnecessary so long as the alignment is within a tolerance range
suitable for a
good weld.
[00738] In one embodiment, the pre-weld profile data may include pipe
ovality/roundness
data. In one embodiment, the pipe ovality/roundness data may include location
and size of
minimum inner diameter, location and size of maximum inner diameter, pipe
average inner
diameter, pipe average wall thickness, location and size of minimum wall
thickness, and/or
location and size of maximum wall thickness. In one embodiment, the pipe
ovality/roundness
data may include a comparison between each of location and size of minimum
inner diameter,
location and size of maximum inner diameter, location and size of minimum wall
thickness,
and location and size of maximum wall thickness, and their respective
predetermined values.
In one embodiment, the pipe ovality/roundness data may include a comparison
between each
of pipe average inner diameter and pipe average wall thickness, and their
respective
predetermined values. In one embodiment, the pipe ovality/roundness data may
include inner
diameter deviations of the pipe at all locations on the circumference of the
pipe based on the
comparison.
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[00739] In one embodiment, the pre-weld profile data may include pipe bevel
profile data.
In one embodiment, the pipe bevel profile data may include pipe bevel
geometry. In one
embodiment, the pipe bevel profile data may include a comparison between each
of size and
shape of the pipe bevel, root face (land) thickness of the pipe bevel, bevel
angle of the pipe
bevel, offset of the pipe bevel, and root angle of the pipe bevel, and their
respective
predetermined values. In one embodiment, the pipe bevel profile data may
include pipe bevel
deviations of the pipe at all locations on the circumference of the pipe based
on the
comparison.
[00740] In one embodiment, the pre-weld profile data may include weld joint
fit-up and
alignment data. In one embodiment, the weld joint fit-up and alignment data
may include data
on the gap between internal adjoining ends of the pipes (after pipe
alignment). In one
embodiment, the weld joint fit-up and alignment data may include data on the
gap between
bevels of the pipes (after pipe alignment). In one embodiment, the weld joint
fit-up and
alignment data may include location and size of minimum gap, location and size
of maximum
gap, and/or average gap. In one embodiment, the weld joint fit-up and
alignment data may
include a comparison between each of location and size of minimum gap, and
location and
size of maximum gap, and their respective predetermined values. In one
embodiment, the
weld joint fit-up and alignment data may include a comparison between average
gap and its
respective predetermined value. In one embodiment, the weld joint fit-up and
alignment data
may include gap deviations of the pipes at all locations on the circumference
of the pipes
based on the comparison. In one embodiment, the weld joint fit-up and
alignment data may
include the minimal differences in height between the pipes (e.g., what is
acceptable
alignment), etc.
[00741] In one embodiment, the one or more processors 5140 are configured to
interact
with the inspection detector 5056 to scan the interface region 5136 subsequent
to the first
clamp 5142 and the second clamp 5144 engaging with the first pipe 1022a and
second pipe
1022b, respectively. In one embodiment, the one or more processors 5140 are
configured to
be operatively connected with the first pipe engagement structure 5052 and the
second pipe
engagement structure 5054. In one embodiment, the one or more processors 5140
are
configured to operate the first pipe engagement structure 5052 and/or the
second pipe
engagement structure 5054 based on the pre-weld profile data to alter the
interface region
5136 between the pipes 1022a, 1022b prior to the welding operation.
[00742] In one embodiment, the one or more processors 5140 are configured to
alter the
interface region 5136 between the pipes 1022a, 1022b prior to the welding
operation by
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driving the first pipe engagement structure 5052 and/or the second pipe
engagement structure
5054 to change the roundness (or ovality) of the first pipe 1022a and/or
second pipe 1022b
based on the pre-weld profile data. For example, in one embodiment, the one or
more
processors 5140 are configured to alter the interface region 5136 between the
pipes 1022a,
1022b prior to the welding operation by selectively driving the one or more
clamp shoes 5157
of the clamps 5142 and/or 5144 to change the roundness of the first pipe 1022a
and/or second
pipe 1022b based on the pre-weld profile data.
[00743] In one embodiment, the one or more processors 5140 are configured to
alter the
interface region 5136 between the pipes 1022a, 1022b prior to the welding
operation by
driving the first pipe engagement structure 5052 and/or the second pipe
engagement structure
5054 to rotate and/or axially move the first pipe 1022a and/or second pipe
1022b based on the
pre-weld profile data. In one embodiment, the one or more processors 5140 are
configured to
alter the interface region 5136 between the pipes 1022a, 1022b prior to the
welding operation
by rotating one pipe 1022a or 1022b relative to the other 1022a or 1022b.
[00744] In one embodiment, the one or more processors 5140 are configured to
develop a
welding protocol based on the pre-weld profile data. In one embodiment, the
welding
protocol includes a welding speed and weld torch position protocol.
[00745] In one embodiment, the one or more processors 5140 are configured to
operate the
cradles 5330 (as shown in FIGS. 10A and 10B) or 6010A and 6010B (as shown in
FIG.73)
for providing the incoming pipe 1022a at the second end of the pipe 1022b
(after the frame
assembly of the internal weld system 5004 is positioned at the second end of
the pipe 1022b)
based on the pre-weld profile data to alter interface region 5136 between the
pipes 1022a,
1022b prior to the welding operation. In one embodiment, the one or more
processors 5140
are configured to control the externally positioned rollers 5332 the cradles
5330 for providing
the incoming pipe 1022a at the second end of the pipe 1022b (after the frame
assembly of the
internal weld system 5004 is positioned at the second end of the first pipe
1022b) based on
the pre-weld profile data.
[00746] In one embodiment, the one or more processors 5140 are configured to
operate the
cradles 5330 (as shown in FIGS. 10A and 10B) or 6010A and 6010B (as shown in
FIG.73) to
generate relative movement between the first pipe 1022a and second pipe 1022b
based on the
pre-weld profile data to alter interface region 5136 between the pipes 1022a,
1022b prior to
the welding operation. In one embodiment, an exterior surface 5346 and/or 5348
(as shown in
FIG. 2G) of the first pipe 1022a and/or second pipe 1022b is engaged to adjust
the relative
positioning of the pipes 1022a, 1022b in the event the pre-weld profile data
determines
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adjustment is required. In one embodiment, the cradles 5330 (as shown in FIGS.
10A and
10B) and 6010A and 6010B (as shown in FIG. 73) are operated by the one or more
processors 5140 (or otherwise controlled) to engage the exterior surfaces 5346
and/or 5348
(as shown in FIG. 2G) of the first pipe 1022a and/or second pipe 1022b to
adjust the relative
positioning of the pipes 1022a, 1022b in the event the pre-weld profile data
determines
adjustment is required.
[00747] In one embodiment, the first clamp and/or the second clamp 5142, 5144
are
released to enable adjustment of relative positioning of the pipes 1022a,
1022b in the event
the pre-weld profile data determined adjustment is required. In one
embodiment, the first and
second clamps are internally positioned clamps and are released to enable
adjustment of
relative positioning of the pipes 1022a, 1022b in the event the pre-weld
profile data
determined adjustment is required. In one embodiment, the first and second
clamps are
externally positioned clamps and are released to enable adjustment of relative
positioning of
the pipes 1022a, 1022b in the event the pre-weld profile data determined
adjustment is
required. In one embodiment, the first and second clamps include both
internally positioned
clamps and the externally positioned clamps. In one embodiment, both the
internally
positioned clamps and the externally positioned clamps are released to enable
adjustment of
relative positioning of the pipes 1022a, 1022b in the event the pre-weld
profile data
determined adjustment is required.
[00748] In one embodiment, the adjustment of the relative positioning of the
pipes 1022a,
1022b (based on the pre-weld profile data) may be either automatically
performed by the
processors 5140 controlling the externally positioned rollers 5332 (as shown
in FIGS. 10A
and 10B) or performed by an operator using a crane and (internal and/or
external) clamps. In
one embodiment, the adjustment of the relative positioning of the pipes 1022a,
1022b (based
on the pre-weld profile data) may also be referred to as re-alignment of the
pipes 1022a,
1022b.
[00749] In one embodiment, the adjustment of the relative positioning of the
pipes 1022a,
1022b (based on the pre-weld profile data) may include an adjustment along the
longitudinal
axis of the pipes 1022a, 1022b, and/or an adjustment along the radial axis of
the pipes 1022a,
1022b. In one embodiment, the adjustment of the relative positioning of the
pipes 1022a,
1022b (based on the pre-weld profile data) may include position adjustment and
orientation
adjustment of the pipes 1022a, 1022b. In one embodiment, the adjustment of the
relative
positioning of the pipes 1022a, 1022b (based on the pre-weld profile data) may
include up
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and down movement and longitudinal movement (along the longitudinal axis of
the pipes
1022a, 1022b).
[00750] In one embodiment, the internal and/or external clamp(s) (holding the
pipes 1022a,
1022b in place during the pre-weld procedure) are released and a crane,
electronically
controlled externally positioned rollers 5332 or other such devices may be
used to maneuver
the pipe based on the pre-weld profile data. In one embodiment, the internal
and/or external
clamp(s) (holding the pipes 1022a, 1022b in place during the pre-weld
procedure) are
released before the re-alignment procedure. In one embodiment, after the re-
alignment of the
pipes 1022a, 1022b, the pipes 1022a, 1022b are clamped back using the external
and/or
internal clamps.
[00751] In one embodiment, a new pipe to be welded 1022a may be rotated about
its
longitudinal axis relative to the prior pipe that has been welded 1022b, based
on the pre-weld
profile data that has been obtained from the inspection detector (e.g., the
inspection laser)
5056. Specifically, the pre-weld profile data can be used to determine that,
in some instances,
the relative rotational positions of the pipes 1022a and 1022b can be changed
to effect a
better match for welding. For example, if each of the pipes 1022a, 1022b has a
slight ovality
to them, then matching the pipes so that major axis of each of the two pipes
are generally
aligned and the minor axis of each of the two pipes are generally aligned, can
have an overall
beneficial effect. Thus, in one embodiment, the inspection detector 5056 can
generate signals
that are processed by the one or more processors 5140 to determine a more
beneficial
rotational position for the incoming pipe 1022a to be welded. Such rotation
can be
accomplished by the one or more processors 5140 activating the front rotation
motor 5030 to
rotate the pipe 1022a prior to a welding operation. In particular, to rotate
the incoming pipe
1022a, the center frame 5068 remains rotatably fixed with respect to the
previously welded
pipe. This rotationally fixed relationship between the center frame 5068 and
pipe 1022b is
accomplished by having the rear clamp 5144 actuated by the one or more
processors 5140 to
be securely engaged with the interior surface of pipe 1022b to prevent
relative rotation
therebetween. In addition to the rear clamp 5144 and the center frame 5068
being rotationally
fixed with respect to the pipe, the rear rotation motor 5074 is not activated
by the processor
5140 and its motor shaft is locked from rotation. As a result of the rear
rotation motor shaft
being prevented from rotation, the entire rotatable hub 5078 remains rotatably
fixed relative
to the center frame 5068 and the pipe 1022b. The front rotation motor 5030 is
then activated.
Its shaft rotates to drive the gear train as shown in Fig. 19 and described
above so that gear
teeth 23 rotatably engage the gear teach 5023 of the ring gear 5021. Because
the wire feed
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module 5020 (which is fixed to the rotatable hub 5078) and the rotatable hub
5078 are fixed
from rotation, the front rotation motor 5030 and gear 5023 operatively
connected thereto is
driven circumferentially along the ring gear 5021. This rotational driving
force posed on the
front rotation motor 5030 rotatably moves the entire forward-most section
frame 5026 to
which the motor 5030 is connected. The rotation of the forward-most section
frame 5026, in
turn, rotatably drives the front clamp 5142. The clamp 5142 rotates around the
rotatable hub
5078 on the bearings 5108, 5098 that are between the clamp 5142 and the
rotatable hub 5078.
Because the clamp 5142 is extended and clamped to the interior surface of the
pipe 1022a,
the pipe 1022a is rotated as a result to the located determined by the one or
more processors
5140 based upon the pre-weld scanned information received from the inspection
detector
5056. During rotation of the pipe 1022a, if an external cradle (5330, 6010A,
6010B) is
engaging the exterior surface of the pipe, the rollers 5332 on the external
cradle (5330,
6010A, 6010B) are instructed by the one or more processors 5140 to optionally
be in a free-
wheeling state where they are passive, or optionally the one or more motors
operatively
connected with the rollers 5332 are instructed by the one or more processors
5140 to drive to
rollers 5332 at a rotational speed commensurate with (similar to or the same
as) the speed at
which the front rotation motor 5030 drives the rotation from inside the pipe
1022a. This latter
approach provides rotational forces to the pipe 1022a from both inside and
outside the pipe,
although in some embodiments, either driving force alone may be sufficient.
[00752] In the embodiment just described, the clamps 5142 and 5144 are engaged
with the
associated pipes 1022a and 1022b to prevent relative rotation between the
frame 5026 and
pipe 1022a, and to prevent rotation between the center frame 5068 and the pipe
1022b. In one
or more embodiments, however, the clamps 5142 and 5144 need not be responsible
for this
function. Instead, wheels operatively associated with both frames may be
configured to
engage the associated pipes with sufficient friction and/or outward force to
prevent relative
rotation between the pipes and frames. In one embodiment, the wheels the
effect or permit
locomotion between the frames and the pipes permit generally longitudinal
movement only
between the frames and pipes and prevent relative rotational movement
therebetween. This
can be true for wheels on one or more of the frames. The wheel engagement
option can be
used on only one of the frames, on both of the frames, and can optionally be
used in
combination with the clamping methodology for one or both of the frames.
[00753] The pipe rotation techniques described herein can also be used to
return the frames
to a desired "start" or "home" rotational position after a welding operation
is completed and a
new pipe comes in for the next pre-weld scan.
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[00754] In one embodiment, the one or more processors 5140 are configured to
send the
pre-weld profile data to a remote processor for further processing.
[00755] In one embodiment, the one or more processors 5140 are configured to
interact
with the inspection detector 5056 to scan the interface region 5136 between
the pipes 1022a,
1022b to determine the profile of the interface region 5136 between the pipes
1022a, 1022b
during a welding operation, at a region of the interface prior to weld
material being deposited
thereon, and generate on-the-fly profile data.
[00756] The on-the-fly scan/inspection procedure is the same for the tie-in
internal weld
system 3001 and the purge and inspection system 7001, and, therefore, will not
be described
again with reference to the tie-in internal weld system 3001 and the purge and
inspection
system 7001.
[00757] In various embodiments, the on-the-fly profile data refers to data
obtained from the
inspection detector during a welding operation. For example, the on-the-fly
profile data is
taken from a position immediately before (in front of) the region that is
being welded (for
example, 1-6 inches in front of the region being welded). In particular, the
inspection detector
scans the interface region in the region about to be welded so as to provide
data on the profile
of the interface region immediately before the weld material is deposited. It
should be
appreciated that the profile of the interface region between the pipes may
change slightly as
increasing more of the interface region is welded. In other words, the
sequential welding
itself may slightly alter the alignment/positioning of the pipes at the
interface region at the
portions of the interface region yet to be welded. The inspection detector
measures the profile
of the interface region immediately before the weld torch deposit's weld
material on the yet-
to-be welded regions of the interface region, and signals from the inspection
detector are
received and used by the one or more processors to output signals/instructions
to the weld
torch and/or its motors to control various weld torch parameters to tailor the
weld to the pipes
as they are being welded. The weld torch parameters can include one or more of
the
following: wire feed speed, wire consumption, oscillation width, oscillation
waveform,
oscillation amplitude, weld time, gas flow rate, power levels of the weld arc,
weld current,
weld voltage, weld impedance, weld torch travel speed, position of the weld
tip of the weld
torch along the pipe axis, angular positioning of the weld tip of the weld
torch with respect to
its rotational plane and/or the distance of the weld tip of the weld torch to
the inner surfaces
of the pipes to be welded.
[00758] In one embodiment, the on-the-fly weld profile data may include a high-
low (Hi-Lo)
data. In one embodiment, the high-low (Hi-Lo) may generally refer to a height
difference
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between the bevel edges of the pipes after their alignment. In one embodiment,
the high-low
(Hi-Lo) data may include a comparison between each of location and size of
minimum height
difference, and location and size of maximum height difference, and their
respective
predetermined values. In one embodiment, the high-low (Hi-Lo) data may include
a
comparison between average height difference and its respective predetermined
value. In one
embodiment, the high-low (Hi-Lo) data may include height difference deviations
of the pipes
at all locations on the circumference of the pipes based on the comparison.
[00759] In one embodiment, the on-the-fly weld profile data may include weld
joint
characteristics.
In one embodiment, the on-the-fly weld profile data may include width of the
weld joint and
root gap of the weld joint.
[00760] In one embodiment, the one or more processors 5140 are configured to
generate
weld signals to control the weld torch 5502 based on the on-the-fly profile
data. In one
embodiment, the one or more processors 5140 are configured to control a
position and speed
of the weld torch 5502 based on-the-fly profile data during a weld operation.
In one
embodiment, the torch motor 5588 is operatively connected to the one or more
processors
5140 to control an angle of the weld torch 5502 during the weld operation.
[00761] In one embodiment, the one or processors 5140 are configured to
instruct the one or
more torch motors 5512 to move the weld tip 5503 further away from the
interface region
5136 after each weld pass to accommodate for weld material build-up. In one
embodiment,
the one or processors 5140 are configured to control the axial weld torch
motor 5550 to
control the axial motion of the weld torch 5502 (i.e., move the weld tip 5503
further away
from the interface region 5136).
[00762] In one embodiment, the one or more processors 5140 are configured to
generate an
initial plotted weld profile based on the pre-weld profile data and
modify/adapt the initial
plotted weld profile based the on-the-fly profile data.
[00763] In one embodiment, wire feed speed, oscillation width, power levels of
the weld arc,
and/or the distance of the weld tip 5503 of the weld torch 5502 to the
surfaces of the pipes to
be welded may be controlled based the on-the-fly profile data.
[00764] In one embodiment, the one or more processors 5140 are configured to
interact
with the inspection detector 5056 to scan the interface region 5136 between
the pipes 1022a,
1022b to determine the profile of the interface region 5136 between the pipes
1022a, 1022b
subsequent to a welding operation and generate post-weld profile data based
thereon. In one
embodiment, the post-weld profile data is obtained with the inspection
detector 5056
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positioned within the first pipe 1022a and/or the second pipe 1022b, without
disengaging the
first pipe engagement structure 5052 or the second pipe engaging structure
5054 from the
interior surface 5130 of the first pipe 1022a or the interior surface 5132 of
the second pipe
1022b, respectively.
[00765] The post-weld scan/inspection procedure is the same for the tie-in
internal weld
system 3001 and the purge and inspection system 7001, and, therefore, will not
be described
again with reference to the tie-in internal weld system 3001 and the purge and
inspection
system 7001.
[00766] Additionally, or alternatively, the one or more processors 5140 are
configured to
interact with the inspection camera 5112, x-ray radiography inspection device,
gamma ray
inspection device, ultrasonic inspection device, magnetic particle inspection
device, eddy
current inspection device or other inspection devices to scan the interface
region 5136
between the pipes 1022a, 1022b to determine the profile of the interface
region 5136
subsequent to a welding operation.
[00767] In one embodiment, the post-weld profile data may include profile(s)
of the formed
weld beads. In one embodiment, the post-weld profile data may include
profile(s) of the
formed root pass weld layer. In one embodiment, the post-weld profile data may
include weld
shape characteristics such as mismatch, bead concavity, and the re-entrant
angle.
[00768] In one embodiment, the one or more processors 5140 are configured to
cause,
based on the post-weld profile data, another weld operation to be performed on
the interface
region 5136 between the pipes 1022a, 1022b.
[00769] Certain weld variables/parameters have well known relationships. That
is, a change
in one weld variable/parameter has a corresponding change in the other weld
variable/parameter. The weld variable/parameters, such as, weld current, weld
voltage, weld
torch travel speed, and heat input are all connected. For example, if the weld
current increases
and all other weld variable/parameters remain constant, then voltage should
decrease. Also, if
the weld torch travel speed increases and all other weld variables/parameters
remain constant,
then heat input should decrease. In one embodiment, the one or more processors
5140 are
configured to analyze of the data gathered (e.g., prior to, subsequent to, or
during a weld
operation) to detect problems and make process/parameter changes. In one
embodiment,
based on the analysis and detection, the one or more processors 5140 are
configured to take
the internal weld system 5004 off-line for maintenance as needed to prevent a
recurrence.
[00770] In one embodiment, every data point collected/received by the one or
more
processors 5140 prior to, subsequent to, or during a weld operation is
compared to its
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corresponding (Gold Standard) ideal weld value. If any process variables
differ by more than
a set/predetermined limit, these differences can be flagged. If the
differences persist for
longer than the maximum allowable defect size, the weld process can be stopped
so that the
weld can be repaired. Over time, the ideal weld values and the allowable
limits may be
improved as more weld data is collected.
[00771] In one embodiment, the one or more processors may be configured to see
what
happened right before the deviation occurred and determine if there is a
deficiency in the
control loop programming that allowed the deviation to occur. If so, the one
or more
processors can send an updated control loop program to the internal weld
system 5004 and
observe if the change improves the performance of the internal weld system
5004.
[00772] In one embodiment, the one or more processors may also be configured
to monitor
the commands being given to the internal weld system 5004 locally by the
operator. If these
commands are determined to cause the weld defects, the one or more processors
are
configured to send a message to the operator to stop providing commands to the
internal weld
system 5004. If the commands are determined to prevent weld defects, the one
or more
processors are configured to send a message to all operators instructing them
to begin using
the commands.
[00773] In one embodiment, the one or more processors are configured to
collect and
analyze the Non-Destructive Test (NDT) data. In one embodiment, the locations
where the
weld defects are detected can be compared back to the weld parameters that
were logged at
the same location, even if the defect is small enough to not require repair.
In one embodiment,
the one or more processors will be able to know about the weld defects that
would not be
included in a traditional inspection report. This gives the one or more
processors a very good
statistical sample for every welding parameter and the quality of the
resulting weld. This
statistical model can be used to determine the best settings for each welding
parameter as
well as the allowable deviation from the setting. These new parameters can be
communicated
directly to the internal weld system 5004 as each new NDT scan improves the
statistical
model.
[00774] In one embodiment, as described herein, the computer system 5138
(comprising the
one or more processors 5140) may be a computer system local to the field
system 5000. In
another embodiment, as described herein, the computer system 5138 may be a
computer
system positioned remotely from the field system 5000 (e.g., remote computer
system 13704
or other remote computer system) and may be communicatively connected to the
field system
5000 or a local computer system thereof.
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[00775] In one embodiment, the one or more processors 5140 may receive (via a
receiver)
inspection data associated with an inspection of the interface region 5136
between the pipes
1022a, 1022b from the field system 5000 (e.g., raw data from the inspection
devices, 2D or
3D imaging data, or other data from the inspection). One or more inspection
devices used for
the inspection may comprise one or any combination of an inspection laser, an
inspection
camera, an x-ray radiography inspection device, a gamma ray inspection device,
an ultrasonic
inspection device, a magnetic particle inspection device, eddy current
inspection device, a
temperature monitor, or other inspection device. The inspection data may
respectively
comprise one or any combination of laser inspection data, camera inspection
data, x-ray
inspection data, gamma ray inspection data, ultrasound inspection data,
magnetic particle
inspection data, eddy current inspection data, temperature inspection data, or
other inspection
data.
[00776] In one embodiment, the one or more processors 5140 may automatically
generate a
response comprising profile data for the interface region 5136 (e.g., pre-weld
profile data, on-
the-fly profile data, post-weld profile data, or other data) based on the
received inspection
data, and transmit (via a transmitter) the profile data to the field system
5000. In one
embodiment, for example, where the received inspection data is based on a scan
of the
interface region prior to a welding operation, the one or more processors 5140
may use the
received inspection data to generate a response comprising pre-weld profile
data for the
interface region 5136, and transmit (via a transmitter) the pre-weld profile
data to the field
system 5000. In one embodiment, where the received inspection data is based on
a scan of
the interface region during a welding operation, the one or more processors
5140 may use the
received inspection data to generate a response comprising on-the-fly-weld
profile data for
the interface region 5136, and transmit (via a transmitter) the on-the-fly
profile data to the
field system 5000. In one embodiment, where the received inspection data is
based on a scan
of the interface region subsequent a welding operation, the one or more
processors 5140 may
use the received inspection data to generate a response comprising post-weld
profile data for
the interface region 5136, and transmit (via a transmitter) the post-weld
profile data to the
field system 5000.
[00777] In one embodiment, the one or more processors 5140 may automatically
generate a
response comprising one or more welding protocols or other operation protocols
based on the
received inspection data, and transmit (via a transmitter) the operation
protocols as control
operation data to the field system 5000. As an example, upon receipt of the
operation
protocols, the field system 5000 may perform one or more operations based on
the received
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operation protocols. In another embodiment, the one or more processors 5140
may generate
profile data based on the received inspection data to obtain the profile data
for the interface
region 5136 (e.g., pre-weld profile data, on-the-fly profile data, post-weld
profile data, or
other profile data). In a further embodiment, the one or more processors 5140
may use the
profile data to obtain the welding protocols or other operation protocols, and
transmit (via a
transmitter) the operation protocols to the field system 5000.
[00778] In one embodiment, the one or more processors 5140 may generate a
welding
protocol or other operation protocol based on inspection data associated with
one or more
other pipes (other than pipes 1022a, 1022b), data related to input parameters
(e.g., welding or
other parameters) used to perform one or more operations (e.g., welding or
other operations)
on the other pipes, data related to observations of the operations, or other
data. As an
example, the one or more processors 5140 may obtain the inspection data from
one or more
field systems, and analyze the inspection data to determine whether and which
of the pipes
have defects. The processors may then compare one or more sets of observations
of an
operation performed on one or more objects determined to have a defect (after
the
performance of the operation) against one or more other sets of observations
of the same
operation performed on one or more other objects without the defect to
determine the
circumstances that likely caused the defect (as described in further detail
herein elsewhere).
Based on the comparison, the one or more processors 5140 may generate the
welding
protocol or other operation protocol such that the operation protocol avoids
or would
otherwise addresses the circumstances (likely to have caused the defect) when
the operation
protocol is used for one or more subsequent operations (e.g., subsequent
operations that are
the same or similar to the operation performed and observed).
[00779] In one embodiment, the one or more processors 5140 may obtain pre-weld
profile
data for the interface region 5136 (between the pipes 1022a, 1022b), where the
pre-weld
profile data is based a scan of the interface region 5136 at the field system
5000 prior to a
welding operation. As an example, the one or more processors may receive the
pre-weld
profile data from the field system 5000. As another example, the one or more
processors
5140 may generate the pre-weld profile data based on inspection data received
from the field
system 5000. Upon obtainment, the one or more processors 5136 may analyze the
pre-weld
profile data to generate a response to the field system 5000. In one
embodiment, the one or
more processors 5140 may compare one or more characteristics of the pre-weld
profile data
(e.g., pipe ovality/roundness characteristics, pipe bevel profile
characteristics, weld joint fit-
up and alignment characteristics, or other characteristics) with one or more
characteristics of
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acceptable predefined pre-weld profiles. Based on the comparison, the
processors 5140 may
transmit (via a transmitter) a response as control operation data to field
system 5000
indicating whether the field system 5000 is to begin the welding operation.
[00780] As an example, the response may specify that the interface region 5136
is within
specification for the welding operation, indicating that the field system 5000
is to be begin
the welding operation. The response may additionally or alternatively comprise
one or more
welding protocols for the welding operation. As another example, the response
may specify
that the interface region 5136 is not within specification, indicating that
the field system 5000
should not perform the welding operation on the interface region 5136 in its
current state. In
one use case, the response may indicate a need to alter the interface region
5136 prior to the
welding operation (e.g., a need to realign the pipes 1022a, 1022b or other
alternations). As
such, the response may cause the field system 5000 to operate a pipe
engagement structure of
the field system 5000 to alter the interface region 5136 prior to the welding
operation so that
the interface region 5136 is within specification for the welding operation.
[00781] In one embodiment, the one or more processors 5140 may compare one or
more
characteristics of profile data (obtain based on a scan of the interface
region 5136 at the field
system 5000) with one or more predefined profile characteristics to determine
one or more
matching characteristics. Based on the matching characteristics, for example,
the one or
more processors 5140 may automatically determine one or more welding protocols
for
welding the interface region 5136 between the pipes 1022a, 1022b, and transmit
(via a
transmitter) the one or more welding protocols to the field system 5000 to
cause the field
system 5000 to perform a welding operation on the interface region 5136 based
on the one or
more welding protocols. As an example, a welding protocol may comprise one or
more input
parameters, such as wire feed speed, wire consumption, oscillation width,
oscillation
waveform, oscillation amplitude, weld time, gas flow rate, power levels of the
weld arc, weld
current, weld voltage, weld impedance, weld torch travel speed, position of
the weld tip of
the weld torch along the pipe axis, angular positioning of the weld tip of the
weld torch with
respect to its rotational plane, the distance of the weld tip of the weld
torch to the inner
surfaces of the pipes to be welded, or other parameters.
[00782] In one embodiment, the one or more processors 5140 may obtain on-the-
fly profile
data for the interface region 5136 (between the pipes 1022a, 1022b), where the
on-the-fly
profile data is based a scan of the interface region 5136 at the field system
5000 during a
welding operation. As an example, the one or more processors 5140 may receive
(via a
receiver) the on-the-fly profile data from the field system 5000. As another
example, the one
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or more processors 5140 may generate the on-the-fly profile data based on
inspection data
received from the field system 5000. Upon obtainment, the one or more
processors 5140
may analyze the on-the-fly profile data to generate a response to the field
system 5000. In one
embodiment, the one or more processors 5140 may compare one or more
characteristics of
the on-the-fly profile data (e.g., pipe ovality/roundness characteristics,
pipe bevel profile
characteristics, weld joint fit-up and alignment characteristics, weld shape
characteristics, or
other characteristics) with one or more characteristics of acceptable
predefined profiles (e.g.,
predefined pre-weld profiles, predefined post-weld profiles, or other
profiles). Based on the
comparison, the processors 5140 may transmit a response to field system 5000
comprising
on-the-fly updates to one or more welding characteristics for the welding
operation. As an
example, the response may cause the field system 5000 to control a weld torch
based on the
on-the fly-updates to the welding characteristics during the welding
operation.
[00783] In one embodiment, the one or more processors 5140 may obtain post-
weld profile
data for the interface region 5136 (between the pipes 1022a, 1022b), where the
post-weld
profile data is based a scan of the interface region 5136 at the field system
5000 subsequent
to a welding operation. As an example, the one or more processors 5140 may
receive (via a
receiver) the post-weld profile data from the field system 5000. As another
example, the one
or more processors 5140 may generate the post-weld profile data based on
inspection data
received from the field system 5000. Upon obtainment, the one or more
processors 5140
may analyze the on-the-fly profile to generate a response to the field system
5000. In one
embodiment, the one or more processors 5140 may compare one or more
characteristics of
the post-weld profile data (e.g., weld shape characteristics or other
characteristics) with one
or more characteristics of acceptable predefined post-weld profiles. Based on
the comparison,
the processors 5140 may transmit (via a transmitter) a response to field
system 5000
indicating whether a result of the welding operation is acceptable.
Additionally or
alternatively, the one or more processors 5140 may automatically determine one
or more
welding protocols for a subsequent operation (e.g., an operation that repairs
or compensates
for a defect resulting from the welding operation, an operation that typically
follows the
welding operation if no defect of significance is detected, etc.), and include
the one or more
welding protocols in the transmitted response.
[00784] As an example, if the welding operation is for a root pass, the
response may specify
that the root pass layer resulting from the welding operation is within
specification, and the
response may specify that preparation for a subsequent welding operation for a
hot pass is to
begin. As such, the response may cause the field system 5000 to initiate
performance of the
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hot pass operation on the interface region 5136. As another example, the
response may
specify that the resulting root pass layer is not within specification. In one
use case, for
instance, the response may specify that the field system 5000 should not
proceed with the hot
pass operation until further notice. In another use case, the response may
specify that the
field system 5000 is to proceed with a different welding protocol (than
otherwise pre-planned
for the hot pass operation), where the different welding protocol repairs or
compensates for
the resulting root pass layer not being within specification.
1007851 In one embodiment, where the one or more processors 5140 are local to
the field
system 5000 (e.g., part of a computer system local to the field system 5000),
the one or more
processors 5140 may transmit, to a remote computer system, inspection data
associated with
an inspection of a region (e.g., interface region 5136 or other region)
between the pipes 1022a,
1022b. The transmitted inspection data may, for example, comprise one or any
combination
of the types of inspection data described herein. In one embodiment, the one
or more
processors 5140 may receive (via a receiver) a response from the remote
computer system
responsive to transmitting the inspection data to the remote computer system
(e.g., a response
comprising pre-weld profile data, on-the-fly profile data, post-weld profile
data, an
affirmation of transmitted profile data, a welding or other operation
protocol, an alert
indicating a defect, or other data). In one embodiment, the response may be
derived from the
transmitted inspection data and additional data received by the remote
computer system. As
an example, the additional data may be related to observations of one or more
operations
performed on other pipes, inspection of the other pipes, one or more input
parameters used to
perform the observed operations, or other data (as described herein). In this
way, for example,
one or more operations in a field system (e.g., field system 5000 or other
field system) may
be managed based on previously unavailable large data pools with data from the
same field
system and/or other field systems. For example, the data pools (comprising
data on the
observation of operations on the other pipes, the inspection of the other
pipes, the input
parameters for performing the observed operations, or other data from the same
field system
or other field systems) may be used to generate and select one or more welding
or other
operation protocols for subsequent operations (as described herein) to prevent
or reduce weld
defects or create better welds for current and future customers. As another
example, the large
pool of data from different field systems may be used to improve inspection
and analysis
thereof (as described herein) to provide current and future customers with
better products
(e.g., by reducing weld defects, detecting defects earlier in the process,
etc.).
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[00786] In one embodiment, where the one or more processors 5140 are local to
the field
system 5000 (e.g., part of a computer system local to the field system 5000),
the one or more
processors 5140 may transmit a profile of the interface region 5136 between
the pipes 1022a,
1022b to a remote computer system (e.g., a profile derived based on a scan of
the interface
region 5136). In response, the one or more processors 5140 may receive (via a
receiver) an
affirmation of the profile of the interface region or a modified version of
the profile of the
interface region 5136 from the remote computer system. In one embodiment, the
one or
more processors may cause a weld torch of the weld system 5004 to create a
weld at the
interface region 5136 based on the affirmation or the modified version of the
profile of the
interface region 3136.
[00787] As an example, the one or more processors 5140 of the field system
5000 may
cause one or more inspection devices to inspect the interface region 5136
between the pipes
1022a, 1022b to obtain inspection data (e.g., raw data from the inspection
devices, 2D or 3D
imaging data, or other data from the inspection). The inspection devices used
for the
inspection may comprise one or any combination of the types of inspection
devices described
herein. The obtained inspection data may respectively comprise one or any
combination of
the types of inspection data described herein. As a further example, the one
or more
processors 5140 may determine the profile of the interface region 5136 based
on the obtained
inspection data, but may also transmit the inspection data to the remote
computer system to
assess the inspection data. The one or more processors 5140 may transmit its
determined
profile of the interface region 5136 to the remote computer system for an
accuracy check.
Based on its own assessment of the inspection data, the remote computer system
may respond
to the one or more processors 5140 with an affirmation of the profile of the
interface region
5136, an indication that the profile provided is inaccurate, or other
response. Additionally or
alternatively, if the profile provided is inaccurate, the remote computer
system may respond
with its own modified version of the profile of the interface region 5316
derived from the
remote computer system's assessment of the inspection data. Responsive to
receipt of an
affirmation, for instance, the one or more processors 5140 may cause a weld
torch of the weld
system 5004 to begin or continue a welding operation based on its determined
profile of the
interface region 5136 to create the weld at the interface region 5316. If,
however, a modified
version of the profile is received, the one or more processors 5140 may cause
a weld torch of
the weld system 5004 to begin or continue a welding operation based on the
modified version
of the profile to create the weld at the interface region 5316.
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[00788] In one embodiment, where the one or more processors 5140 are local to
the field
system 5000 (e.g., part of a computer system local to the field system 5000),
the one or more
processors 5140 may interact with an inspection laser of the weld system 5004
to scan the
interface region 5136 between the pipes 1022a, 1022b to determine a profile of
the interface
region 5136 prior to a welding operation and generate pre-weld profile data
based on the scan.
In a further embodiment, the one or more processors 5140 may transmit the pre-
weld profile
data to a remote computer system. In response, the one or more processors 5140
may receive
(via a receiver) an affirmation of the pre-weld profile data or a modified
version of the pre-
weld profile data from the remote computer system. In one embodiment, the one
or more
processors may operate pipe engagement structure 5052 and/or pipe engagement
structure
5054 based on the affirmation or the modified version of the pre-weld profile
data to alter the
interface region 5136 between the pipes prior to the welding operation.
[00789] As an example, the one or more processors 5140 of the field system
5000 may
cause one or more inspection devices to inspect the interface region 5136
between the pipes
1022a, 1022b to obtain inspection data prior to a welding operation on the
interface region
5136. The inspection devices used for the inspection may comprise one or any
combination
of the types of inspection devices described herein. The obtained inspection
data may
respectively comprise one or any combination of the types of inspection data
described
herein. The one or more processors 5140 may generate pre-weld profile data
based on the
obtained inspection data, but may also transmit the inspection data to the
remote computer
system to assess the inspection data. The one or more processors 5140 may
transmit its
generated pre-weld profile data to the remote computer system for an accuracy
check. Based
on its own assessment of the inspection data, the remote computer system may
respond to the
one or more processors 5140 with an affirmation of the pre-weld profile data,
an indication
that the pre-weld profile data provided is inaccurate, or other response.
Additionally or
alternatively, if the pre-weld profile data provided is inaccurate, the remote
computer system
may respond with its own modified version of the pre-weld profile data derived
from the
remote computer system's assessment of the inspection data. As a further
example, if the
pre-weld profile data indicates that the pipes 1022a, 1022b are misaligned,
and an affirmation
of the pre-weld profile data is received, the one or more processors 5140 may
cause pipe
engagement structures 5052, 5054 realign the pipes 1022a, 1022b prior to a
welding
operation to create the weld at the interface region 5136. If, however, a
modified version of
the pre-weld profile data is received, the one or more processors 5140 may
instead utilize the
modified version to perform subsequent operations, such as using the modified
version to
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determine whether realignment is needed and how it is to be performed, to
select a welding
protocol to use to create a weld at the interface region 5136, etc.
[00790] In one embodiment, where the one or more processors 5140 are local to
the field
system 5000 (e.g., part of a computer system local to the field system 5000),
the one or more
processors may develop a welding protocol based on the affirmation or the
modified version
of the pre-weld profile data (received from the remote computer system). As an
example, if
the affirmation of the pre-weld profile data is received, the one or more
processors 5140 may
use its generated pre-weld profile data to develop a welding protocol to be
used to perform a
welding operation on the interface region 5136. As another example, if the
modified version
of the pre-weld profile data is received, the one or more processors 5140 may
use the
modified version to develop a welding protocol to be used to perform a welding
operation on
the interface region 5136.
[00791] In one embodiment, where the one or more processors 5140 are local to
the field
system 5000 (e.g., part of a computer system local to the field system 5000),
the one or more
processors 5140 may interact with an inspection laser of the weld system 5004
to scan the
interface region 5136 between the pipes 1022a, 1022b to determine the profile
of the
interface region 5136 during a welding operation and generate on-the-fly
profile data based
on the scan. In a further embodiment, the one or more processors 5140 may
transmit (via a
transmitter) the on-the-fly profile data to a remote computer system. In
response, the one or
more processors 5140 may receive (via a receiver) an affirmation of the on-the-
fly profile
data or a modified version of the on-the-fly profile data from the remote
computer system. In
one embodiment, the one or more processors 5140 may control a weld torch of
the weld
system 5004 based on the affirmation or the modified version of the one-the-
fly profile data
during the welding operation.
[00792] As an example, the one or more processors 5140 of the field system
5000 may
cause one or more inspection devices to inspect the interface region 5136
between the pipes
1022a, 1022b to obtain inspection data during a welding operation on the
interface region
5136. The inspection devices used for the inspection may comprise one or any
combination
of the types of inspection devices described herein. The obtained inspection
data may
respectively comprise one or any combination of the types of inspection data
described
herein. The one or more processors 5140 may generate on-the-fly profile data
based on the
obtained inspection data, but may also transmit the inspection data to the
remote computer
system to assess the inspection data. The one or more processors 5140 may
transmit its
generated on-the-fly profile data to the remote computer system for an
accuracy check.
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Based on its own assessment of the inspection data, the remote computer system
may respond
to the one or more processors 5140 with an affirmation of the on-the-fly
profile data, an
indication that the on-the-fly profile data provided is inaccurate, or other
response.
Additionally or alternatively, if the post-weld profile data provided is
inaccurate, the remote
computer system may respond with its own modified version of the on-the-fly
profile data
derived from the remote computer system's assessment of the inspection data.
[00793] As a further example, if the affirmation of the on-the-fly profile
data is received,
the one or more processors 5140 may use its generated on-the-fly profile data
to update the
welding parameters being used to control the weld torch of the weld system
5004 protocol (to
perform the welding operation on the interface region 5136) as the welding
operation is being
performed. As another example, if the modified version of the on-the-fly
profile data is
received, the one or more processors 5140 may use the modified version to
update the
welding parameters being used to control the weld torch of the weld system
5004 protocol (to
perform the welding operation on the interface region 5136) as the welding
operation is being
performed.
[00794] In one embodiment, where the one or more processors 5140 are local to
the field
system 5000 (e.g., part of a computer system local to the field system 5000),
the one or more
processors 5140 may interact with an inspection laser of the weld system 5004
to scan the
interface region 5136 between the pipes 1022a, 1022b to determine the profile
of the
interface region 5136 subsequent to a welding operation and generate post-weld
profile data
based on the scan. In a further embodiment, the one or more processors 5140
may transmit
the post-weld profile data to a remote computer system. In response, the one
or more
processors 5140 may receive (via a receiver) an affirmation of the post-weld
profile data or a
modified version of the post-weld profile data from the remote computer
system.
[00795] As an example, the one or more processors 5140 of the field system
5000 may
cause one or more inspection devices to inspect the interface region 5136
between the pipes
1022a, 1022b to obtain inspection data subsequent to a welding operation on
the interface
region 5136. The inspection devices used for the inspection may comprise one
or any
combination of the types of inspection devices described herein. The obtained
inspection data
may respectively comprise one or any combination of the types of inspection
data described
herein. The one or more processors 5140 may generate post-weld profile data
based on the
obtained inspection data, but may also transmit the inspection data to the
remote computer
system to assess the inspection data. The one or more processors 5140 may
transmit its
generated post-weld profile data to the remote computer system for an accuracy
check.
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Based on its own assessment of the inspection data, the remote computer system
may respond
to the one or more processors 5140 with an affirmation of the post-weld
profile data, an
indication that the post-weld profile data provided is inaccurate, or other
response.
Additionally or alternatively, if the post-weld profile data provided is
inaccurate, the remote
computer system may respond with its own modified version of the post-weld
profile data
derived from the remote computer system's assessment of the inspection data.
[00796] In one embodiment, where the one or more processors 5140 are local to
the field
system 5000 (e.g., part of a computer system local to the field system 5000),
the one or more
processors 5140 may cause, based on the affirmation or the modified version of
the post-weld
profile data (received from the remote computer system), another weld
operation to be
performed on the interface region 5136 between the pipes. As an example, if
the affirmation
of the post-weld profile data is received, the one or more processors 5140 may
use its
generated post-weld profile data to determine whether a result of a welding
operation has one
or more defects, whether the interface region 5136 is ready for the next stage
of operations, or
other determinations. In one use case, for instance, upon completing a root
pass operation in
the interface region 5316, post-weld profile data of the root pass layer in
the interface region
5316 may reveal that the root pass layer is insufficiently thick. In response,
the post-weld
profile data may be utilized to determine welding parameters for a welding
operation to repair
the insufficient thickness or welding parameters for a hot pass operation to
produce a hot pass
layer (on the root pass layer) that compensates for the insufficient thickness
of the root pass
layer. As another example, if the modified version of the pre-weld profile
data is received,
the one or more processors 5140 may use the modified version to perform the
foregoing in
lieu of its generated post-weld profile data.
[00797] In one embodiment, the welding parameters that affect the quality of
the weld may
include voltage, current, weld torch travel speed, wire feed speed, gas flow,
etc. In one
embodiment, the other welding parameters that affect the quality of the weld
may include
impedance, temperature, etc.
[00798] In one embodiment, the voltage used during the welding procedure may
affect the
weld bead width and weld bead shape. In one embodiment, the voltage is
measured in volts.
In one embodiment, the weld system may include a voltage sensor configured to
measure the
voltage of the power source that is used to create the welding arc.
[00799] In one embodiment, the current used during the welding procedure may
affect the
penetration of the weld bead. In one embodiment, the current is measured in
amperes. In one
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embodiment, the weld system may include a current sensor configured to measure
the current
of the power source that is used to create the welding arc.
[00800] In one embodiment, the weld feed speed is a rate of travel of a weld
electrode,
during the welding procedure, along a joint being welded. In one embodiment,
the weld
electrode is fed from a welding torch. In one embodiment, the weld speed may
be controlled
by controlling the welding torch that feeds the weld electrode. In one
embodiment, the weld
speed during the welding procedure may affect the size of the weld bead and/or
the
penetration of the weld bead. In one embodiment, the weld speed is measured in
millimeters/second or inches/minutes.
[00801] In one embodiment, the wire feed speed/wire usage is a rate at which
the weld
electrode material/filler material is being consumed (or fed into the weld)
during the welding
procedure. In one embodiment, the wire feed speed is measured in
millimeters/second or
inches/minutes. In one embodiment, the weld system may include a wire feed
speed sensor
that is configured to sense a flow of the weld electrode material.
[00802] In one embodiment, the rate of change of the weight of the spool
allows the weld
system to measure the rate at which weld wire 5007 is feeding into the weld.
In one
embodiment, the feed motor runs at a set/predetermined rate, but the wheel
that pushes the
wire 5007 may slip due to either minor variations in the wire 5007 or due to
wear of the feed
wheel itself. These slips may be temporary in nature, and their presence may
be logged and
used in the quality control feedback loop. If the slippage is persistent, the
one or more
processors 5140 may be configured to increase the speed of the feed motor to
compensate.
Over time, the speed overdrive ratio may need to be increased. Eventually it
will not be
possible to compensate, and the weld system 5004 will be taken out of service
for
maintenance. In one embodiment, tracking the rate of overdrive ratio increase
across all weld
systems allows the one or more processors to determine the best limit for the
maximum
allowable overdrive ratio. That setting may then be transmitted to all of the
weld systems in
service. In one embodiment, the one or more processors 5140 may be configured
to update
the value at any time as data becomes available in order to minimize process
interruptions
and minimize the frequency of machine down time for maintenance.
[00803] In one embodiment, the weld system may include a gas flow sensor that
is
configured to sense/detect the flow rate of the shield gases used in the
welding procedure. In
one embodiment, the shield gas may be an active gas that is configured to
shield the molten
weld pool. In one embodiment, the gas flow sensor is configured to provide a
signal
proportional to the gas flow rate in the shield gas line. In one embodiment,
the one or more
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processors 5140 of the field system 5000 are configured to stop welding if the
gas flow rate
of the shield gas is not within a predetermined gas flow rate range.
[00804] In one embodiment, the pipes are preheated before the welding
procedure. In one
embodiment, the temperature of the pipes may be monitored by one or more
temperature
sensors of the weld system. In one embodiment, the one or more temperature
sensors are
configured to measure the temperature of the pipe at each point along the
weld. In one
embodiment, the one or more processors 5140 of the field system 5000 are
configured to stop
the welding procedure if the temperatures of the pipes are not within a
predetermined
temperature range.
[00805] In one embodiment, the weld system may include an impedance sensor
that is
configured to sense/detect an input electrical impedance of the weld system.
[00806] In one embodiment, the correct wire/weld electrode/filler material is
to be used for
each welding pass. For example, the only difference between two spools of wire
is a 0.1
millimeter difference in the wire diameter. If the manufacturer label for the
spool of wire has
been smudged or has faded, the wrong spool could be loaded onto the weld
system. An RFID
tag on the spool has a spool identifier. In one embodiment, the RFID tag on
the spool may be
read by a sensor on the weld system. If the RFID tag has the wrong spool
identifier, the weld
system is configured to not feed the wire material and to alert the user to
change to the correct
wire.
[00807] In one embodiment, the spool weight may be monitored by the one or
more
processors 5140 of the field system 5000. If the weld wire runs out during a
weld procedure,
the voltage signal that the processor uses to manage the distance between the
weld tip and the
work piece goes to zero. The processor moves the tip closer to the work piece
in response
which causes the tip to touch the molten weld metal and cause a copper
inclusion defect.
Therefore, knowing the exact weight of the wire remaining on the spool helps
the weld
system prevent the start of a welding pass that requires more weld wire than
what is available.
Also, if the spool weight stops changing, then that may be an indication of an
empty spool or
a failure in a wire feeding mechanism. In either case, the one or more
processors 5140 of the
field system 5000 are configured to stop the welding procedure.
[00808] In one embodiment, the one or more processors 5140 of the field system
5000 are
configured to track the weight of every spool in real time. Each welding pass
in a weld joint
requires a different amount of wire due to the change in diameter and the
change in the width
of the weld groove being filled.
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[00809] If the one or more processors 5140 of the field system 5000 determines
that a spool
will end up with too little wire to complete the next weld pass, but that it
would have enough
wire to complete a different weld pass, the one or more processors 5140 of the
field system
5000 may be configured to inform an operator to remove the spool and give it
to a different
operator. For example, a spool starts with 10 pounds of wire, and the weld
pass being
performed by the weld system requires 1.3 pounds of wire. The weld system will
be able to
complete its weld passes on 7 weld joints before the spool has too little
wire.
[00810] When that spool is removed after the 7th weld pass, that spool will
have 0.9 pounds
of wire on it that will be wasted. If there is another weld pass that
requires, for example, 1.1
pounds of wire, then the one or more processors 5140 of the field system 5000
are configured
to alert the operator to remove the spool after only 6 weld passes. In this
case, the spool will
have 2.2 pounds of wire remaining. That spool can then be used for the weld
pass that needs
only 1.1 pounds of wire to complete 2 such weld passes (and waste no wire).
[00811] In one embodiment, the weld wire 5507 passes through the weld tip
5503. The tip
weld tip 5503 also carries a high welding current. Both these factors cause
the bore of the
weld tip 5503 to wear. As this happens the contact point inside shifts which
inherently affects
the arc characteristics and hence the weld quality. In one embodiment, the
weld parameters
like voltage, current, wirefeed, power and impedance are monitored in real
time. That data is
sent to a tablet via the one or more processors to be analyzed for signature
comparison of the
above mentioned variables due the computationally intensive nature of
analysis. When the
analysis detects an impending problem, the internal weld system 5004 and the
operator are
sent a message to change the weld tip 5503 before the next weld. Additionally,
this data may
be used in the quality control feedback loop. In one embodiment, the results
from the quality
control feedback loop may be used to update the weld tip deterioration
signatures on the fly.
[00812] In one embodiment, the exemplary weld parameters that are used for the
uphill and
downhill weld procedures are shown in FIG. 72D. For example, in one
embodiment, at least
one of the plurality of weld torches 5502 weld in an upwards rotational
direction (i.e., uphill)
while at least another of the plurality of weld torches 5502 weld in an
downwards rotational
direction (i.e., downhill). In one embodiment, the weld parameters shown here
are exemplary
and are by no means optimized or inclusive of everything that may need to be
changed during
these welding procedures. In one embodiment, the travel speed for the downhill
weld
procedure is 13.5 inches/minute and for the uphill procedure is 10.0
inches/minute. In one
embodiment, the amplitude of the cross-groove oscillation is 0.09 inches for
the downhill
weld procedure and 0.15 inches for the uphill weld procedure. In one
embodiment, the
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oscillation speed is 160 beats per minute for the downhill weld procedure and
130 beats per
minute for the uphill weld procedure. In one embodiment, the wave control 1
(i.e., related to
the wire feed speed) is 400 for the downhill weld procedure to 370 for the
uphill weld
procedure. In one embodiment, the weld passes were welded at 16.5V with the
power supply
controlling voltage.
[00813] The operation of the internal weld system 5004 is now described. In
one
embodiment, the internal weld system 5004 is configured to be operated through
a repeating
cycle of operation.
[00814] After it has been determined that a weld has been completed in the
current weld
joint, the one or more processors 5140 are configured to send communication
signals to the
wire feed electronics module 5046 to control (via control signals) the weld
torch motors 5512,
5550, 5588 (via) to retract the weld torches 5502 to their original, retracted
positions. The one
or more processors 5140 are also configured to send communication signals to
the forward-
most section electronics module 5014 to control/turn off (via control signals)
the front clamp
control valve 5018 to retract the first engagement structure 5052 to its
original, retracted
position and send communication signals to the center section electronics
module 5064 to
control/turn off (via control signals) the rear clamp control valve 5062 to
retract the second
engagement structure 5054 to its original, retracted position. The internal
weld system 5004
(including the weld torches 5502 and the clamps 5144, 5142) has to be moved to
the next
weld joint.
[00815] In one embodiment, the one or more processors 5140 are configured to
send
communication signals to the drive section electronics module 5118 to control
(via control
signals) the drive motors 5124 to accelerate the internal weld system 5004 to
travel a
predetermined speed and then decelerate and stop at the next weld joint. In
one embodiment,
the predetermined speed at which the internal weld system 5004 accelerates may
be 6
feet/second.
[00816] When the second engagement structure 5054 is positioned at the next
weld joint,
the drive section electronics module 5118 sends communication signals to the
wire feed
electronics module 5046 to check alignment with the end of the pipe. In one
embodiment, the
wire feed electronics module 5046 is configured to operate (turn on) the one
or more
inspection detectors 5056 to measure where the second engagement structure
5054 are in
relation to the end of the pipe. In one embodiment, the rotatable hub 5072 may
not be
operated when the one or more inspection detectors 5056 are measuring where
the second
engagement structure 5054 are in relation to the end of the pipe.
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[00817] In one embodiment, the wire feed electronics module 5046 is configured
send the
measured distance data to the drive section electronics module 5118. In one
embodiment, the
drive section electronics module 5118 is configured to control (via control
signals) the drive
motors 5124 to move the first and second engagement structures 5052, 5054 by
the measured
distance data.
[00818] In one embodiment, when the second engagement structure 5054 is
properly
aligned and positioned in relation to the end of the pipe, the drive section
electronics module
5118 is configured to send communication signals to the center section
electronics module
5064 that the internal weld system 5004 is in position at the next weld joint.
In one
embodiment, the center section electronics module 5064 controls (opens via
control signals)
the rear clamp control valve 5062 to raise the second engagement structure
5054 and grip the
old/existing pipe.
[00819] The next/new pipe segment 1002a is then brought in, and slid over the
forward-
most section 5006 of the internal weld system 5004 into position by the
working crew. At this
time, the one or more processors 5140 are configured to send communication
signals to the
wire feed electronics module 5046 to operate the one or more inspection
detectors 5056 to
check the alignment of the pipes. In one embodiment, the one or more
processors 5140 may
rotate the rotatable hub 5078 to take measurements at multiple locations.
[00820] If the pipe alignment data is within a predetermined tolerance, the
wire feed
electronics module 5046 sends communication signals to the forward-most
electronics
module 5014 to actuate the front clamp 5142. In one embodiment, the forward-
most
electronics module 5014 controls/opens (via control signals) the front clamp
control valve
5018 to raise the first engagement structure 5052 and grip the new pipe
segment 1002a.
[00821] If the pipe alignment data is not within the predetermined tolerance,
the wire feed
electronics module 5046 sends communication signals (a message) to the one or
more
processors 5140 identifying the misalignment between the pipes 1022a, 1022b.
In one
embodiment, this information may be relayed to a crane operator by traditional
crane operator
hand signals or by an electronic signal to a computer display terminal in the
crane cab.
[00822] After the pipes are clamped, the one or more processors 5140 are
configured to
send communication signals to the wire feed electronics module 5046 to operate
the one or
more 1 inspection detectors 5056 to measure the gap and radial offset (Hi-Lo)
at a plurality of
points along the circumference of the weld joint. In one embodiment, this data
is
communicated out to the one or more processors 5140 and compared against the
allowable
tolerances.
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[00823] If the joint fit up (i.e., the gap and radial offset (Hi-Lo)) is
within a predetermined
tolerance, either the one or more processors 5140 or the wire feed electronics
module 5046
sends communication signals to the operator indicating that welding may begin
or sends
communication signals to the wire feed electronics module 5046 to
automatically begin the
welding procedure.
[00824] If the joint fit up (i.e., the gap and radial offset (Hi-Lo)) is not
within the
predetermined tolerance, a warning is sent to the operator, who can restart
the clamping
sequence or override the warning. In one embodiment, the internal weld system
5004 is
configured to weld up to a 4 millimeters of the gap and radial offset (Hi-Lo).
[00825] In one embodiment, the wire feed electronics module 5046 is configured
to
automatically begin the welding procedure. In one embodiment, the one or more
processors
5140 are configured to send communication signals through the umbilical 5034
to a weld
power supply to turn on the weld power supply to the weld torch(es) 5502. In
one
embodiment, the wire feed electronics module 5046 is configured to
control/move one or
more weld torches 5502 radially, axially and/or angularly to a proper welding
position. In one
embodiment, the wire feed electronics module 5046 moves one or more weld
torches 5502
radially, axially and/or angularly to the correct working distance from the
pipe and to the
center of the weld joint as measured by the one or more inspection detector(s)
5056.
[00826] In one embodiment, the wire feed electronics module 5046 is also
configured to
operate (turn on) the shield gas valve(s) 5042 to supply shield gas to the
weld torch(es) 5502
and operate the motors of the weld feed system 5044 to begin feeding weld wire
or electrode
to the weld torch(es) 5502.
[00827] In one embodiment, the wire feed electronics module 5046 sends
communication
signals to both the forward-most section electronics module 5014 and the
center section
electronics module 5064 to begin rotation of the rotatable hub 5078. In one
embodiment, the
wire feed electronics module 5046 sends communication signals to both the
forward-most
section electronics module 5014 and the center section electronics module 5064
to
synchronize the front rotation motor 5030 and the rear rotation motor 5074. In
one
embodiment, the forward-most section electronics module 5014 sends control
signals to
operate the front rotation motor 5030 and the center section electronics
module 5064 sends
control signals to operate the rear rotation motor 5074. The front rotation
motor 5030 and the
rear rotation motor 5074 are configured to rotate the rotatable hub 5078 while
keeping the
front and rear clamps 5142, 5144 stationary. In one embodiment, the rotatable
hub 5078
continues to rotate for the full length of the weld.
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[00828] In one embodiment, the wire feed electronics module 5046 is configured
to operate
the one or more inspection detector(s) 5056 to locate the center of the weld
joint and move
the weld torch 5502 axially to follow the weld joint.
[00829] In one embodiment, the wire feed electronics module 5046 is configured
to
measure the voltage of the weld power. The measured voltage data may be used
by the wire
feed electronics module 5046 to determine the distance of the weld torch 5502
from the pipe.
In one embodiment, the wire feed electronics module 5046 is configured to
adjust the weld
torch 5502 radially to maintain a constant distance of the weld torch 5502
from the pipe. In
one embodiment, the wire feed electronics module 5046 may oscillate the weld
torch 5502
axially to improve weld quality.
[00830] In one embodiment, the wire feed electronics module 5046 is configured
to change
the tilt angle of the weld torch 5502 based on which portion of the weld joint
is being welded.
For example, the tilt angle of the weld torch 5502 in the plane of travel is
adjusted to
compensate for gravity.
[00831] In one embodiment, the wire feed electronics module 5046 may be
configured to
vary the wire feed speed or send communication signals to the weld power
supply (via the
umbilical 5034) to vary the welding current based on the measurement data from
the one or
more inspection detectors 5056.
[00832] In one embodiment, the welding procedure may be performed by one weld
torch in
one weld pass by rotating 360 . In one embodiment, the start and stop position
of the weld
may be anywhere along the weld joint.
[00833] In one embodiment, the welding procedure may be performed with N
equally
spaced weld torches 5502 where the rotatable hub 5078 rotates through (360/N)
degrees to
deposit one weld pass. In one embodiment, the welding procedure may be
performed with N
equally spaced weld torches 5502 where the rotatable hub 5078 rotates through
(2 times
(360/N)) degrees to deposit two weld passes. For example, in one embodiment,
where the
internal weld system 5004 has three equally spaced weld torches 5502, the
rotatable hub 5078
rotates through 120 to deposit one weld pass and rotates through 240 to
deposit two weld
passes.
[00834] When the weld torches 5502 reach a point where the previous weld torch
5502
started its weld pass, the one or more inspection detectors 5056 detect the
existing weld bead
and the wire feed electronics module 5046 is configured to move the weld
torches 5502 in
radially to compensate.
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[00835] In one embodiment, the two welding passes may be deposited as above
with a
pause between the weld passes for a full laser and visual post weld
inspection. In one
embodiment, the welding may be done 3600 with N unequally spaced torches 5502
with each
weld torch 5502 depositing a successive weld pass for a total of N weld passes
in 360 plus
the distance from the first torch to the Nth torch.
[00836] After it has been determined that the weld has been completed, the one
or more
processors 5140 are configured to send communication signals to the wire feed
electronics
module 5046 to control (via control signals) the weld torch motors 5512, 5550,
5588 (via) to
retract the weld torches 5502 to their original, retracted positions. For
example, the weld
torches 5502 may be retracted back to their original, home positions for each
axis (radial,
axial, tilt).
[00837] In one embodiment, the rotatable hub 5078 continues to rotate while
the wire feed
electronics module 5046 operates the one or more inspection detectors 5056 and
one 2D
camera 5112 to inspect the quality of the weld. In one embodiment, if certain
types of weld
defects (e.g. under fill, lack of reinforcement) are discovered, the one or
more processors
5140 are configured to send communication signals to the wire feed electronics
module 5046
to move a weld torch 5502 to that location and apply additional weld material
to repair the
defect.
[00838] Once the inspection and any repairs are completed and verified by the
operator, the
operator may sends communication signals to the forward-most electronics
module 5014 to
control/turn off (via control signals) the front clamp control valve 5018 to
retract the first
engagement structure 5052 to its original, retracted position and send
communication signals
to the center section electronics module 5064 to control/turn off (via control
signals) the rear
clamp control valve 5062 to retract the second engagement structure 5054 to
its original,
retracted position.
[00839] In the offshore pipeline applications, both angular and positional
pipe alignment
errors may be corrected by sending the control signals from the one or more
processors 5140
to the cradles 5330 or the cradles 6010A and 6010B (to control the associated
rollers 5332).
[00840] In one embodiment, the purge and inspection system 7001 or the
internal weld
system 5004 may include one clamp that is constructed and arranged to grip the
inner surface
of the first pipe 1022b. In one embodiment, the cradles 5330 or the cradles
6010A and 6010B
are configured to move the second/incoming pipe 1022a into position. In one
embodiment,
the one or more processors 7062 or 5140 are configured to interact with the
inspection
detector 5056 or 7042 to check the alignment between the pipes and send
control signals to
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the cradles 5330 or the cradles 6010A and 6010B to fix any pipe alignment
errors (angular or
positional). In one embodiment, the control signals from the one or more
processors 5140 are
configured to adjust the relative positioning between the pipes (to correct
their alignment
errors). In one embodiment, this procedure may be used on small or thick
walled pipes that
have a very low (<20) diameter to wall thickness ratio because no amount of
clamping power
can noticeably change the shape of low D/t pipe.
[00841] In one embodiment, the purge and inspection system 7001 or the
internal weld
system 5004 may include two clamps. For example, one clamp is constructed and
arranged to
grip the inner surface of the first pipe 1022b. In one embodiment, the cradles
5330 or the
cradles 6010A and 6010B are configured to move the second/incoming pipe 1022a
into
position. In one embodiment, the second clamp is constructed and arranged to
grip the inner
surface of the second/incoming pipe 1022a. In one embodiment, the one or more
processors
7062 or 5140 are configured to interact with the inspection detector 5056 or
7042 to check
the alignment between the pipes. For example, if the alignment is not good,
the second clamp
releases the second pipe 1022a. The one or more processors 7062 or 5140 are
configured to
send control signals to the cradles 5330 or the cradles 6010A and 6010B to fix
any pipe
alignment errors (angular or positional). In one embodiment, the control
signals from the one
or more processors 5140 are configured to adjust the relative positioning
between the pipes
(to correct their alignment errors), for example, by altering the positioning
of the pipe 1022a.
The procedure may continue until the acceptable pipe alignment is achieved by
the inspection
detector or a predefined number of attempts (e.g., 10) at which time the
second pipe 1022a is
rejected and a new second pipe is moved into place.
[00842] In one embodiment, the crane and the clamp alignment is used in the
onshore
pipeline alignment and welding procedure. In the onshore pipeline
applications, the angular
pipe alignment error may be corrected by providing the instructions to the
crane operator and
the positional alignment error may be corrected by providing the instructions
to the workers
to place a shim between the clamp and the pipe.
[00843] In one embodiment, the purge and inspection system 7001 or the
internal weld
system 5004 may include one clamp that is constructed and arranged to grip the
inner surface
of the first pipe 1022b. In one embodiment, the crane operator moves the
second/incoming
pipe 1022a into position and the workers place the external clamp around the
joint. In one
embodiment, the one or more processors 7062 or 5140 are configured to interact
with the
inspection detector 5056 or 7042 to check the alignment between the pipes. If
the inspection
detector 5056 or 7042 detects angular misalignment/pipe alignment error,
instructions are
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sent to the crane operator to correct angular misalignment/pipe alignment
error and the
workers release the clamp while the pipe is being moved. If the inspection
detector 5056 or
7042 detects positional misalignment/pipe alignment error, instructions are
sent to the
workers for the placement and thickness of the shims needed to correct
positional
misalignment/pipe alignment error. The workers remove the clamp, place the
shims, and
replace the clamp. The process repeats until the pipe alignment is accepted by
the inspection
detector.
[00844] In one embodiment, the purge and inspection system 7001 or the
internal weld
system 5004 may include two clamps. For example, one clamp is constructed and
arranged to
grip the inner surface of the first pipe 1022b. In one embodiment, the crane
operator moves
the second/incoming pipe 1022a into position. In one embodiment, the second
clamp is
constructed and arranged to grip the inner surface of the second/incoming pipe
1022a. In one
embodiment, the one or more processors 7062 or 5140 are configured to interact
with the
inspection detector 5056 or 7042 to check the alignment between the pipes. If
the inspection
detector 5056 or 7042 detects an angular misalignment/pipe alignment error,
the second
clamp releases the second pipe and instructions are sent to the crane operator
to correct the
misalignment. If the inspection detector 5056 or 7042 detects a positional
misalignment/pipe
alignment error, the second clamp releases the second pipe and instructions
are sent to the
workers for the placement and thickness of the shims needed to correct
positional
misalignment/pipe alignment error. The crane operator moves the second pipe
away from the
first pipe, the workers place the shims. The crane operator moves the second
pipe back into
position. The second clamp grips the second pipe. The process repeats until
the pipe
alignment is accepted by the inspection detector.
[00845] FIG. 103B shows the pipe alignment, welding and inspection procedures
of the
internal weld system 5004.
[00846] In one embodiment, the inspection detector 5056 scans 360 of the
interface region
5136 between the pipes 1022a, 1022b before any welding takes place. In one
embodiment,
during the procedure of generating the pre-weld profile data, the inspection
detector 5056 is
positioned between the clamps and/or seals of the internal weld system 5004
and is turned on.
In one embodiment, the weld torch(es) 5502 are turned off during the procedure
of generating
the pre-weld profile data. In one embodiment, the one or more processors 5140
are
configured to interact with the inspection detector 5056 to scan the interface
region 5136 to
obtain the pre-weld profile data subsequent to the first clamp 5142 and the
second clamp
5144 engaging with the first pipe 1022a and second pipe 1022b, respectively.
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[00847] In one embodiment, the cradles 5330 (as shown in FIGS. 10A and 10B)
and 6010A
and 6010B (as shown in FIG. 73) are operated by the one or more processors
5140 (or
otherwise controlled) to engage the exterior surfaces 5346 and/or 5348 (as
shown in FIG. 2G)
of the first pipe 1022a and/or second pipe 1022b to adjust the relative
positioning of the pipes
1022a, 1022b in the event the pre-weld profile data determines adjustment is
required. In one
embodiment, an interior surface 5130, 5132 of the first pipe 1022a and/or the
second pipe
1022b is engaged and manipulated by the first clamp 5142 and the second clamp
5144,
respectively to adjust the relative positioning of the pipes 1022a, 1022b in
the event the pre-
weld profile data determines adjustment is required.
[00848] In one embodiment, during the procedure of generating the on-the-fly
weld profile
data, the inspection detector 5056 is positioned between the clamps and/or
seals of the
internal weld system 5004 and is turned on. In one embodiment, the one or more
processors
5140 are configured to control a position and speed of the weld torch 5502 (or
7502) based
on the on-the-fly weld profile data. In one embodiment, the on-the-fly
scan/inspection
procedure is performed during the root pass weld procedure, the hot pass weld
procedure, the
fill pass weld procedure, and the cap pass weld procedure. In one embodiment,
an optional
radiography inspection procedure (e.g., 1044 as shown in and described with
respect to FIG.
1B) may be performed between the on-the-fly scan/inspection & hot pass weld
procedure and
the on-the-fly scan/inspection & fill and cap pass weld procedure.
[00849] In one embodiment, the inspection detector 5056 scans 360 of the
interface region
5136 between the pipes 1022a, 1022b subsequent to a welding operation. In one
embodiment,
during the procedure of generating the post-weld profile data, the inspection
detector 5056 is
positioned between the clamps and/or seals of the internal weld system 5004
and is turned on.
In one embodiment, the weld torch(es) 5502 are turned off during the procedure
of generating
the post-weld profile data.
[00850] In one embodiment, a weld inspection procedure (e.g., 1008 as shown in
and
described with respect to FIG. 1B) may be performed after the post-weld
scan/inspection
procedure.
[00851] The procedures of FIG. 103B are described with respect to the internal
weld system
5004. However, as shown in FIG. 103B, it is contemplated that the same
procedures apply
the tie-in internal weld system 3001 and the purge and inspection system 7001,
and, therefore,
will not be described again with reference to the tie-in internal weld system
3001 and the
purge and inspection system 7001.
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[00852] Because, in one or more embodiments, the pipe has been welded from the
interior,
(i.e. the root pass weld has been applied from inside the pipe) the resulting
root weld can be
superior in that it better takes into account any mismatch and/or high-low
regions within the
pipe. In addition, if a hot weld pass (a second weld layer on top of the root
pass layer) is also
applied internally, the pipe can also be provided with positive root
enforcement on top of the
root weld pass. The hot weld pass, and even a further weld pass applied
internally, can
provide a small curved bump that extends slightly internally in the pipe to
further reinforce
the pipe. For example, the internal diameter of the pipe could be structured
to be slightly
smaller at the region of the weld than the internal diameter of the welded
pipe at regions that
contain just the pipe material without the weld. In one aspect of this
application, the hot pass
layer of the weld material has at least a portion thereof disposed closer to
the longitudinal
axis of the pipe than the interior surfaces of the welded pipes in regions of
the welded pipes
immediately adjacent to the weld material on opposite sides of the weld
material.
[00853] In some embodiments, the internal weld system 5004 disclosed herein is
configured
to weld pipes that are at least 30' long. In other embodiments, the internal
weld system 5004,
3001 disclosed herein is configured to weld pipes that are 26" in diameter or
less. In yet other
embodiments, the internal weld system 5004 can weld pipes that are less than
24" in diameter.
In yet other embodiments, the internal weld system 5004 disclosed herein is
configured to
weld pipes that are both, at least 30' long and less than 24" in diameter.
[00854] FIGS. 73-85 show and disclose another embodiment of the internal weld
system in
accordance with another embodiment of the present patent application.
[00855] The present patent application provides a system for aligning and
welding together
the faces of two pipe segments. The system includes an external alignment
mechanism and a
welding mechanism. The external alignment mechanisms may be as sophisticated
as the line
up modules shown in the drawings or as simple as a tipton clamp as illustrated
in U.S. Patent
No. 1,693,064. The mechanisms used may also be suitable for on or off shore
pipeline
construction. U.S. Patent No. 1,693,064 is incorporated herein by reference in
its entirety.
Whatever mechanism is employed, the external alignment mechanism supports and
adjustably positions each segment so that the segments are substantially
collinear or axially
aligned along their longitudinal axes.
[00856] The external alignment mechanism may support a pipe segment and may
include
powered features that allow the position and orientation of the pipe to be
adjusted.
Specifically, the external alignment mechanism may include rollers that allow
the pipe to
move longitudinally. The pipe may also be supported by rollers that allow the
pipe to be
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rolled about the longitudinal axis and moved up and down. The position and
orientation
adjustments may be automatic as by motor power or hydraulic power controlled
at an
operator station or fed into a central controller that automatically controls
an aligns the
segments based on predetermined alignment parameters or feedback from an
internal laser
reading an interface or joint profile.
[00857] The welding mechanism is an internal welding machine that applies a
weld (e.g., a
gas metal arc weld "GMAW" ) from inside the pipe segments to a face or edge
joint of the
segment and into a v-shaped opening formed by chamfered edges of the two pipe
segments
(other cross-sectional shapes other than a V may be used also). The welding
mechanism
includes a carriage capable of engaging the inner walls of the pipe to secure
or lock itself
within the pipe in a fixed position and a welding portion rotatably supported
from the
carriage within the pipe. Specifically, the internal welder is located within
the aligned pipe
and then positioned longitudinally so that a weld head or torch is in
longitudinal proximity to
the edge joint. The welding mechanism also includes a rotary mechanism for
rotating the
welding portion relative to the carriage. The weld head or torch is rotatably
supported on the
welding portion about the pipe longitudinal axis so that the torch may closely
follow the
entire interior joint interface in an orbital rotation. Specifically, during
welding, the torch of
the articulating head follows the edge joint around the entire interior
circumference of the
pipe applying weld material. In addition to circular rotation relative to the
carriage, various
control elements may move the weld head axially along the pipe relative to the
carriage,
radially toward and away from the joint, and pivotally about a point or axis
(e.g., an axis
parallel or perpendicular to pipe longitudinal axis A-A). A controller may
direct the torches
pivoting. These degrees of freedom of articulation allow the weld head to be
very effective
and efficient in filling in interface profiles optimally and where necessary.
[00858] The welding mechanism also includes a laser tracking mechanism that
works in
conjunction with the torch of the welding portion to sense interface joint
profile or/and weld
material profile to apply weld material to the edge joint in the appropriate
location and
amount. The laser mechanism surveys the weld and sends a signal to the
controller of the
articulating weld head to control movement of the head around the entire edge
joint.
Specifically, the torch follows the laser as the weld head control system
continuously receives
weld profile information from the edge joint. The information is then used to
continuously
adjust the torch to achieve the desired weld structure.
[00859] In addition to the laser tracking mechanism, the system may include a
2D camera
for visual inspection of the weld. The 2D camera is mounted on the welding
portion and
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follows the torch so that an operator can inspect the weld as soon as it is
created by the torch.
A visual signal is delivered to an external operator display. For example, the
2D camera may
be a color camera and a change in coloration may indicate a weld defect to the
operator. A
perceived change in profile may also indicate a defect.
[00860] Referring to FIGS. 73-75, the system for welding pipeline segments
together is
described as follows. FIG. 73 shows an external alignment mechanism 6010A and
6010B
which is capable of supporting, positioning, and repositioning multiple
lengths of pipeline.
Each mechanism 6010A and 6010B may include supports (e.g., rollers) upon which
a length
of pipeline may be supported. A longitudinal roller 6012 moveably supports
pipeline segment
6105 such that segment 6105 may be repositioned along its longitudinal
direction defined by
arrow A. In addition, rotational rollers 6014 are rotatable about an axis
parallel to axis A-A of
support segment 6105 on either side of segment 6105 enabling them to rotate or
adjust the
angular orientation of segment 6105 about axis A-A. External alignment
mechanism 6010 is
able to automatically manipulate multiple segments into various positions and
orientations
via motors, hydraulics, etc. For example the segments may be raised, lowered,
rotated, tilted,
pivoted, etc.
[00861] As shown in FIG. 73, the external alignment mechanisms 6010A and 6010B
support multiple segments 6105, 6110 and adjust their position and orientation
until segments
6105, 6110 are both aligned such that their longitudinal axes A-A are
collinear and one end
of each of the segments 6105, 6110 abuts at interface edges. Specifically,
FIG. 74 illustrates
an enlarged view of detail 6100 of FIG. 73 in which the edges form a pipe
interface 6120
(known as a "fit up" joint).
[00862] The pipeline aligning and weld system of the present patent
application applies a
weld to the interior of the interface 6120 from inside the fitted up segments
6105, 6110. To
apply a weld to the interior of the joint 6120, an internal welding mechanism
6300 is rolled
into an end of one of the segments 6105 as shown in FIG. 75. A second segment
6110 is then
placed on the external alignment mechanism 6010B and manipulated until both
the segments
6105, 6110 are satisfactorily aligned. An external force may then be applied
to a reach rod
6345 of the internal welding mechanism 6300 or the mechanism may include
automatic self
propulsion means for adjusting its axial position within the aligned segments
6105, 6110.
[00863] As shown in FIGS. 76-79, the welding mechanism 6300 includes a
carriage 6301
and a welding portion 6302. The carriage 6301 includes at least one alignment
mechanism
6340A, 6340B which may expand radially to engage the interior surface of
segments 6105 or
6110. This expansion and engagement both secures the axial/longitudinal
position of the
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welding mechanism 6300 relative to segment 6105, 6110 and aligns or radially
centers the
welding mechanism 6300 within the segments 6105, 6110. The carriage 6301 also
includes a
body 6311 on which rotating mechanism 6335 is supported. The body 6311 is
comprised of
multiple elongated structural support members that extend between alignment
mechanism
6340A and 6340B. As discussed below the welding portion 6302 includes a
similar
corresponding structure 6313.
[00864] The welding portion 6302 is rotatably connected to the carriage 6301
and extends
from an end of the carriage 6301. The relative rotation between the carriage
6301 and the
welding portion 6302 is facilitated by a rotary mechanism 6335. The rotary
mechanism 6335
is secured to the carriage 6301 and automatically (via a motor and gears)
rotates welding
portion 6302 relative to the carriage 6301 about longitudinal axis A-A. The
welding portion
6302 may be cantilevered from the carriage 6301 or may be supported by an
additional
alignment mechanism 6340C located so that torch 6305 is positioned between
alignment
mechanisms 6340B and 6340C. When alignment mechanism 6340C is provided, the
welding
portion 6302 is rotatable relative to and between both the alignment
mechanisms 6340B and
6340C when the alignment mechanisms 6340B and 6340C expand to secure
themselves to
the interior of a segment. Furthermore, the carriage 6301 may include a reach
rod 6345 which
can be structured as an elongated extension from the carriage 6301 which an
operator may
grasp to insert/push or retract/pull the welding mechanism 6300 to axially
position it within a
segment 6105, 6110.
[00865] FIG. 76 shows an enlarged view of section 6200 of FIG. 75 in which
only segment
6105 is present and segment 6110 is absent. As shown in FIG. 76, the welding
portion 6302
includes a welding group 6303 which comprises a torch 6305, a laser sensor
6310, and a
color camera 6320. The welding portion 6302 further has a body 6313 on which
torch 6305,
the laser sensor 6310, and the color camera 6320 are supported. The laser 6310
tracks an
interior joint of segments 6105, 6110, and detects an interface profile to be
used to position
the torch 6305 in applying a weld to the joint interface. The body 6313
extends between the
alignment mechanism 6340B and 6340C. Section 6200 shows the welding mechanism
6300
located inside the segment 6105 with the torch 6305 generally pointed in a
radially outward
direction and positioned to apply a weld to face joint 6120. FIG. 77 shows an
embodiment of
a general schematic cross-sectional view of the welding mechanism 6300 through
section B-
B which shows welding group 6303 looking in the direction of insertion of the
welding
mechanism 6300. FIG. 77 also shows a direction D of rotation of the welding
group 6303
when it is rotated by the rotary mechanism 6335. Therefore, a welding action
on a particular
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point along weld joint 6120 will first be acted on by the laser sensor 6310
followed by the
torch 6305 and finally by the 2D inspection camera 6320.
[00866] FIGS. 82-84 illustrate multiple perspectives of the welding portion
6302. FIG. 82
shows a wire delivery system 6322. The wire delivery system 6322 includes a
wire spool
storage 6323, an optional wire straightener 6325, and a wire feed mechanism
6330 which is
automatically controlled to deliver the appropriate amount of wire to the
torch 6305. As the
rotary mechanism 6335 rotates the welding portion 6302, wire is fed to the
torch 6305 by
wire delivery mechanism 322.
[00867] As mentioned above, the torch 6305 may be positioned and oriented in
multiple
ways by multiple mechanisms. The torch 6305 is supported on a manipulator. The
manipulator includes a radial positioner, an axial positioner and a pivoter.
Specifically, a
radial positioner 6307 (e.g., a rack and pinion) on which the torch 6305 is
supported is
capable of moving the torch radially toward and away from the interior surface
of segments
6105, 6110. In other words, towards and away from the interface of the
segments 6105, 6110
to be welded. In addition, an axial positioner 6309 (e.g., a rack and pinion)
may move the
torch 6305 axially within segments 6105, 6110. The manipulator also includes a
pivoter
6308 that allows the torch to pivot (e.g., about an axis parallel to segment
longitudinal axis
A-A). The pivotal movement by the pivoter 6308 may be powered by a motor and
gears 6306.
For example, the motor may be a stepper motor.
[00868] The torch manipulator may compound the manipulative movements of the
above
mentioned elements by dependently supporting the elements. For example, the
body 6313
may support the axial positioner which in turn supports the radial positioner
which in turn
supports the pivoter which in turn supports the torch. Similarly, the axial
positioner may be
supported by the radial positioner. Furthermore, any order of support may be
employed.
[00869] The elements of the manipulator are controlled by a controller which
receives as
input, a series of signals including a signal from the laser 6310 and then
processes the
information before transmitting a signal to at least the radial positioner
6307, the axial
positioner 6309, the pivoter 6308, and the wire delivery system 6322. The
torch 6305 is then
repositioned and reoriented continuously according to predetermined parameters
of the
controller based on signals from profile reading laser 6310.
[00870] The operation of the present internal welding system will now be
described. FIGS.
73, 80 and 81 illustrate the process of positioning and welding the segments
6105 and 6110
together. In operation, one or more of the following lettered steps may be
executed so that: a)
a pipe segment 6105 is placed on the alignment device/pipe stand 6010A; b) the
internal
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welding machine 6300 is then inserted into the pipe segment 6105; c) a second
pipe segment
6110 is then aligned with the pipe segment 6105 and the welding mechanism 6300
is pulled
forward by the reach rod 6345 or automatically driven so that the torch 6305
generally lines
up with faces joint 6120 of the pipe segments 6105, 6110; d) the alignment
mechanisms
6340A, 6340B (and if necessary 6340C) are then engaged to secure the welding
mechanism
6300 within the pipe segments 6105, 6110; e) in one embodiment (optional), the
rotary
mechanism 6335 rotates the weld head 6305 to perform an initial scan of
interface joint 6120
of the pipe segments 6105, 6110 by the laser sensor device 6310 to ensure
optimal fit up; f) if
required, steps (c), (d) and (e) may be repeated, i.e. the pipe segments 6105,
6110 are
realigned/rotated and rescanned by the laser 6310, to improve "fit up"; g)
optionally, the
internal alignment mechanism 6340C on the rear of the welding mechanism 6300
is engaged
to hold the axial position of the welding mechanism 3600 with respect to both
the pipe
sections 6105, 6110; h) with the welding mechanism 6300 secure in the pipe
segments 6105
and 6110, the root weld (first weld) cycle begins so that the laser 6310 scans
the pipe
interface 6120, the torch 6305 follows the laser 6310, and the output from the
laser 6310 is
used to control the position of the articulated torch 6305, where the position
and orientation
of the torch 6305 with respect to the interface 6120 is controlled so as to
produce the best
quality weld; i) in addition to a signal from the laser 6310, thru the arc
current monitoring can
also be used in directing the torch position; j) after the completion of a 360
weld, the weld
head 6305 is rotated back to an original position; k) the profile (using the
laser 6310) and the
visual inspections (with the 2D color camera 6320) are performed either in the
previous step
(j) or on a separate inspection run; 1) after inspection, aligning mechanism
6340A-C are
released and welding mechanism 6300 is pulled or driven forward towards the
open end of
the welded pipe 6105, 6110 and with the nose of the welding mechanism 6300
exposed, like
(b), the pipe segment 6110 is placed on external alignment mechanism 6010B and
advanced
to the next joint; m) steps (c) to (1) are then repeated for the entire
production run.
[00871] In one embodiment, a signal from the laser sensor 6310 is sent to an
electronic
controller of the external alignment mechanism 6010 to automatically
reposition one or both
of the segments 6105, 6110 for a more desirable face joint 6120 arrangement.
Furthermore,
the foregoing steps may be executed in the stated order. However, variations
in the order are
also contemplated.
[00872] In another embodiment, instead of stopping after the first 360 weld,
the rotation is
continued to lay another weld pass, the laser 6310 could be used to inspect &
track
simultaneously while the trailing 2D color camera continues inspection after
the second weld.
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[00873] In still another embodiment, instead of welding a complete 3600 weld,
the weld is
performed in two 1800 halves with the same start position. This implementation
would
require either multiple laser sensors for tracking or a mechanism to
physically oscillate the
laser and/or the torch in order to maintain the tracking sensor's lead
position in both
directions of rotation (i.e., rotate the torch and laser so that they switch
positions).
[00874] In one embodiment, the present patent application discloses a tie-in
internal weld
system 3001. In one embodiment, the tie-in internal weld system 3001
incorporates all of the
features of the internal weld system 5004. In one embodiment, the additional
features of the
tie-in internal weld system 3001 may include a large capacity battery so that
the tie-in
internal weld system 3001 can travel long distances, and has on-board weld
power. In one
embodiment, the tie-in internal weld system 3001 is configured to operate
autonomously so
that there is no external cables to the tie-in internal weld system 3001.
[00875] As a result of the welding power, locomotion power, and other required
power
being carried on-board (the full battery system carried by the frame), the tie-
in internal weld
system 3001 can be used to traverse very long spans of pipe, and perform a
welding operation
at such locations. This is achievable as the system need not be tethered for
power from an
external power source.
[00876] In one embodiment, the tie-in internal weld system 3001 may also
include a device
for pulling the pipes together to close any gaps. In one embodiment, the
device for pulling the
pipes together to close any gaps may be referred to as an ungapping device. In
one
embodiment, the upgapping device is constructed and arranged such that one of
the clamps is
configured to be moveable relative to the other clamp. In one embodiment, the
upgapping
device is constructed and arranged to be external to the main weld section. In
one
embodiment, the upgapping device is constructed and arranged to be within the
pipes.
[00877] In one embodiment, the tie-in internal weld system 3001 includes the
forward-most
section 3002, the center section 3004, and the drive section 3006 that are
similar to that in the
internal weld system, 5004. In one embodiment, the structure, configuration,
components,
and operation of the forward-most section 3002, the center section 3004 and
the drive section
3006 of the tie-in internal weld system 3001 are similar to the forward-most
section, the
center section and the drive section of the internal weld system 5004
described in detail
above, and, therefore, the structure, configuration, components, and operation
of the forward-
most section 3002, the center section 3004 and the drive section 3006 of the
tie-in internal
weld system 3001 will not be described in detail here. In one embodiment, the
electronics
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module of the forward-most section 3002, the electronics module of the center
section 3004,
and the electronics module of the drive section 3006 each include one or more
processors.
[00878] For example, the tie-in internal weld system 3001 includes a frame
that is
configured to be placed within the pipes 1022a, 1022b, a plurality of rollers
3125 that are
configured to rotatably support the frame of the tie-in internal weld system
3001, a drive
motor 3124 that drives the rollers 3125 to move the frame of the tie-in
internal weld system
3001 within the pipes 1022a, 1022b, a brake system that secures the frame of
the tie-in
internal weld system 3001 from movement at a desired location within the pipes
1022a,
1022b, an inspection detector that is carried by the frame of the tie-in
internal weld system
3001 and configured to detect a characteristic of an interface region between
the pipes 1022a,
1022b, and a weld torch carried by the frame of the tie-in internal weld
system 3001. In one
embodiment, like the internal weld system 5004, the brake system of the tie-in
internal weld
system 3001 may include the clamps of the tie-in internal weld system 3001
that are
configured to clamp to the pipes 1022a, 1022b, respectively. In one
embodiment, like the
internal weld system 5004, the brake system of the tie-in internal weld system
3001 may
include the brake cylinder and the brake valve of the tie-in internal weld
system 3001. In one
embodiment, the structure, configuration, and/or operation of the rollers
3125, the drive
motor 3124, the inspection detector, and the weld torch the tie-in internal
weld system 3001
are similar that of the internal weld system 5004 and, therefore will not be
described in detail
here.
[00879] In one embodiment, the tie-in internal weld system 3001 also includes
one or more
processors that are operatively connected with the drive motor 3124, the
inspection detector
and the weld torch. The configuration and operation of the one or more
processors of the tie-
in internal weld system 3001 are similar to that of the internal weld system
3004 and,
therefore will not be described in detail here.
[00880] In one embodiment, the tie-in internal weld system 3001 is entirely
untethered.
Specifically, the tie-in internal weld system 3001 need not include the reach
rod or the
umbilical and all the communications to and from the tie-in internal weld
system 3001 are
entirely wireless. In one embodiment, the tie-in internal weld system 3001 may
include a
transmitter that is configured to transmit all the communication signals
entirely wirelessly
from the tie-in internal weld system 3001 to the remote uLog processing system
and a
receiver that is configured to receive all the communication signals entirely
wirelessly from
the remote uLog processing system. In one embodiment, the one or more
processors and/or
all the electronic modules of the tie-in internal weld system 3001 are
configured to
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communicate entirely wirelessly with the remote uLog processing system. In one
embodiment, the inspection detector, the inspection camera, all the sensors,
all the motors, all
the valves and/or other components/elements of the tie-in internal weld system
3001 are
configured to communicate entirely wirelessly with the remote uLog processing
system.
[00881] In one embodiment, any information from the tie-in internal weld
system can be
communicated wirelessly with systems outside the pipe by WiFi, Bluetooth, NFC,
by radio
frequency, or through cell tower transmissions, just for example. In some
embodiments
where appropriate, the information is communicated by use of repeaters or
extenders, where
the transmission signal is to travel long distances or through curved areas.
[00882] In one embodiment, the one or more processors and one or more sensors
of the tie-
in internal weld system 3001 are configured to monitor the charge levels of
the on-board
weld power supply, on-board locomotion power supply, and other on-board power
supplies.
For example, the voltage output by these power supplies may be (continuously
or at regular
intervals) monitored. In one embodiment, the transmitter of the tie-in
internal weld system
3001 transmits the monitored battery life/charge level information entirely
wirelessly to the
remote uLog processing system for further processing. For example, the
monitored charge
level information of the on-board power supplies may be used to determine an
estimated
remaining operating time of the tie-in internal weld system 3001. In one
embodiment, the one
or processors of the tie-in internal weld system 3001 may be configured to
determine the
estimated remaining operating time of the tie-in internal weld system 3001
locally on the tie-
in internal weld system 3001. In one embodiment, the remote uLog processing
system may
be configured to determine the estimated remaining operating time of the tie-
in internal weld
system 3001 based on the wirelessly transmitted battery life/charge level
information. In one
embodiment, the remote uLog processing system may be configured to transmit
the estimated
remaining operating time of the tie-in internal weld system 3001 to the one or
more
processors of the tie-in internal weld system 3001. In one embodiment, the
remote uLog
processing system may also be configured to transmit (entirely wirelessly to
the tie-in internal
weld system 3001) further instructions about the operation of the tie-in
internal weld system
3001 based on the estimated remaining operating time of the tie-in internal
weld system 3001.
[00883] In one embodiment, the one or more processors and one or more sensors
of the tie-
in internal weld system 3001 are configured to monitor the gas levels of the
on-board inert
(shield/purge) gas supply, the on-board air supply, and other on-board gas
supplies (e.g.,
volume or pressure of the compressed air in the on-board compressed air tanks,
volume of
pressure of the shield or purge gas in the on-board shield/purge gas tanks,
etc.). For example,
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the gas consumption of these gas supplies may be monitored (continuously or at
regular
intervals). In one embodiment, the transmitter of the tie-in internal weld
system 3001
transmits the monitored gas level information entirely wirelessly to the
remote uLog
processing system for further processing. For example, the monitored gas level
information
of the on-board gas supplies may be used to determine an estimated remaining
operating time
of the tie-in weld system 3001. In one embodiment, the one or more processors
of the tie-in
internal weld system 3001 may be configured to determine the estimated
remaining operating
time of the tie-in internal weld system 3001 locally on the tie-in internal
weld system
3001. In one embodiment, the remote uLog processing system may be configured
to
determine the estimated remaining operating time of the tie-in internal weld
system 3001
based on the wirelessly transmitted gas level information. In one embodiment,
the remote
uLog processing system may be configured to transmit the estimated remaining
operating
time of the tie-in internal weld system 3001 to the one or more processors of
the tie-in
internal weld system 3001. In one embodiment, the remote uLog processing
system may also
be configured to transmit (entirely wirelessly to the tie-in internal weld
system 3001) further
instructions about the operation of the tie-in internal weld system 3001 based
on the
estimated remaining operating time of the tie-in internal weld system 3001.
[00884] In one embodiment, the one or more processors and one or more sensors
of the tie-
in internal weld system 3001 are configured to monitor the weld wire material
levels of the
tie-in internal weld system 3001. For example, the rotations of the wire feed
motor (that
dispenses the weld wire) and the weight of the remaining weld wire material in
the tie-in
internal weld system 3001 may be monitored (continuously or at regular
intervals) to
determine weld wire material levels of the tie-in internal weld system 3001.
In one
embodiment, the transmitter of the tie-in internal weld system 3001 transmits
the monitored
weld wire material level information entirely wirelessly to the remote uLog
processing
system for further processing. For example, the monitored weld wire material
level
information may be used to determine an estimated remaining operating time of
the tie-in
internal weld system 3001 (e.g., before the weld wire material runs out or is
below a
minimum threshold level for operating the tie-in internal weld system 3001).
In one
embodiment, the one or more processors of the tie-in internal weld system 3001
may be
configured to determine the estimated remaining operating time of the tie-in
internal weld
system 3001 locally on the tie-in internal weld system 3001. In one
embodiment, the remote
uLog processing system may be configured to determine the estimated remaining
operating
time of the tie-in internal weld system based on the wirelessly transmitted
weld wire material
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level information. In one embodiment, the remote uLog processing system may be
configured
to transmit the estimated remaining operating time of the tie-in internal weld
system 3001 to
the one or more processors of the tie-in internal weld system 3001. In one
embodiment, the
remote uLog processing system may also be configured to transmit (entirely
wirelessly to the
tie-in internal weld system 3001) further instructions about the operation of
the tie-in internal
weld system 3001 based on the estimated remaining operating time of the tie-in
internal weld
system 3001.
[00885] In one embodiment, the remote uLog processing system receives battery
charge
data from numerous tie-in internal weld systems at different locations (for
example, different
locations across a country or across the globe) and establishes a data base
thereon. That data
base is used by the uLog processing system to determine, based on a large data
set, expected
battery life times based on different operating parameters of the internal
weld system. This
can be used by the uLog processing system and/or by one or more processors of
the tie-in
internal weld system 3001 to anticipate battery life times for various
components based upon
present operating conditions of those components. This information can be used
by the one or
more processors to reduce or regulate power consumption of one or more
components by
modifying one or more operating parameters. For example, weld speed, weld wire
speed,
voltage, and current, can all be regulated (e.g., lowered) to conserve battery
life if the one or
more processors determine that such operating conditions can be modified
without adversely
affecting the associated operation being performed.
[00886] In one embodiment, the battery life, voltage output, and any of the
operating
parameters are sent wirelessly to a user interface, such as a computer monitor
having
computer display, so that they can be monitored by a user.
[00887] In one embodiment, the tie-in internal weld system 3001 also includes
the power
section 3008 positioned next to the drive section 3006 (i.e., at the back of
the tie-in internal
weld system 3001).
[00888] In one embodiment, referring to FIG. 101, the forward-most section
3002 includes
forward-most section frame 3522, the center section 3004 includes a center
section frame
3524, the drive section 3006 includes a drive section frame 3526, and the
power section 3008
includes a power section frame 3528. In one embodiment, the frame or frame
assembly of tie-
in internal weld system 3001 includes the forward-most section frame 3522, the
center
section frame 3524, the drive section frame 3526 and the power section frame
3528. In one
embodiment, the frame or frame assembly of the tie-in internal weld system
3001 is
configured to be placed within the pipes 1022a, 1022b.
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[00889] In one embodiment, the power section 3008 includes an universal joint
3010, a
motor power source 3012, a weld torch power source 3014, weld power supplies
3016, and
adjustable wheels 3018.
[00890] In one embodiment, the drive section 3006 may be connected to the
power section
3008 via the universal joint 3010. In one embodiment, the universal joint 3010
is constructed
and arranged to allow the tie-in internal weld system 3001 to articulate
around bends in the
pipeline.
[00891] In one embodiment, the weld torch power source 3014 may include a
plurality of
weld torch power batteries 3014a-3014e. In one embodiment, the weld torch
power source
3014 is configured to power the weld torch(es) 3502. In one embodiment, the
weld torch
power source 3014 is carried by the frame assembly of the tie-in internal weld
system 3001.
In one embodiment, the number of the weld torch power batteries may vary. In
one
embodiment, the weld torch power source 3014 is configured to supply
electrical power to
the weld torch power supplies 3016 for generating a welding arc. In one
embodiment, the
weld torch power source 3014 is separate from the other electrical systems so
that, if the weld
torch power is depleted, the rest of the tie-in internal weld system 3001 can
still operational.
[00892] In one embodiment, the motor power source 3012 is configured to power
the
electric drive motors 3124 in the drive section 3006. In one embodiment, the
motor power
source 3012 may include a plurality of motor power batteries 3012a-3012e. In
one
embodiment, the motor power source 3012 may also be referred to as the drive
power source.
In one embodiment, the motor power source 3012 is carried by the frame
assembly of the tie-
in internal weld system 3001. In one embodiment, the number of the motor power
batteries
may vary. In one embodiment, the motor power source 3012 is only used for
drive (i.e., to
supply power to the electric drive motors 3124 in the drive section 3006) so
that, in case, the
other battery packs 3014a-3014e are depleted, the tie-in internal weld system
3001 will not be
trapped in the pipeline.
[00893] In one embodiment, the motor power source 3012 (including the
batteries 3012a-e)
and the weld torch power source 3014 (including the batteries 3014a-e) are
carried by the
frame of the tie-in internal weld system 3001. In one embodiment, the one or
more battery
cells (e.g., motor power source 3012, the weld torch power source 3014,
batteries 3514, etc.)
of the tie-in internal weld system 3001 are configured to power the drive
motor 3124, the
inspection detector and the weld torch. In one embodiment, the one or more
battery cells
3514, 3012 or 3014 of the tie-in internal weld system 3001 may include a
plurality of
independent battery cells. In one embodiment, the battery cells 3014, 3014a-e
for the weld
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torch are independent of the battery cells 3012, 3012a-e, 3514 for the drive
motor and the
inspection detector. In one embodiment, the battery cells 3012, 3012a-e for
the drive motor
3124 are independent of the battery cells 3514 for the inspection detector.
That is, in one
embodiment, the battery cells 3012, 3012a-e are configured to power the drive
motors 3124,
the battery cells 3514 are configured to power the inspection detector, and
the battery cells
3014, 3014a-e are configured to power the weld torch of the tie-in internal
weld system 3001.
[00894] In one embodiment, referring to FIG. 101, the drive motors 3124 are
configured to
drive rollers 3125 so as to move the frame or frame assembly of the tie-in
weld system 3001,
the first pipe engagement structure 3127, the second pipe engagement 3129 and
the
inspection detector 3130 of the tie-in internal weld system 3001 along the at
least one of the
pipes 1022a, 1022b within its interior. In one embodiment, the drive rollers
3125 are
configured to engage the interior surfaces 5130, 5132 of one or more of the
pipes 1022a,
1022b. In one embodiment, the tie-in internal weld system 3001 includes a
plurality of drive
rollers 3125 that are configured to rotatably support the frame or frame
assembly of the tie-in
weld system 3001.
[00895] In one embodiment, the weld power supplies 3016 are configured to take
the DC
power from the weld torch power source 3014 and transform the DC power to the
correct
current and voltage waveforms for the weld procedure being performed by the
welding
torches 3502.
[00896] In one embodiment, the adjustable wheels 3018 are constructed and
arranged to be
adjusted so that the power section 3008 of the tie-in internal weld system
3001 runs straight
and level in the pipeline.
[00897] FIG. 103 shows a schematic diagram showing the flow of power including
weld
power, communication data, and controls data through the tie-in internal weld
system 3001,
where some components of the tie-in internal weld system 3001 are not shown
for sake of
clarity and to better illustrate the other components and/or features of the
tie-in internal weld
system 3001.
[00898] The flow of communication data and controls data through the tie-in
internal weld
system 3001 in FIG. 103 are similar to the flow of communication data and
controls data
through the internal weld system 5004 in FIG. 71, except for the differences
noted below.
[00899] In one embodiment, the drive section electronics module 3126 is
configured to be
operatively connected to the drive batteries 3012 positioned/located in the
power section
3008 of the tie-in internal weld system 3001.
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[00900] In one embodiment, the batteries 3012 of the power section 3008 are
connected to
the drive motors 3124 of the tie-in internal weld system 3001 via the drive
section electronics
module 3126.
[00901] The flow of weld power through the tie-in internal weld system 3001 in
FIGS. 103
and 103A is different from the flow of weld power through the internal weld
system 5004 in
FIG. 71.
[00902] For example, the weld power comes from different directions in the
internal weld
system 5004 and the tie-in internal weld system 3001. That is, unlike the
internal weld system
5004 where the weld power comes from the front of the system via its umbilical
5034, the
weld power comes from the back for the tie-in internal weld system 3001. This
configuration
where the weld power comes from the back of the tie-in internal weld system
3001 may be
made possible by adding a second slip ring or by turning the weld portion
around and pushing
it backwards through the pipe (which may make it difficult to access the
spools of the weld
wire for maintenance).
[00903] In one embodiment, the weld power is received by the welding torches
3502 of the
tie-in internal weld system 3001 from the on-board weld torch power source
3014. In one
embodiment, the weld power, from the on-board weld torch power source 3014, is
supplied
to the weld power supplies 3016. In one embodiment, the weld power supplies
3016 are
configured for generating a welding arc. That is, the weld power supplies 3016
are configured
to take the DC power from the weld torch power source 3014 and transform the
DC power to
the correct current and voltage waveforms for the weld procedure being
performed by the
welding torches 3502. In one embodiment, the correct current and voltage
waveforms from
the weld power supplies 3016 are supplied to the weld torches 5502 via the
rear slip ring
3512.
[00904] Like the internal weld system 5004, in one embodiment, the batteries
3514 of the
drive section 3006 are configured to supply the power to all the electronics
modules in the
tie-in internal weld system 3001, including the forward-most electronics
module, the wire
feed electronics module, the center section electronics module and the drive
section
electronics module 3126, and are also configured to supply the power to all
the electric drive
motors in the tie-in internal weld system 3001, including the front rotation
motor, the motors
of the wire feed systems, the rear rotation motor, the axial weld torch motor,
the radial weld
torch motor, and the tilt weld torch motor. In one embodiment, the batteries
3514 are
configured to power the inspection camera and/or the inspection detector of
the tie-in internal
weld system 3001. However, the batteries 3514 of the drive section 3006 are
not configured
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to supply the power to the drive motors 3124 of the tie-in internal weld
system 3001. In one
embodiment, the batteries 3012 of the power section 3008 are configured to
supply the power
to the drive motors 3124 of the tie-in internal weld system 3001. In one
embodiment, the
batteries 3012 of the power section 3008 are connected to the drive motors
3124 of the tie-in
internal weld system 3001 via the drive section electronics module 3126.
[00905] In one embodiment, the batteries used in the tie-in internal weld
system 3001 may
be electrically chained together to get higher current and higher energy
content. For example,
two 12 volts batteries may be chained together to obtain 24 volts. In one
embodiment, both
batteries are mounted to the same frame and wired together in series. In one
embodiment, the
batteries may also be connected to each other (e.g., via a universal joint or
otherwise) so that
the batteries may articulate with respect to one another to maneuver a pipe.
[00906] In one embodiment, the tie-in internal weld system 3001 may include
four batteries
of which one battery may be used for driving the tie-in internal weld system
3001 and the
other three batteries may be connected in parallel and may be used for the
welding
procedures in the tie-in internal weld system 3001.
[00907] In one embodiment, the tie-in internal weld system 3001 may use
internally
positioned (positioned inside the pipes) clamps or externally positioned
(positioned outside
the pipes) clamps. For example, in one embodiment, the tie-in internal weld
system 3001 may
use internally positioned (positioned inside the pipes) clamps during its
welding procedures.
In one embodiment, the tie-in internal weld system 3001 may use externally
positioned
(positioned outside the pipes) clamps during an internal scanning procedure
(where the
internally positioned laser/detector and/or other device are configured to
scan the weld joint
from inside the pipes).
[00908] A tie-in weld is conducted to weld a long stretch of pipe to another
long stretch of
pipe. Generally speaking the new pipe to be welded is at least 120 feet long,
and can be over
two miles long. The tie in internal welding machine disclosed herein has on-
board battery
power and can be used to perform a tie in root weld pass, and optionally also
a hot weld pass
from inside the pipe.
[00909] In one embodiment, the pipes are externally aligned. Like the internal
weld
machine disclosed herein, the tie-in welder can be provided with only a single
weld head
(with a single weld torch) or a plurality of weld heads (e.g., anywhere from 2
to 8, just for
example).
[00910] As shown in FIGS. 103C and 103D, and as will be appreciated from the
prior
discussions herein, the tie-in weld machine 9000 has a nose cone section 9002
for electronics,
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support wheels 9004, an on-board welding power supply 9006, and a pair of
clamps 9008 that
ensure that the tie-in internal welder is concentric to the pipe. As will be
described in more
detail later, the tie-in welder includes clockwise and counterclockwise weld
head "cartridges"
9010, with individual lasers and 2D color cameras. In FIGS. 103C and 103D, the
tie-in
welder machine is shown positioned within a slightly curved (e.g., 30D bent)
pipe 9012
having an inner diameter of 38 inches. As also shown in FIG. 103C and 103D,
the tie-in
welder has a drive system and brakes 9014 that are 90 degrees offset to reduce
length, as well
as an on-board power source (i.e., battery pack) 9020 for the drive motor and
brakes.
[00911] As will be appreciated from FIGS. 103E4, and the following
description, the
model shown has four weld heads, two that will rotate clockwise (weld heads
9022 and 9024)
during a welding operation and two that will rotate counterclockwise (weld
heads 9032 and
9034) during a welding operation. In an alternate embodiment, all 4 weld heads
shown are
rotated in a single rotational direction as described elsewhere in this
application. In addition,
in the embodiment shown in FIGS. 103E4, four on-board welding power
sources/supplies
(e.g., batteries), labelled 9042, 9044, 9046, 9048 are provided. The more
welding
heads/torches that are provided, the shorter the weld cycle time can be. This
is true whether
the welding is done in a single rotational direction or both clockwise and
counterclockwise
directions. It should be appreciated, however, that rotating in a single
rotational direction may
be faster than rotating both clockwise and counterclockwise, the latter of
which may employ
a reversal of motor direction.
[00912] Each weld head 9022, 9024, 9032, and 9034 has the following equipment:
a weld
torch, at least one torch motor of the type previously described herein to
allow for angular,
axial, and side to side movement of each torch, a wire feeder, wire
straightener and wire
spool to feed the welding wire material to the weld torch. A laser
inspection/detector device
of the type previously described is also provided to guide the welding torch
and inspect the
weld. Further, a color CCD/CMOS camera is used to inspect the weld in the
manner
previously described.
[00913] Each weld head is associated and connected with one of the four power
supplies
9042, 9044, 9046 and 9048. The four weld heads and four power supplies are all
mounted on
a rotating assembly 9050. The rotating assembly performs the same function as
the rotatable
hub 5078 previously described. The rotating assembly can be driven by one or
more
orientation motors, as previously described.
[00914] To effect a welding operation, the tie-in weld machine is fed into one
open end of
one of the pipes, for example the shorter pipe or the one with the lesser
obstructions to be
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driven out. The face of the second pipe is matched and aligned (externally)
with the face of
the first pipe. The tie-in weld machine is driven to where the weld heads are
directly at the
pipe interface region. The laser detector provides feedback, and the at least
one weld torch
motor aligns the weld torch tips at the appropriate position at the interface.
The clamps 9008
are actuated and expanded (they function as an expander) to make the tie-in
weld machine
concentric with the pipes, and the clamps are engaged to hold the position on
the tie-in weld
machine. When the tie-in weld machine is secured by the clamps, the rotational
axis of the
rotatable mechanism 9050 is co-axial with the longitudinal axis of the pipe
9012.
[00915] In one embodiment, welding is achieve by first operating weld heads
9032 and
9034 in a counterclockwise direction. As shown in FIG. 103H, the four weld
heads are
rotationally spaced 90 degrees apart. Weld heads 9032 starts at 12 o'clock and
9034 starts at
9 O'clock as shown in FIG. 103H, as they commence welding. The rotating
assembly 9050
rotates 90 degrees until weld head 9032 ends at 9 o'clock and weld head 9034
ends at 6
o'clock (see progression through FIGS. 103H and 1031). At this point, the weld
heads 9032
and 9034 discontinue welding (at FIG. 1031), and weld heads 9022 and 9024
commence
welding (at FIG. 1031). The one or more orientation motors then rotate the
rotatable assembly
9050 in a clockwise direction as shown in FIG. 103J until weld head 9022 ends
up at 3
o'clock and weld head 9024 ends up at 6 o'clock. In this manner, a full root
weld pass is
completed.
[00916] After the root weld has been laid, the rest of the welding may be
completed from
the outside, either using automatic welding machines or manually. The
expanders or clamps
are then disengaged and the tie-in welder is driven out to the open end of the
pipe.
[00917] In one embodiment, each of the power supplies 9042, 9044, 9046 and
9048
comprises a rechargeable battery cartridge than can be inserted in an
associated opening 9062,
9064, 9066 and 9068. When inserted into the opening, the battery cartridge
becomes
electrically connected to its associated weld head. Each battery cartridge can
be easily
removed for recharging and then replaced.
[00918] As shown, the tie-in welder has a self-powered drive and brake
mechanism 9014,
powered by the on-board welding power source 9020. This tie-in welder can
utilize all of the
attributes of the internal welding machine without the on-board power
capability, in various
previous embodiments described herein.
[00919] In this tie-in welder embodiment described, it can be appreciated that
a plurality
(e.g., two) of the weld torches are dedicated to clockwise welding, while
another plurality
(e.g., two) are dedicated to counterclockwise welding. In addition, as
described, all weld
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torches conduct the weld in a downwards direction. As such, the weld torches
can optionally
be fixed at a predetermined weld angle (this is true for any of the internal
welding machines
disclosed herein, whether a tie-in untethered type or a tethered type) so that
the torch tip is
pointing in the forward weld direction (the weld pool is being "pushed").
Alternatively, as
was discussed above with respect to FIG. 56A, the weld torches can be mounted
for pivotal
movement about point P so that the weld torch axis A can be positioned on
either side of the
radial line R. This alternative enables the same weld torch to be used for
both clockwise and
counterclockwise welding, by pivoting the weld torch so that it can pivot in
the forwards
weld direction irrespective of whether the welding is conducted in clockwise
or
counterclockwise direction.
[00920] In one embodiment, the weld torch is configured to be positioned
externally to the
first pipe 1022a and/second pipe 1022b to provide an external welding
operation. In one
embodiment, the externally positioned weld torch is mounted to an outer
surface of the pipes
1022a, 1022b.
[00921] In one embodiment, referring to FIG. 86, the present patent
application provides the
purge and inspection system 7001. For example, in one embodiment, the first
pipe segment
1022a and the second pipe segment 1022b each may be made completely or in-part
from
some Corrosion Resistant Alloy (CRA) materials that may require shield gas on
both sides of
the weld. In one embodiment, the purge and inspection system 7001 may be
positioned
internally within the pipes 1022a, 1022b to provide a purge gas chamber 7054
(as shown in
FIG. 89) inside the pipes 1022a, 1022b and around the interface region 5136
(as shown in
FIG. 97), while an external weld system 7500 (as shown in FIG. 97) performs
the welding
procedure (including the root pass weld procedure 1002, the hot pass weld
procedure 1004
and the fill and cap weld procedure 1006) at the interface region 5136 from
outside the pipes
1022a, 1022b.
[00922] In one embodiment, the purge and inspection system 7001 also provides
internal
clamps that are positioned internally within the pipes 1022a, 1022b to be
welded. That is, in
one embodiment, clamps 7050 and 7052 of the purge and inspection system 7001
are
configured to clamp the inner surfaces 5130, 5132 (as shown in FIG. 33) of the
pipes 1022a,
1022b to be welded.
[00923] In one embodiment, the purge and inspection system 7001 also provides
inspection
detector 7042 and/or inspection camera 7044 that are positioned internally
within the pipes
1022a, 1022b. In one embodiment, the inspection detector 7042 and/or
inspection camera
7044 of the purge and inspection system 7001 are positioned in the purge gas
chamber 7054
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of the purge and inspection system 7001. In one embodiment, one or more
processors 7062
(as shown in FIG. 90) of the purge and inspection system 7001 are configured
to interact with
the inspection detector 7042 and/or inspection camera 7044 to scan the
interface region 5136
between the pipes 1022a, 1022b to determine the profile of the interface
region 5136 between
the pipes 1022a, 1022b prior to, during and subsequent to the welding
procedure, to generate
pre-weld profile data, on-the-fly weld profile data, and post-weld profile
data based on the
scanned data, and to control the external weld system 7500 or its operation
based on the
generated pre-weld profile data, on-the-fly weld profile data, or post-weld
profile data.
[00924] In one embodiment, the purge and inspection system 7001 may be used
for the first
pipe segment 1022a and the second pipe segment 1022b having an external
diameter of 26 to
28 inches. In one embodiment, the purge and inspection system 7001 may be used
for the
first pipe segment 1022a and the second pipe segment 1022b having an external
diameter of
less than 24 inches.
[00925] In one embodiment, the purge and inspection system 7001 includes a
forward-most
section 7002, a center section 7004 and a drive section 7006. In one
embodiment, the
structure, configuration, components, and operation of the forward-most
section, the center
section and the drive section of the purge and inspection system 7001 are
similar to the
forward-most section, the center section and the drive section of the internal
weld system
5004 described in detail above, and, therefore, the structure, configuration,
components, and
operation of the forward-most section, the center section and the drive
section of the purge
and inspection system 7001 will not be described in detail here, except for
the differences
noted below.
[00926] Unlike the center section of the internal weld system 5004, the center
section 7004
does not include the weld torch assembly mounted on its rotatable hub. In one
embodiment,
the center section 7004 of the purge and inspection system 7001 includes the
inspection
detector 7042 mounted on its rotatable hub 7012. In one embodiment, the center
section 7004
of the purge and inspection system 7001 includes the inspection detector 7042
and the
inspection camera 7044 mounted on its rotatable hub 7012. In one embodiment,
the center
section 7004 of the purge and inspection system 7001 includes the inspection
camera 7044
mounted on its rotatable hub 7012.
[00927] In one embodiment, the forward-most section 7002 houses all of the
purge support
components. In one embodiment, the center section 7004 is the part of the
purge and
inspection system 7001 that aligns the pipe, seals the purge area, and
inspects the weld. In
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one embodiment, the drive section 7006 houses the batteries, compressed air
and purge gas
that the rest of the purge and inspection system 7001 needs to operate.
[00928] FIG. 87 shows a detailed view of the forward-most section 7002 of the
purge and
inspection system 7001 and FIG. 88 shows a detailed view of a purge assembly
of the
forward-most section 7002. In one embodiment, the forward-most section 7002 of
the purge
and inspection system 7001 includes a tow hitch, a forward-most electronics
module, a front
slip ring, a front clamp control valve, a front position sensor, adjustable
ramps, a forward-
most section frame, guide wheels, a front rotation motor, and a front rotary
union 7104, and
the structure and operation of each of these components are similar those in
the forward-most
section of the internal weld system 5004.
[00929] In one embodiment, the forward-most section 7002 of the purge and
inspection
system 7001 does not include a wire feed assembly. Instead, the forward-most
section 7002
of the purge and inspection system 7001 includes the purge assembly 7014.
[00930] In one embodiment, the purge assembly 7014 is rotatably connected to
the rotatable
hub 7012 of the center section 7004 such that, when the rotatable hub 7012 is
rotated by the
first and second rotation motors, the purge assembly, connected to the
rotatable hub 7012,
also rotates with the rotatable hub 7012.
[00931] In one embodiment, the purge assembly 7014 is configured to house
valves,
sensors, and regulators to control the flow of purge gas into the purge gas
chamber 7054. In
one embodiment, the purge assembly 7014 is also configured to house the
electronics for
operating all of the components in the purge assembly and the rotatable hub
7012.
[00932] In one embodiment, referring to FIG. 88, the purge assembly 7014
includes a low
purge valve 7016, a primary low purge regulator 7018, a secondary low purge
regulator 7020,
a high purge valve 7022, a high purge regulator 7024, an oxygen sensor 7026, a
pump 7028,
a purge assembly frame 7030, and a purge electronics module 7032.
[00933] In one embodiment, the low purge valve 7016 is configured to control
the flow of
purge gas into the purge gas chamber 7054. In one embodiment, low purge is
generally
referred to as a purge when the purge and inspection system 7001 is
maintaining the inert
atmosphere inside the purge gas chamber 7054. In one embodiment, output from
the low
purge valve 7016 goes to the primary low purge regulator 7018. In one
embodiment, the low
purge valve 7016 is always open (or on) except when seals 7046 and 7048 (as
shown in FIG.
89) are not inflated and there is no purging in the purge and inspection
system 7001.
[00934] In one embodiment, the primary low purge regulator 7018 is configured
to reduce
the pressure of the purge gas from the pressure of 5 psi down to the pressure
of 0.5 psi. In one
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embodiment, the output from the primary low purge regulator 7018 goes to the
secondary
low purge regulator 7020. In one embodiment, the primary low purge regulator
7018 is
configured to be manually set.
[00935] In one embodiment, the secondary low purge regulator 7020 is an
electronic device
that is configured to control the pressure (between 0.1 and 0.5 psi) of the
purge gas flowing
into the purge gas chamber 7054 through a closed-loop feedback. In one
embodiment, the
output from the secondary low purge regulator 7020 goes to the purge gas
chamber 7054.
[00936] In one embodiment, the high purge valve 7022 is configured to control
the flow of
purge gas into the purge gas chamber 7054. In one embodiment, high purge is
generally
referred to as a purge when the purge and inspection system 7001 is
establishing the inert
atmosphere inside the purge gas chamber 7054. In one embodiment, the output
from the high
purge valve 7022 goes to the high purge regulator 7024. In one embodiment, the
high purge
valve 7022 is configured to shut off when the oxygen (as measured by the
oxygen sensor
7026) in the purge gas chamber 7054 is below a predetermined oxygen content
value.
[00937] In one embodiment, the high purge regulator 7024 is configured to
reduce the
pressure of the purge gas from the supply pressure (up to 75 psi) down to the
maximum
desired low purge pressure (typically 5-20 psi). In one embodiment, output
from the high
purge regulator 7024 goes to the purge gas chamber 7054. In one embodiment,
the high purge
regulator 7024 is configured to be manually set. In one embodiment, the high
purge regulator
7024 is configured to be open or operational until the oxygen (as measured by
the oxygen
sensor 7026) in the purge gas chamber 7054 is below the predetermined oxygen
content value.
[00938] In one embodiment, the oxygen sensor's 7026 input is connected to an
exit port of
the purge gas chamber 7054. In one embodiment, the oxygen sensor 7026 is
operatively
connected to the one or more processors 7062. In one embodiment, the oxygen
sensor is
configured to detect an amount of oxygen between the first seal and the second
seal 7046 and
7048. In one embodiment, the oxygen sensor 7026 is configured to measure
oxygen content
of the gas in the purge chamber 7054 and to send an oxygen content data, which
is indicative
of the oxygen content of the gas in the purge chamber 7054, to the one or more
processors
7062. In one embodiment, the oxygen sensor 7026 is configured to measure the
level of
oxygen present in the gas leaving the purge gas chamber 7054 and send the
oxygen content
data to the purge electronics module 7032.
[00939] In one embodiment, the one or more processors 7062 are configured to
enable the
welding operation after the amount of oxygen between the first seal and the
second seal 7046
and 7048 is below a threshold level or predetermined oxygen content value. In
one
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embodiment, the one or more processors 7062 are configured to receive the
oxygen content
data, compare the received oxygen content data to its predetermined oxygen
content value,
and generate an excess oxygen gas signal if the oxygen content data is greater
than the
predetermined oxygen content value. In one embodiment, based on the excess
oxygen gas
signal, the purge and clamp system 7100 may be configured to open the high
purge regulator
7024 to allow purge gas (from the purge gas source/tank 7070) to flow into the
purge
chamber 7054 until the measured oxygen content falls below the predetermined
oxygen
content value. In one embodiment, based on the excess oxygen gas signal, the
one or more
processors 7062 of the purge and clamp system 7100 may send communication
signals to the
external weld system 7500 to stop the welding procedure.
[00940] In one embodiment, the predetermined oxygen content value is 500 parts
per
million (ppm). In one embodiment, the oxygen content value may be within a
predetermined
range of 50 to 100 ppm.
[00941] In one embodiment, during the low purge, the low pressure in the purge
gas
chamber 7054 does not generate sufficient flow through the oxygen sensor 7026.
In one
embodiment, the pump 7028 is used to draw the gas through the oxygen sensor
7026 from the
purge gas chamber 7054. In one embodiment, the pump 7028 may be used
continuously or
intermittently. In one embodiment, the pump 7028 is used for the low purge
operation.
[00942] In one embodiment, the purge electronics module 7032 is configured to
pass
communications upstream through the front slip ring 7034 to the forward-most
section
electronics module 7036. In one embodiment, the purge electronics module 7032
is
configured to pass communications downstream through the rear slip ring 7038
to the center
section electronics module 7040.
[00943] In one embodiment, the purge electronics module 7032 is configured to
control all
of the sensors and valves attached to the rotatable hub 7012 of the center
section 7004. For
example, in one embodiment, the purge electronics module 7032 is configured to
control the
oxygen sensor 7026, the pump 7028, the low purge valve 7016, the high purge
valve 7022
and the secondary low purge regulator 7020. In one embodiment, the purge
electronics
module 7032 is configured to communicate with and control the one or more
inspection
detectors 7042 and the camera 7044.
[00944] FIGS. 89 and 90 show a front view and a cross-sectional view of the
center section
7004 of the purge and inspection system 7001, and the structure and operation
of each of
these components are similar those in the center section of the internal weld
system 5004.
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FIG. 91 shows a detailed view of purge seal 7046 or 7048 and FIG. 92 shows a
detailed view
of the rotatable hub 7012.
[00945] In one embodiment, as discussed above, the frame of the forward-most
section
7002 is connected to the front clamp 7050 (as shown in FIG. 95) of the center
section 7004,
and the purge assembly 7014 is rotatably connected to the rotatable hub 7012.
[00946] In one embodiment, the center section 7004 of the purge and inspection
system
7001 includes the front clamp 7050, a first and second pipe engagement
structures 7050 and
7052, the inspection detector 7042, the inspection camera 7044 (as shown in
FIG. 92), a rear
clamp 7052, a rear clamp control valve 7058, a center section electronics
module 7040, toe
wheels, a center section frame, adjustable ramps, the rear rotary union 7072,
the rear rotation
motor, a rear position sensor, the rotation module 7012, the purge seals 7046
and 7048 and
the rear slip ring 7038.
[00947] In one embodiment, the purge seals 7046 and 7048 are configured to
inflate at the
same time as the clamps 7050 and 7052 are actuated. When both the purge seals
7046 and
7048 are inflated, they are constructed and arranged to engage the inner
surfaces 5130, 5132
of the pipes 1022a, 1022b, respectively forming the chamber 7054 therebetween.
In one
embodiment, the purge seals 7046 and 7048, when inflated, engage on opposite
sides of the
interface region 5136. In one embodiment, the chamber 7054 is a closed volume
that may be
referred to as a purge gas chamber 7054. In one embodiment, the chamber 7054
is
constructed and arranged to receive a purge gas (or an insert gas) therein.
[00948] In one embodiment, the front clamp control valve 7056 and the rear
clamp control
valve 7058 are continuous 4-way directional valves (e.g., having four
hydraulic connections,
corresponding to inlet port (P), actuator ports (A and B), and return port
(T), and one physical
signal port connection (S)). For example, in one embodiment, one of the
actuator ports A or
B are used for extending their corresponding clamps 7050 or 7052 and inflating
their
corresponding seal 7046 or 7048 and the other of the actuator ports A or B are
used for
retracting their corresponding clamps 7050 or 7052 and deflating their
corresponding seal
7046 or 7048.
[00949] FIG. 93 shows a detailed side view of the drive section 7006 of the
purge and
inspection system 7001. In one embodiment, the drive section 7006 of the purge
and
inspection system 7001 includes the shield gas tanks 7070, batteries, drive
section electronics
module 7064, pneumatic valves, drive wheels, drive motors 7068, brakes and the
compressed
air tank, and the structure and operation of each of these components are
similar those in the
drive section of the internal weld system 5004.
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[00950] FIG. 94 shows a schematic diagram showing the flow of purge gas
through the
purge and inspection system 7001, where some components of the purge and
inspection
system 7001 are not shown for sake of clarity and to better illustrate the
other components
and/or features of the purge and inspection system 7001.
[00951] In one embodiment, an inert/purge gas supply line is configured to
communicate
purge/insert inert gas source 7070 to the region 7054 between the first seal
and the second
seal 7046 and 7048. In one embodiment, the gas from the inert/purge gas source
7070 is
directed into the region 7054 between the first seal and the second seal 7046
and 7048 to
reduce oxidation during a welding operation.
[00952] Referring to FIG. 94, the purge gas tanks 7070 are shown in the drive
section 7006
of the purge and inspection system 7001. In one embodiment, a high pressure
regulator 7074
may be positioned in the drive section 7006 of the purge and inspection system
7001. In one
embodiment, the high pressure regulator 7074 may be positioned in the center
section 7004
of the purge and inspection system 7001. In one embodiment, the rear rotary
union 707, the
rotatable hub 7012, the purge gas chamber 7054, the front and rear clamps 7050
and 7052,
and the front and rear seals 7046 and 7048 are shown in the center section
7004 of the purge
and inspection system 7001. The low purge valve 7016, the primary low purge
regulator 7018,
the secondary low purge regulator 7020, the high purge valve 7022, the high
purge regulator
7024, the oxygen sensor 7026, and the pump 7028 are shown in the forward-most
section
7002 of the purge and inspection system 7001.
[00953] In one embodiment, the purge gas tanks 7070 are configured to be
maintained at a
pressure of 500-2400 psi. The purge gas tanks 7070 are in fluid communication
through fluid
communication lines with the rear rotary union 7072. In one embodiment, the
purge gas tanks
7070 are in fluid communication with the rear rotary union 7072 via a valve
7071 and the
high pressure regulator 7074. In one embodiment, the high pressure regulator
7074 is
configured to automatically cut off the flow of the purge gas at a pressure of
75 psi. That is,
the high pressure regulator 7074 is typically set to reduce the pressure in
the purge gas tanks
7070 to about 75 psi in the fluid communication line downstream of the high
pressure
regulator 7074, and from the rear rotary union 7072 to the low purge valve
7016 and the high
purge valve 7022.
[00954] In one embodiment, the rear rotary union 7072 is in fluid
communication through
fluid communication lines with the low purge valve 7016 and the high purge
valve 7022. In
one embodiment, the purge gas stored in the purge gas tanks 7070 is sent
through the fluid
communication lines to the rear rotary union 7072, and then through the fluid
communication
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lines from the rear rotary union 7072 to the low purge valve 7016 and the high
purge valve
7022.
[00955] In one embodiment, the high purge regulator 7024 is connected to an
outlet of the
high purge valve 7022. That is, the high purge regulator 7024 is positioned
downstream of
the high purge valve 7022. In one embodiment, the high purge regulator 7024 is
set to reduce
the pressure output by the high purge valve 7022 to typically between 30 and 5
psi in the
fluid communication line downstream of the high purge regulator 7024, and
between the high
purge regulator 7024 and the purge gas chamber 7054.
[00956] In one embodiment, a fluid communication line extends from the low
purge valve
7016 to the primary low purge regulator 7018. In one embodiment, the primary
low purge
regulator 7018 is connected to an outlet of the low purge valve 7016. That is,
the primary low
purge regulator 7018 is positioned downstream of the low purge valve 7016.
[00957] In one embodiment, the primary low purge regulator 7018 is typically
set to reduce
the pressure output by the low purge valve 7016 to about between 0.5 and 5 psi
in the fluid
communication line downstream of the primary low purge regulator 7018, and
between the
primary low purge regulator 7018 and the secondary low purge regulator 7020.
[00958] In one embodiment, a fluid communication line extends from the primary
low
purge regulator 7018 to the secondary low purge regulator 7020. In one
embodiment, the
secondary low purge regulator 7020 is positioned downstream of the primary low
purge
regulator 7018.
[00959] In one embodiment, the secondary low purge regulator 7020 is set to
reduce the
pressure output by the primary low purge regulator 7018 to typically between
0.1 and 0.5 psi
in the fluid communication line downstream of the secondary low purge
regulator 7020, and
between the secondary low purge regulator 7020 and the purge gas chamber 7054.
[00960] In one embodiment, the welding procedure is started at a pressure of
about 0.5 psi
and, during the welding procedure, when the leakage of the purge gas through
the weld joint
slows as a result of welding (e.g., based on how much gap between the pipe
ends is welded),
the secondary low purge regulator 7020 may then be throttled back to 0.1 psi.
[00961] In one embodiment, the pump 7028 is in fluid communication (through
fluid
communication lines) with the output/exit port of the purge gas chamber 7054
on one side
and is in fluid communication (through fluid communication lines) with the
oxygen sensor
7026 on the other side. In one embodiment, the pump 7028 is in fluid
communication with
the output of the purge gas chamber 7054 such that the pump 7028 is configured
to operate
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(either continuously or intermittently) to draw a sample of the gas from the
purge gas
chamber 7054.
[00962] In one embodiment, the purge gas from the purge gas tanks 7070 is only
used to fill
and maintain the purge gas in the purge gas chamber 7054. In one embodiment,
the
compressed air is used to inflate the seals 7046 and 7048 and to expand the
clamps 7050 and
7052. In one embodiment, the drive section 7006 of the purge and inspection
system 7001
may include both the purge gas tanks 7070 and also the compressed air gas
tanks.
[00963] FIG. 95 shows a schematic diagram showing the flow of compressed air
through
the purge and inspection system 7001, where some components of the purge and
inspection
system 7001 are not shown for sake of clarity and to better illustrate the
other components
and/or features of the purge and inspection system 7001.
[00964] The flow of compressed air through the purge and inspection system
7001 in FIG.
95 is similar to the flow of compressed air through the internal weld system
5004 in FIG. 70,
except for the differences noted below.
[00965] In one embodiment, a valve 7076 is positioned on a fluid communication
line 7078.
In one embodiment, the fluid communication line 7078 is between the rear clamp
control
valve 7058, the rear clamps 7052 and the rear seal 7046 and is configured to
supply
compressed air to expand the rear seal 7046 of the rear clamps 7052. In one
embodiment, one
output of the valve 7076 is configured to supply compressed air to expand the
rear clamps
7052 and the other output of the valve 7076 is configured to supply compressed
air to inflate
the rear seal 7046.
[00966] In one embodiment, a valve 7082 is positioned on a fluid communication
line 7084.
In one embodiment, the fluid communication line 7084 is between the front
clamp control
valve 7056 and the front clamp 7050 and the front seal 7046 and is configured
to supply
compressed air to expand the front clamps 7050 and the front seal 7046. In one
embodiment,
one output of the valve 7082 is configured to supply compressed air to expand
the front
clamps 7050 and the other output of the valve 7082 is configured to supply
compressed air to
inflate the front seal 7046.
[00967] FIG. 96 shows a schematic diagram showing the flow of purge gas
through the
purge and inspection system 7001, where some components of the purge and
inspection
system 7001 are not shown for sake of clarity and to better illustrate the
other components
and/or features of the purge and inspection system 7001. For example, in one
embodiment, in
smaller purge and inspection systems 7001, the purge gas is used to not only
to fill and
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maintain the purge gas in the purge gas chamber 7054 but also to inflate the
seals 7046 and
7048 and to expand the clamps 7050 and 7052.
[00968] The flow of purge gas through the purge and inspection system 7001 in
FIG. 96 is
similar to the flow of purge gas through the purge and inspection system 7001
in FIG. 94,
except for the differences noted below.
[00969] In one embodiment, the rear rotary union 7072 is in fluid
communication through
fluid communication lines with the low purge valve 7016, the high purge valve
7022 and the
front rotary union 7104. In one embodiment, the purge gas stored in the purge
gas tanks 7070
is sent through the fluid communication lines to the rear rotary union 7072,
and then through
the fluid communication lines from the rear rotary union 7072 to the low purge
valve 7016
and the high purge valve 7022. In one embodiment, the purge gas is also sent
through the
fluid communication lines from the rear rotary union 7072 to the front rotary
union 7104. The
front rotary union has essentially the same components and operates in
essentially the same
way as the front rotary union 5032 shown in FIG. 25 and hence not illustrated
in the same
detail as front rotary union 5032.
[00970] In one embodiment, the purge gas is sent through the fluid
communication lines
from the rear rotary union 7072 to the rear clamp control valve 7058. In one
embodiment, the
purge gas from the rear clamp control valve 7058 is supplied via fluid
communication line
7088 to expand the rear clamps 7052 and is supplied via fluid communication
line 7090 to
inflate the rear seal 7048. In one embodiment, a pressure regulator 7092 is
positioned on the
fluid communication line 7090 and is configured to automatically cut off the
flow of the
purge gas to the seal 7048 at a predetermined pressure. In one embodiment, the
purge gas
from the rear clamps 7052 is received by the rear clamp control valve 7058 via
fluid
communication line 7094 to retract the rear clamps 7052.
[00971] In one embodiment, the purge gas is sent through the fluid
communication lines
from the front rotary union 7104 to the front clamp control valve 7056. In one
embodiment,
the purge gas from the front clamp control valve 7056 is supplied via fluid
communication
line 7098 to expand the front clamps 7050 and is supplied via fluid
communication line 7100
to inflate the front seal 7046. In one embodiment, a pressure regulator 7102
is positioned on
the fluid communication line 7100 and is configured to automatically cut off
the flow of the
purge gas to the seal 7046 at a predetermined pressure. In one embodiment, the
purge gas
from the front clamps 7050 is received by the front clamp control valve 7056
via fluid
communication line 7096 to retract the front clamps 7050.
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[00972] FIG. 97 shows a partial view of the purge and inspection system 7001
in which the
inspection detector 7042 and the camera 7044 are configured to perform the
inspection from
inside the pipes while an external weld torch 7502 of the external weld system
7500 is
configured to perform the welding external to the pipes 1022a, 1022b. In one
embodiment,
the externally positioned weld torch 7502 may be mounted to an outer surface
of one of the
first pipe and the second pipe 1022a, 1022b.
[00973] For example, in FIG. 97, an ideal alignment of the weld torch 7502 to
a bevel 7106
(along the longitudinal axis A-A of the pipes 1022a, 1022b) is shown. FIG. 98
shows a close-
up view of the weld torch 7502 being aligned perfectly with the bevel 7106.
The pipes 1022a,
1022b shown in FIGS. 97 and 98 are perfectly aligned and do not have any Hi-
Lo.
[00974] FIGS. 99 and 100 show close-up views of the external weld torch of the
external
weld system used in a prior art system and the purge and inspection system
7001,
respectively, where the pipes have a gap and radial offset (Hi-Lo) alignment.
For example, as
shown in FIGS. 99 and 100, the pipes 1022a, 1022b have a 1 millimeter gap and
radial offset
(Hi-Lo).
[00975] As shown in FIG. 99, in the prior art system, the raised edge of the
pipe shields the
right side of the weld groove causing reduced weld penetration. As shown in
FIG. 100, the
external weld system 7500 used with the purge and inspection system 7001 is
configured to
receive weld profile data (e.g., prior to, during and subsequent to the
welding procedure)
from the purge and inspection system 7001 and is configured, based on the
received weld
profile data, to shift its external weld torch 7502 and/or to tilt its
external weld torch 7502 to
achieve a full weld penetration. Thus, the weld profile data from the purge
and inspection
system 7001 may be used by the external weld system 7500 to make better weld.
[00976] The operation of the purge and inspection system 7001 is now
described. In one
embodiment, the purge and inspection system 7001 is configured to be operated
through a
repeating cycle of operation.
[00977] After it has been determined that a weld has been completed in the
current weld
joint, one or more processors 7062 (of a computer system 7060) are configured
to send
communication signals to the purge electronics module 7032 to control (via
control signals)
the low purge valve 7016, the high purge valve 7022 and the secondary low
purge regulator
7020 to deflate the purge seals 7046 and 7048. The one or more processors 7062
are also
configured to send communication signals to the forward-most section
electronics module
7036 to control/turn off (via control signals) the front clamp control valve
7056 to retract the
first engagement structure 7050 to its original, retracted position and/or to
deflate the purge
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seal 7046. The one or more processors 7062 are also configured to send
communication
signals to the center section electronics module 7040 to control/turn off (via
control signals)
the rear clamp control valve 7058 to retract the second engagement structure
7052 to its
original, retracted position and/or to deflate the purge seals 7048. The purge
and inspection
system 7001 (including the purge seals 7046 and 7048 and the clamps 7050 and
7052) has to
be moved to the next weld joint.
[00978] In one embodiment, the one or more processors 7062 are configured to
send
communication signals to the drive section electronics module 7064 to control
(via control
signals) the drive motors 7068 to accelerate the purge and inspection system
7001 to travel a
predetermined speed and then decelerate and stop at the next weld joint. In
one embodiment,
the predetermined speed at which the purge and inspection system 7001
accelerates may be 6
feet/second.
[00979] When the second engagement structure 7052 is positioned at the next
weld joint,
the drive section electronics module 7064 sends communication signals to the
purge
electronics module 7032 to check alignment with the end of the pipe. In one
embodiment, the
purge electronics module 7032 is configured to operate (turn on) the one or
more inspection
detectors 7042 to measure where the second engagement structure 7052 are in
relation to the
end of the pipe. In one embodiment, the rotatable hub 7012 may not be operated
when the
one or more inspection detectors 7042 are measuring where the second
engagement structure
7052 are in relation to the end of the pipe.
[00980] In one embodiment, the purge electronics module 7032 is configured
send the
measured distance data to the drive section electronics module 7064. In one
embodiment, the
drive section electronics module 7064 is configured to control (via control
signals) the drive
motors 7068 to move the second engagement structure 7052 by the measured
distance data.
[00981] In one embodiment, when the second engagement structure 7052 is
properly
aligned and positioned in relation to the end of the pipe, the drive section
electronics module
7064 is configured to send communication signals to the center section
electronics module
7040 that the purge and inspection system 7001 is in position at the next weld
joint. In one
embodiment, the center section electronics module 7040 controls (opens via
control signals)
the rear clamp control valve 7058 to raise the second engagement structure
7052 and grip the
old/existing pipe. In one embodiment, the center section electronics module
7040 controls
(opens via control signals) the rear clamp control valve 7058 to inflate the
rear seal 7048 at
the same time.
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[00982] The next/new pipe segment 1002a is then brought in, and slid over the
forward-
most section 7002 of the purge and inspection system 7001 into position by the
working crew.
At this time, the one or more processors 7062 are configured to send
communication signals
to the purge electronics module 7032 to operate the one or more inspection
detectors 7042 to
check the alignment of the pipes. In one embodiment, the one or more
processors 7062 may
rotate the rotatable hub 7012 to take measurements at multiple locations.
[00983] If the pipe alignment data is within a predetermined tolerance, the
purge electronics
module 7032 sends communication signals to the forward-most electronics module
7036 to
actuate and operate the front clamp 7050. In one embodiment, the forward-most
electronics
module 7036 controls/opens (via control signals) the front clamp control valve
7056 to raise
the first engagement structure 7052 and grip the new pipe segment 1002a. In
one
embodiment, the forward-most electronics module 7036 controls/opens (via
control signals)
the front clamp control valve 7056 to inflate the front seal 7046 at the same
time.
[00984] If the pipe alignment data is not within the predetermined tolerance,
the purge
electronics module 7032 sends communication signals (a message) to the one or
more
processors 7062 identifying the misalignment between the pipes 1022a, 1022b.
In one
embodiment, this information may be relayed to a crane operator by traditional
crane operator
hand signals or by an electronic signal to a computer display terminal in the
crane cab.
[00985] After the pipe is clamped, the one or more processors 7062 are
configured to send
communication signals to the purge electronics module 7032 to operate the one
or more
inspection detectors 7042 to measure the gap and radial offset (Hi-Lo) at a
plurality of points
along the circumference of the weld joint. In one embodiment, this data is
communicated out
to the one or more processors 7062 and compared against the allowable
tolerances.
[00986] If the joint fit up (i.e., the gap and radial offset (Hi-Lo)) is
within a predetermined
tolerance, either the one or more processors 7062 or the purge electronics
module 7032 sends
communication signals to the operator indicating that welding may begin.
[00987] If the joint fit up (i.e., the gap and radial offset (Hi-Lo)) is not
within the
predetermined tolerance, a warning is sent to the operator, who can restart
the clamping
sequence or override the warning.
[00988] In one embodiment, the purge electronics module 7032 is configured to
send
control signals to the high purge valve 7022 to open and the high purge
regulator 7024 to
operate. In one embodiment, the purge electronics module 7032 is configured to
continuously
monitor the reading of the oxygen content level in the purge gas chamber 7054
from the
oxygen sensor 7026. When the oxygen sensor's 7026 measurement data is below
the
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predetermined oxygen content value (e.g., 500 parts per million (ppm)), the
purge electronics
module 7032 is configured to send control signals to the high purge valve 7022
to close and
the low purge valve 7016 to open. In one embodiment, the oxygen sensor's 7026
measurement data is to be within a predetermined range (e.g., 50 to 100 ppm).
[00989] In one embodiment, while the high purge valve 7022 is open, the purge
electronics
module 7032 together with the forward-most section electronics module 7036 and
the center
section electronics module 7040 are configured to use the one or more
inspection detectors
7042 to measure the gap and Hi-Lo of the weld joint at a plurality of points
along the
circumference of the weld joint. The results of the scan are communicated to
the one or more
processors 7062 to pre-program the external weld system 7500.
[00990] In one embodiment, after the low purge valve 7016 is closed, the
secondary low
purge regulator 7020 is configured to maintain a constant, set pressure in the
purge gas
chamber 7054. In one embodiment, the secondary low purge regulator 7020 is
configured to
maintain the pressure between 0.1 and 0.5 psi and is configured to stop its
operation when the
pressure is above 0.5 psi.
[00991] In one embodiment, the pressure starts out at a relatively high value
(e.g., 5 psi) and
is progressively gets to lower values as the weld proceeds. In one embodiment,
the secondary
low purge regulator 7020 may include a pressure sensor that is configured to
communicate
with the one or more processors 7062. In one embodiment, the pressure sensor
is configured
to measure pressure of the purge gas in the purge chamber 7054 and send a
pressure data,
which is indicative of the pressure of the purge gas in the purge chamber
7054, to the one or
more processors 7062. In one embodiment, the one or more processors 7062 are
configured
to receive the pressure data, compare the received pressure data to its
predetermined pressure
value, and generate an overpressure signal if the pressure data is greater
than the
predetermined pressure value of 0.5 psi. In one embodiment, based on the
overpressure signal,
the purge and inspection system 7100 may be configured to open an exhaust
valve structure
to release the pressure in the purge chamber 7054 until the measured pressure
falls below the
predetermined pressure value. In one embodiment, based on the overpressure
signal, the
purge and inspection system 7100 may be configured to send communication
signals to the
external weld system to stop the welding procedure.
[00992] In one embodiment, communication signals are sent out the umbilical
that correct
purge gas level has been reached and the weld procedure can begin. In one
embodiment, the
operator issues the commands to the external weld system 7500 to begin the
welding
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procedure. In one embodiment, the commands are automatically sent from the one
or more
processors 7062 to the external weld system 7500 to begin the welding
procedure.
[00993] In one embodiment, the purge electronics module 7032 together with the
forward-
most section electronics module 7036 and the center section electronics module
7040 are
configured to use the one or more inspection detectors 7042 to measure the gap
and Hi-Lo of
the weld joint a short distance ahead of where the external weld system 7500
is currently
welding. In one embodiment, the inspection data from the inspection detector
7042 may be
communicated in real-time to the one or more processors 7062 which use the
inspection data
to send updated welding parameters to the external weld system 7500.
[00994] In one embodiment, the external weld system 7500 is configured to
communicate
its position to the one or more processors 7062 which relay the information to
the purge
electronics module 7032 so that the purge electronics module 7032 can maintain
the proper
purge gas chamber pressure and control the position of the inspection detector
7042
appropriately.
[00995] In one embodiment, the weld procedure may be performed in several
different
ways.
[00996] In one embodiment, the weld procedure may be performed top to bottom
on one
side of the pipes and then top to bottom on the other side of the pipes. In
one embodiment,
the first weld is completed before the second weld begins. In this situation,
the inspection
detector 7042 scans ahead of the weld in real-time.
[00997] In one embodiment, the weld procedure may be performed top to bottom
on each
side of the pipe with the second weld starting before the first weld finishes.
In one
embodiment, the inspection detector 7042 scans a distance ahead of one weld
faster than the
welder is traveling then rapidly change position to the other weld to scan
ahead of it. In one
embodiment, the inspection detector 7042 may alternate between the two weld
locations until
the first weld finishes.
[00998] In one embodiment, the weld procedure may be performed all the way the
pipes
around in one pass with the inspection detector 7042 scanning a short distance
ahead of the
weld.
[00999] In one embodiment, after the weld is complete, the rotatable hub 7012
continues to
rotate while the purge electronics module 7032 uses the inspection detector
7042 and the
camera 7044 to inspect the weld. In one embodiment, the weld inspection data
is
communicated to the one or more processors 7062.
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[001000] In one embodiment, if one or more weld defects are detected in the
weld inspection
data, the weld defects can be repaired while the clamps 7050 and 7052 are
still in position
and the purge gas chamber 7054 is still filled with inert gas.
[001001] In one embodiment, once the inspection and any repairs are complete
and verified
by the operator, the operator sends a command to the forward-most section
electronics
module 7036 and the center section electronics module 7040 to turn off the
front and rear
clamp control valves 7056 and 7058, lower/retract the clamping shoes 7050 and
7052, and
deflate the seals 7046 and 7048.
[001002] In one embodiment, the one or more processors 7062 of the purge and
inspection
system 7100 may operatively connected to the forward-most electronics module
of the purge
and inspection system 7100, the purge electronics module 7032, the center
section electronics
module of the purge and inspection system 7100, and the drive section
electronics module
7064.
[001003] In one embodiment, the field system of the present patent application
may include
one or more of splitters/hubs/routers that are configured to transmit data,
control signals and
communication signals between the one or more processors 5140 or 7062 and one
or more
electronics modules described in this application.
[001004] During pipeline forming procedures (e.g., for offshore or on land (on
shore)
applications), one section of pipe 1022a or 1022b is connected to another
section of pipe
1022b or1022a at a tie-in weld (the location at which the two pipe sections
are welded
together) by aligning two facing ends of the pipe sections together and
forming the weld joint
1026. Such a weld joint 1026 connects the two pipe sections 1022a, 1022b at
their facing
ends such that the weld joint 1026 yields a fluid tight seal and thus a
continuous fluid passage
between the two joined pipe sections. Each pipe section 1022a, 1022b may be
considerably
long (e.g., hundreds or thousands of feet or even as long as 1 mile), making
it difficult to
provide internal cooling within the pipe sections 1022a, 1022b at or near the
tie-in weld
location after the weld joint 1026 has been formed. In particular, placement
of a cooling
structure as well as removal of such structure internally within the pipe
sections 1022a, 1022b
for cooling at the weld joint 1026 could be challenge.
[001005] The internal cooling system of the present application provides
internal cooling
within pipe sections 1022a, 1022b after the pipe sections have been secured
together via the
weld joint 1026. In one embodiment, the internal cooling system may be an
internal heat
exchanger that may be referred to as "IHEX." In one embodiment, the internal
cooling
system includes a cooling section to provide direct cooling to internal
surface portions of pipe
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sections 1022a, 1022b, and a control section or controller that is configured
to control
components of the cooling section and further is configured to facilitate
mobility of the
internal cooling system within pipe sections 1022a, 1022b. In one embodiment,
the cooling
section utilizes a coolant to provide cooling internally within pipe sections
1022a, 1022b. In
one embodiment, the internal cooling system may further include a coolant
supply section
that includes coolant to be supplied to the cooling section during operation
of the internal
cooling system. In one embodiment, the internal cooling system of the present
patent
application includes a mechanism configured for internally cooling the pipe
sections 1022a,
1022b after being welded together as well as a mechanism for placement of the
internal
cooling system within and retrieval of the internal cooling system from the
pipe sections
1022a, 1022b during the pipeline forming process, which results in a reduction
in the time
required to cool the pipe sections after heating and also a speed up in
progress through the
stations necessary for fabrication.
[001006] FIG. 104 shows an exemplary internal cooling system 2010 of the
present patent
application. In one embodiment, the internal cooling system 2010 includes a
suitably rigid
frame that houses components of the internal cooling system, where the frame
comprises a
plurality of longitudinally or lengthwise extending rods 2019, 2021
constructed of one or
more suitable materials (e.g., a metal such as steel or other suitably rigid
and durable
materials) and has a suitable configuration to permit insertion of the frame
within pipe
sections to facilitate internal cooling within the pipe sections 1022a, 1022b.
[001007] A first section 2011 of the frame includes a coolant supply source
2012 comprising
one or more tanks (a single tank is shown in FIG. 104) secured within the
first section 2011.
The coolant supply source tanks may include any suitable cooling fluid
including, but not
limited to, water, a cryogenic fluid such as liquid argon or liquid nitrogen,
etc. A second,
cooling section 2016 is secured at an intermediate location of the frame
adjacent the first
section 2011 and communicates with the coolant supply source 2012 via a
suitable valve
structure 2014 (e.g., shown in FIG. 104 as one or more valves, regulators,
piping, etc.) that
facilitates supply of coolant from the coolant supply source 2012 to outlet
nozzles 2007 of the
cooling section 2016 at one or more suitable pressures and/or flow rates.
[001008] A third section 2018 of the frame is disposed adjacent the cooling
section 2016 and
comprises a plurality of rods 2021 that form a caged enclosure surrounding a
controller 2020.
A pneumatic and/or an electronic drive system 2022 may also be at least
partially disposed
within the third section 2018 and may include one or more motor-controlled
rollers 2025
and/or any other suitable locomotive structure(s) configured to engage with
internal surface
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portions of pipe sections when the internal cooling system 2010 is disposed
within such pipe
sections to control movement of the internal cooling system 2010 in forward
and reverse
directions within pipe sections during procedures as described herein. In one
embodiment, the
drive system 2022 may be in communication (e.g., hardwire or wireless
communication) with
the controller 2020 to facilitate control, via the controller 2020, of forward
and reverse
movements of the internal cooling system 2010 during procedures (e.g., control
of a motor of
the drive system 2022 by the controller 2020 controls rotation of the
roller(s) and thus
forward or rear movement of the internal cooling system 2010). In one
embodiment, the drive
system 2022 may be substantially encompassed within and/or as part of the
frame of the
internal cooling system 2010. In one embodiment, the drive system 2022 may
include a
structure that extends beyond the frame. In one embodiment, the drive system
2022 may
include a suitable cable structure that extends from the internal cooling
system 2010 and
through one or more pipe sections to an open end of a pipe section, where the
cable structure
is used to facilitate forward and/or reverse movement of the internal cooling
system 2010
within pipe sections (e.g., via a winch structure provided within the internal
cooling system
frame and/or at an anchored location exterior to the pipe sections and
connected with the
cable structure). In one embodiment, the rollers may also be provided at one
end of the
internal cooling system 2010 (e.g., rollers 2023 provided at a terminal end of
the frame first
section 2011 as shown in FIG. 104) to enhance mobility of the internal cooling
system 2010
within pipe sections 1022a, 1022b.
[001009] In one embodiment, the controller 2020 may include at least one
suitable processor
that controls operations of the internal cooling system 2010 via suitable
control process logic
instructions stored within a memory of the controller as well as electronic
signals provided
remotely via another user-controlled device disposed at a suitable distance
from the internal
cooling system. In one embodiment, the controller 2020 may be configured to
communicate
with a remote control device operable by a user (e.g., a computer, hand
control device, or any
other suitable electronic device) via electronic signals, where the electronic
signals are
communicated via a wireless or hardwire link between the controller 2020 and
the remote
control device. In one embodiment, the remote control device is shown in FIG.
104 as a
computer 2030 (e.g., laptop, notepad, personal digital assistant, smart phone,
etc.) that
communicates with the controller 2020 via a wireless communication link (shown
as the
dashed line in FIG. 104). Electronic signal communications may include two way
communications between the controller 2020 and the remote control device, such
that the
controller 2020 is configured to provide information to the remote control
device (such as
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measured internal temperature information and/or other types of measured
conditions within
the pipe sections) as well as received control information to effect remote
control operations
of the internal cooling system 2010.
[001010] In one embodiment, one or more electronic sensors 2017 may be
provided at one or
more suitable locations within the internal cooling system frame and may be in
communication (via hardwire or wireless communication link) with the
controller 2020 to
provide information about conditions within the pipe sections during
procedures. For
example, in one embodiment, the one or more electronic sensors 2017 comprise
one or more
temperature sensors (e.g., IR temperature sensors, RTD temperature sensors,
thermocouples,
etc.) may be provided at one or more different locations at the first section
2011, the cooling
section 2016 and/or third section 2018 of the internal cooling system 2010,
where the
temperature sensors are configured to measure temperature and provide such
measured
temperature information to the controller 2020 during procedures. In one
embodiment, the
one or more electronic sensors 2017 comprise pressure and/or flow rate sensors
may be
provided at one or more suitable locations within the tank(s) 2012 of the
coolant source 2012,
within the valve structure 2014 and/or proximate the outlet nozzles 2007 of
the cooling
section 2016, where measured pressure and/or flow rate information is provided
by such
sensors to the controller 2020 during procedures. It should be appreciated
that the sensors
2017 can also comprise a combination of temperature and pressure sensors. In
one
embodiment, one or more cameras 2027, controlled by the controller 2020 (and
remotely
controlled by the remote control device), may also be provided at one or more
suitable
locations to facilitate a view within the pipe sections (e.g., to determine a
suitable location for
positioning the internal cooling system 2010 within the pipe sections 1022a,
1022b during
procedures). Example pressure/temperature sensors and/or cameras are
generically shown at
locations 2017 and 2027 in FIG. 104.
[001011] In one embodiment, the internal cooling system 2010 may include a
suitable power
supply source to provide electrical power to the controller 2020, the drive
system 2022, the
electronic sensors, the valve structure 2014 (e.g., to electronically control
one or more valves
and thus control flow of coolant from the coolant supply source 2012 to the
cooling section
2016). In one embodiment, the power supply source may be contained within the
internal
cooling system frame (e.g., one or more batteries disposed in a battery pack
provided within
the third section 2018 or at any other suitable location within the internal
cooling system
frame). In one embodiment, the power supply source may be located external to
the pipe
sections, where an electrical cable connects the power supply source with the
internal cooling
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system 2010 to provide electrical power to the various components of the
internal cooling
system.
[001012] In one embodiment, the cooling section 2016 may include any suitable
structure
that facilitates cooling via heat exchange with the internal weld portion as
well as other
internal wall portions of the pipe sections. In one embodiment, the coolant
from the coolant
supply source 2012 is provided via the valve section 2014 to the cooling
section 2016. In one
embodiment, the cooling section 2016 include a plurality of nozzles 2007
disposed around an
external periphery of the cooling section 2016 to facilitate a flow of coolant
at a suitable flow
rate (as controlled by the valve section 2014 and nozzle design of the cooling
section nozzles
2007) from the cooling section 2016 toward the internal surfaces at the weld
joint and other
internal portions of the two joined pipe sections.
[001013] The operation of the internal cooling system 2010 in relation to
pipeline welding
procedures is now described with reference to FIGS. 105-107. In preparation
for welding an
open end of the first pipe section 1022a to a facing open end of the second
pipe section 1022b,
the two pipe sections 1022a, 1022b are axially aligned in position with each
other. In one
embodiment, the two pipe sections 1022a, 1022b may be held in such alignment
with a tie-in
clamp (not shown in FIGS. 105-107). A suitable tie-in clamp (e.g., clamps 5302
(positioned
external to the pipe) as disclosed elsewhere in this application) may be
externally secured to
the facing ends of the pipe sections 1022a, 1022b to hold the sections 1022a,
1022b in place
in relation to each other during the welding procedure. In one embodiment, an
internal tie-in
clamp (e.g., internal clamps 5142,5144 (positioned inside the pipe) as
disclosed elsewhere in
this application) may be used to hold the facing ends in place during the
welding procedure.
Both types of tie-in clamps (external and internal) are known in the pipe
welding art and are
thus not described in further detail herein. After the tie-in clamp is applied
to hold the ends of
the pipe sections 1022a, 1022b in place in relation to each other, the weld
joint 1026 is
formed at the tie-in weld location (i.e., at the two facing open ends of the
first and second
pipe sections). The weld joint 1026 is formed in the manner as described in
detail above and
may include the root pass weld layer, hot pass weld layer, the fill pass weld
layer(s) and the
cap pass weld layer to ensure a proper weld joint is formed. In one
embodiment, the
formation of the weld joint 1026 may involve a preheating of the facing ends
of the first and
second pipe sections 1022a, 1022b to a minimum temperature of about 150 C. The
remainder
of the welding procedure may cause a temperature rise around the weld joint as
high as about
300 C. After the weld joint 1026 is formed, the weld joint 1026 is typically
AUT (ultrasonic
tested) and/or X-ray inspected, as disclosed elsewhere in this application, to
confirm the
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quality/integrity of the weld joint 1026. In one embodiment, the AUT weld
inspection may
not be conducted above temperatures of about 50 C to about 75 C (T.), where T.
is the
highest temperature at which inspection may be effectively conducted.
Furthermore, the AUT
weld inspection procedure of the pipe fabrication procedure has to be halted
until the pipe
temperatures near the weld joint 1026 are reduced to a temperature around such
inspection
temperature range. The internal cooling system of the present application is
configured to
remove heat from the weld area in order to reduce the temperature of the pipe
weld area at
least down to the acceptable AUT inspection temperature (Tmax).
[001014] In one embodiment, after the weld inspection procedure, the field
joint coating
(FJC) is also applied to external areas of the pipe sections 1022a, 1022b
surrounding the weld
joint 1026 to provide an insulation barrier in order to prevent or minimize
corrosion at weld
areas. Such insulation may usually be applied effectively only when the pipe
temperature is
above a minimum pipe temperature T.. Heat is therefore added to the welded
area until the
pipe temperature in the weld area to be insulated rises back up to around 220
to 240 C
where Tmin is the lowest temperature at which insulation may be effectively
applied to the
insulation area.
[001015] After the coating/insulation application procedure, the pipe may be
spooled for in-
the-field installation. However, at temperatures around Tmõõ the spooling
procedure cannot be
accomplished effectively while maintaining weld integrity. Therefore, the pipe
fabrication
procedure again may be stalled while the pipe temperature is gradually allowed
to drop
naturally (relative to ambient temperature) from T. to an acceptable spooling
temperature
(Tmax), where Tmax is the highest/maximum temperature at which the pipe may be
effectively
spooled. In one embodiment, the internal cooling system of the present
application is
configured to again remove heat from the weld area in order to reduce the
temperature to a
maximum temperature of about 50 to about 75 C (T.) acceptable for effective
spooling
(winding the pipe onto a spool). Therefore, the internal cooling system of the
present
application is configured to reduce the temperature before the weld inspection
procedure
and/or reduces the temperature before the spooling procedure in order to
minimize the time it
takes to weld, inspect, insulate, and spool a length of pipe segments.
[001016] During the operational period at which the pipe sections 1022a, 1022b
are being
welded together (with subsequent application of the coating/insulation), the
internal cooling
system 2010 is loaded within an open end of pipe section 1022a as shown in
FIG. 105. In one
embodiment, one or both pipe sections 1022a, 1022b may comprise a single unit
of pipe. In
another embodiment, one of pipe sections 1022a, 1022b may comprise a plurality
of pipe
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units welded together. In one embodiment, when one of the pipe sections 1022a
or 1022b
comprises a plurality of pipe units already welded together, it may be
desirable to load the
internal cooling system 2010 at the pipe section 1022a or 1022b comprising a
single unit of
pipe (or the pipe section having the shorter length) so as to reduce the time
necessary for the
internal cooling system 2010 to travel within the pipe section to reach the
tie-in weld location.
Thus, in one embodiment, the pipe section 1022a may comprise a single pipe
unit that is
being connected with a longer section of pipe represented by the pipe section
1022b (e.g., two
or more pipe units connected via weld joints).
[001017] In one embodiment, the internal cooling system 2010 is loaded into
the open end of
the pipe section 1022a (i.e., the end that opposes the open end facing the
open end of pipe
section 1022b that defines the tie-in weld location) such that the first
section 2011 of the
internal cooling system frame serves as the front end and thus enters first
within pipe section
1022a. In one embodiment, the internal cooling system 2010 is moved (leading
with the first
section 2011) within the pipe section 1022a to a suitable position proximate
the tie-in weld
location as shown in FIG. 106. In one embodiment, the controller 2020 (which
may be
remotely controlled by a user) is configured to control operation of the drive
system 2022
(e.g., by controlling one or more motors which move the rollers 2025 in
contact with internal
wall portions of pipe section 1022a) to facilitate advancement of the internal
cooling system
2010 within the pipe section 1022a and toward the tie-in weld location. Upon
reaching a
suitable location proximate the tie-in weld location (e.g., a location of the
internal cooling
system as shown in FIG. 106), the controller 2020 may control the drive system
2022 so as to
cease further movement of the internal cooling system 2010 until such time as
cooling
procedures are to be initiated. For example, a camera 2027 mounted at a
suitable location on
the first section 2011 and which is controlled by the controller 2020 may
provide video
images to the remote control device so that a user may determine how close the
internal
cooling system is to the weld joint 1026. In one embodiment, in combination
with video
images provided by the camera 2027, one or more temperature sensors 2017
suitably located
on the internal cooling system 2010 frame that measures internal temperatures
within pipe
section 1022a and provide such temperature information to the controller 2020.
When one or
more measured temperatures reach a threshold value (e.g., about 100 C or
greater), this may
provide an indication that the internal cooling system 2010 has reached a
location proximate
the weld joint 1026. Any other suitable mechanism may also be utilized to
provide a suitable
indication of the location of the internal cooling system 2010 within the pipe
section 1022a
during its movement toward the tie-in weld location.
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[001018] Upon reaching the desired location that is proximate or near the tie-
in weld location,
a cooling procedure may be performed after the weld joint 1026 is formed and
before the
AUT/X-ray inspection has occurred (if required). In one embodiment, the
cooling procedure
may be performed after the pipe is reheated for application of an external
coating, and an FJC
has been applied (if required). In one embodiment, when the internal cooling
system 2010
reaches a suitable location within pipe section 1022a that is proximate the
tie-in weld location
and before completion of the welding procedure, the internal cooling system
2010 is kept in
its position and is ready to be used for cooling as soon as the welding or
reheating procedure
is completed. The cooling procedure is performed by first positioning the
cooling section
2016 at a suitable location (e.g., relative to the weld joint 1026, such as
shown in FIG. 107).
This may be achieved by advancing the internal cooling system 2010 from its
position in FIG.
106 to its position in FIG. 107 via the controller 2020 (which is user
controlled via the remote
control device) controlling the drive system 2022 until the internal cooling
system 2010 is at
the desirable position. Movement to such location (e.g., as shown in FIG. 107)
may be
achieved based upon video images within the pipe sections 1022a, 1022b being
provided to
the remote control device, temperature sensor information being provided to
the remote
control device and/or via any other suitable mechanism.
[001019] Upon reaching a desired location within the pipe sections 1022a,
1022b (e.g., where
the cooling section 2016 is disposed in close proximity to the weld joint 1026
as shown in
FIG. 107), the controller 2020 (which may be user controlled via the remote
control device)
controls operation of the valve structure 2014 (e.g., via control of one or
more electronic
valves) to facilitate a flow of coolant from the coolant supply source 2012 at
a suitable
pressure and/or flow rate to the cooling section 2016, where the coolant flows
from the
nozzles 2007 disposed at the cooling section 2016 and suitably oriented to
direct coolant flow
away from the cooling section 2016 and toward inner wall surface portions
within the pipe
sections 1022a, 1022b. The temperature sensor(s) monitor the internal
temperature at the
internal cooling system 2010 within the pipe sections 1022a, 1022b and provide
measured
temperature information to the controller 2020. Upon reaching a sufficient
temperature within
pipe sections 1022a, 1022b (as measured by the temperature sensor(s), e.g., a
temperature of
T. C or lower), the controller 2020 may control the valve structure 2014 to
cease flow of
coolant to the cooling section 2016.
[001020] In one embodiment, the internal cooling system 2010 may be moved in
forward or
reverse directions, via control of the drive system 2022 by the controller
2020, to provide
further cooling procedures (as desired and based upon measured internal pipe
temperatures)
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at other locations along internal wall surface portions of the pipe section
1022a and/or the
pipe section 1022b. When it has been determined that sufficient cooling has
been achieved,
the internal cooling system 2010 may be withdrawn from the connected pipe
sections 1022a,
1022b. For example, the internal cooling system 2010 may be moved in reverse,
by
controlling the drive system 2022 via the controller 2020, to move toward the
free and open
end of the pipe section 1022a such that the third section 2018 would emerge
first from the
pipe section 1022a. A further pipe section may then be aligned (the internal
cooling system
may remain inside section 1022a as the new section is fitted up to 1022a) with
the free and
open end of pipe section 1022a (now connected via the weld joint 1026 with
pipe section
1022b) to form a tie-in weld location, and the process is then repeated in
which the internal
cooling system 2010 enters via the free and open end of the further pipe
section and is
advanced toward the tie-in weld location for performing cooling procedures at
the weld joint
to be formed between the pipe sections.
[001021] While the drive system 2022 shown in the embodiment of FIGS. 104 ¨
107
comprises the rollers 2025 operable by a motor system that is controlled by
the controller
2020, the drive system 2022 for the internal cooling system may also implement
any suitable
mechanism capable of providing user-controlled movements of the internal
cooling system
within the pipe sections. For example, one or more cable/winch systems may be
implemented,
in which one or more winches may be provided as part of the internal cooling
system and/or
located at one or more anchor points that are external to the pipe sections. A
cable extends
between each winch and a connection point (either at the internal cooling
system or a
connection point external to the pipe sections) so as to facilitate placement
of the internal
cooling system within and/or withdrawal of the internal cooling system from
the pipe
sections during procedures.
[001022] It is noted that the procedures described above in relation to the
internal cooling
system may be performed for any types of tie-in weld applications between pipe
sections in a
pipeline system. For example, the internal cooling system may be used in
creating pipelines
for offshore, underwater applications as well as mainline applications. In one
embodiment,
the internal cooling system 2010 may be used for the spool base tie-in weld
sequence (as
shown in described with respect to FIG. 6) and barge weld sequence (as shown
in described
with respect to FIG. 7).
[001023] In a mainline application, 40 foot (12 meter) to 80 foot (24 meter)
pipe sections are
welded together to form long "tie-in" sections. In scenarios in which an
umbilical cable may
be required for controlling movement and/or other procedures of the internal
cooling system,
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the umbilical cable may be at least 240 feet (72 meters) in length. The
procedure of loading
the internal cooling system within a pipe section and moving the internal
cooling system into
position for cooling after a welding procedure (with optional AUT/X-ray weld
inspection and
coating/insulation/FJC application) takes place in similar to that previously
described in
relation to FIGS. 104 ¨ 107.
[001024] FIG. 108 shows an internal cooling system 2010-1 in accordance with
another
embodiment of the present patent application. The internal cooling system 2010-
1 is similar
to the embodiments previously described, except for the differences as will be
noted below.
In one embodiment, the internal cooling system 2010-1 is configured to connect
with an
internal tie-in clamp 2060 at an end section 2024 of the third frame section
2018 of the
internal cooling system 2010-1. In one embodiment, the internal tie-in clamp
2060 includes a
frame 2062 with a suitable configuration that allows for insertion of the tie-
in clamp 2060
within the pipe sections (e.g., pipe sections 1022a and 1022b) and includes a
section 2064
that is configured to align and hold two open and facing ends of pipe sections
1022a, 1022b
in place at the tie-in weld location (e.g., by expanding to form a frictional
engagement with
the internal wall surface portions of the pipe sections at their facing ends
when the tie-in
clamp 2060 is suitably positioned within the pipe sections 1022a and 1022b).
In one
embodiment, the section 2064 and the clamp 60 correspond to the sections in
the internal
weld system 5004 having the first pipe clamp 5142 and the second pipe clamp
5144. In one
embodiment, a connection member 2080 (e.g., a rod or spring member) is
configured to
connect an end 2066 of the tie-in clamp 2060 with the end section 2024 of the
frame of the
internal cooling system 2010-1.
[001025] In one embodiment, the internal cooling system 2010-1 may be a
trailer member for
the tie-in clamp 2060. For example, the tie-in clamp 2060, with internal
cooling system 2010-
1 connected thereto (via the connection member 2080) may be inserted at its
end 2065 (i.e.,
an end of the frame that opposes the frame end 2066 which connects with the
internal cooling
system 2010-1 via the connection member 2080) into a pipe section, where
movement of the
tie-in clamp 2060 within the pipe section also results in corresponding
movement of the
internal cooling system 2010-1 within the pipe section. In one embodiment, the
internal
cooling system 2010-1 may be inserted via its first frame section 2011 into
the pipe section
and then moved into position so as to also bring the tie-in clamp 2060 into
suitable alignment
with the tie-in weld location between the two aligned pipe sections. In one
embodiment, the
drive system 2022 of the internal cooling system 2010-1 may be used to move
the tie-in
clamp 2060/internal cooling system 2010-1 combined structure to a suitable
location within
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the pipe sections or, alternatively, any other suitable drive mechanism may
also be utilized to
move such structure within the pipe sections (e.g., one or more cable/winch
systems).
[001026] In one embodiment, the tie-in clamp 2060 holds the ends of the pipe
sections 1022a,
1022b together until the weld joint 1026 is formed. In one embodiment, the
section 2064 and
the clamp 60 correspond to the sections in the internal weld system 5004
having the first pipe
clamp 5142 and the second pipe clamp 5144. After formation of the weld joint
1026 (and
formation of the coatings as needed), the tie-in clamp 2060 may be disengaged
from the
internal wall surface portions of the pipe sections to facilitate movement of
the internal
cooling system 2010-1 to a suitable location (e.g., such that cooling section
2016 is aligned
with the weld joint) to initiate internal cooling within the pipe sections
1022a, 1022b.
[001027] FIG. 109 discloses another embodiment for connecting the internal
cooling system
to an internal tie-in clamp, in which a longer connection member 2082 (e.g.,
an elongated rod)
is provided to connect the internal cooling system 2010-1 with the tie-in
clamp 2060. In one
embodiment, the connection member 2082 has a greater lengthwise dimension than
the
connection member 2080 (shown in FIG. 108), which minimizes heating of the
internal
cooling system 2010-1 during welding procedures (due to a greater separation
distance
between internal cooling system and tie-in clamp).
[001028] In one embodiment, the procedure includes loading of the tie-in clamp
2060 with
internal cooling system 2010-1 into one of the pipe sections and aligned so
that the tie-in
clamp 2060 holds the two facing ends of the pipe sections in place at the tie-
in weld location.
After certain welding procedures are performed (e.g., the root and hot pass
weld procedures),
the tie-in clamp 2060 with the internal cooling system 2010-1 may be moved
together and
away from the tie-in weld location to avoid exposure to further heat from the
ongoing
welding process needed to complete the weld joint. In one embodiment, if the
connecting
member has a sufficient length (e.g., connection member 2082 of FIG. 109), the
tie-in clamp
2060 with the internal cooling system 2010-1 may be moved such that the tie-in
clamp is on
one side while the internal cooling system is on the other side of the tie-in
weld location (with
only the connection member 2082 being disposed directly under or in close
proximity in
relation to the tie-in weld location). After completion of welding and AUT/X-
ray inspection(s)
(if required), and further after any coating/insulation/FJC has been applied,
the tie-in clamp
2060 with the internal cooling system 2010-1 may be moved into position such
that the
cooling section 2016 of the internal cooling system is in close proximity with
the weld joint
and cooling procedures may be performed (e.g., in a manner similar to that
previously
described in relation to the embodiment of FIGS. 104 ¨ 107).
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10010291 In one embodiment, the cooling section of the internal cooling system
may be
implemented with any sort of cooling structure to rapidly and/or efficiently
cool the pipe
sections at the newly formed weld joint and therefore is not limited to the
example
embodiments shown in FIGS. 104 - 109. For example, in one embodiment, the
cooling
structure integrated as part of the internal cooling system may include,
without limitation,
cooling fans (e.g., fans 2122 shown and described below) that force air across
internal surface
portions of pipe sections and/or across heat exchange fins or other cooling
elements of the
internal cooling system cooling section, discharging of liquid and/or gaseous
fluids (e.g.,
cryogenic fluids, liquids, air) at suitable pressures and temperatures from
the nozzles 2007 or
2318 of the cooling section 2016 or 2316 toward internal surface portions of
the pipe sections,
utilizing cooling fluids in a closed circuit recirculating loop (e.g., pump
2212, manifold 220,
and fin members 2218 as shown in FIGS. 111A and 111b) and across heat exchange
structure
of the cooling section, utilizing thermoelectric cooling (e.g., via Peltier
devices in direct
contact with internal wall surface portions of the pipe sections), etc.
10010301 FIGS. 110A and 110B show an internal cooling system 2110 in
accordance with
another embodiment of the present patent application. The internal cooling
system 2110 is
similar to the embodiments previously described, except for the differences as
will be noted
below. In one embodiment, the cooling section 2116 of the internal cooling
system 2110
comprises a heat sink including a plurality of fin members 2118 arranged
around the
periphery of and extending radially outward from a central support member 2120
of the
cooling section 2116 and include curved outer surface portions that correspond
with the
curved internal surface portions of the pipe sections toward which the fins
2118 extend. In
one embodiment, each fin member 2118 includes a plurality of thin material
sections that
extend from a central heat sink location of the cooling section 2116 radially
outward toward a
curved end wall section of the fin member 2118. In one embodiment, the fin
members 2118
are constructed of a material having a suitable thermal conductivity (e.g.,
copper, aluminum,
etc.) to facilitate a high rate of heat transfer from the internal wall
surface portions of the
pipes sections 1022a, 1022b to the heat sink of the cooling section 2116. In
one embodiment,
the fin members 2118 include open channels 2120 defined between neighboring
thin material
sections, where the open channels 2120 extend in a lengthwise direction
through the fin
members. In one embodiment, electric fans 2122 may be mounted to the central
support
member 2123 and located in close proximity with ends of the fin members 2118
and in
alignment with the fin channels 2120. In one embodiment, the electric fans
2122 provide a
flow of air through the fin channels 2120 to cool the fin members 2118 and
thus force heat
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via convective air currents from the heat sink of the cooling section 2116. In
one embodiment,
the fans 2122 are in communication (e.g., via a hardwire or wireless
communication link)
with controller 2020 to facilitate selective operation of the fans 2122 during
cooling
procedures In one embodiment, each fan 2122 may be implemented with a variable
speed of
operation so as to selectively control the fan speed and corresponding air
flow rate through
fin members 2118 differently and as needed during the cooling procedure.
[001031] The procedure of the internal cooling system 2110 of FIGS. 110A and
110B is
similar to that previously described for the embodiment of FIGS. 104 ¨ 107 in
relation to
placement of the internal cooling system during the welding procedure and
positioning for
cooling after welding procedures have been completed. During cooling, the fans
2122 may be
activated to provide a flow of cooling air at one or more desired flow rates
through the
channels 2120 of the fin members 2118. In one embodiment, the fin members 2118
draw heat
from the interior wall surface portions of the pipe sections 1022a, 1022b
(including at the
weld joint 1026) toward the central support member 2123 of the cooling section
2116, and
forced air currents provided by the fans 2122 remove the heat from the fin
members 2118,
thus achieving a cooling of the pipe sections 1022a, 1022b at the location of
the cooling
section 2116. As described in previous embodiments, temperature sensors of the
internal
cooling system may provide measured temperature information to the controller
2020, and
such measured temperature information may be used to control operation of the
fans 2122
(including changing fan speeds of one or more fans 2122) during the cooling
procedure.
When a desired temperature is reached within the pipe sections 1022a, 1022b,
the fans 2122
may be turned off via the controller 2020. In one embodiment, the internal
cooling system
2110 may further be moved to different positions as needed within the pipe
sections 1022a,
1022b to effect cooling at different locations.
[001032] FIGS. 111A and 111B show an internal cooling system 2210 in
accordance with
another embodiment of the present patent application. The internal cooling
system 2210 is
similar to the embodiments previously described, except for the differences as
will be noted
below. In one embodiment, the internal cooling system 2210 includes a cooling
section 2216
that includes a series of fin members 2218 arranged along a periphery of and
extending
radially outward from a central support member 2223 of the cooling section
2216, where the
fin members 2218 have a similar exterior shape or profile as the fin members
2118 of the
embodiment of FIGS. 110A and 110B. In one embodiment, the fin members 2218 may
also
be constructed of a material having a suitable thermal conductivity (e.g.,
aluminum or
copper). However, each fin member 2218 may have a hollow and sealed interior
to facilitate
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a flow of coolant fluid through the fin member 2218. In one embodiment, each
fin member
2218 includes an inlet at one end and an outlet at another end, and suitable
piping structure is
provided to facilitate a recirculating flow circuit of a coolant from a pump
2212 to the fin
member 2218, where the coolant flows through the fin member 2218 and back to
the pump
2212. Any suitable type of coolant (e.g., water, a cryogenic fluid such as
liquid nitrogen or
liquid argon, etc.) may be utilized.
[001033] In one embodiment, the pump 2212 (shown in FIG. 111A) may be
positioned
externally from the pipe sections 1022a, 1022b, with supply and return flow
conduits 2214
extending between the pump 2212 and a manifold structure 2220 (shown in FIG.
111B). In
one embodiment, the manifold structure 2220 includes a plurality of pipe
connections that
connect with the inlets and outlets of the fin members 2218. Thus, the cooling
section 2216
facilitates heat exchange between the circulating flow of coolant within the
fin members 2218
and the interior wall surface portions of the pipe sections 1022a, 1022b
(e.g., at or near the
weld joint 1026) during the cooling procedures.
[001034] In one embodiment, the pump 2212 may be controlled (via a suitable
hardwire or
wireless communication link) via the controller of internal cooling system
2210.
Alternatively, the pump 2212 may be externally controlled (since it is easily
user accessible).
The coolant flow by the pump 2212 may be controlled based upon measured
temperature
information provided by one or more temperature sensors at the internal
cooling system 2210.
Once a desired temperature has been achieved within the pipe sections 1022a,
1022b, the
pump may be de-activated or turned off to cease the recirculating flow of
coolant and to
facilitate movement of the internal cooling system 2210 within the pipe
sections 1022a,
1022b.
[001035] FIGS. 112A and 112B show an internal cooling system 2310 in
accordance with
another embodiment of the present patent application. The internal cooling
system 2310 is
similar to the embodiments previously described, except for the differences as
will be noted
below. In one embodiment, the internal cooling system 2310 includes a cooling
section 2316
that has a plurality of spray nozzles 2318 positioned around a central support
member 2323
of the cooling section 2316. In one embodiment, the spray nozzles 2318 are
positioned in
generally linear rows extending lengthwise along the central support member
2323. Suitable
piping structure is provided at each end of each linear row of spray nozzles
2318, where the
piping structure connects with a manifold 2320. The manifold 2320 connects via
a fluid
conduit 2314 to a coolant pump 2312 provided externally or outside of the pipe
sections. In
one embodiment, operation of the coolant pump 2312 provides a flow of coolant
(e.g., water,
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a cryogenic fluid such as liquid nitrogen or liquid argon, etc.) from a
coolant source through
the manifold 2320 and out of the spray nozzles 2318 and toward the interior
surface portions
of the pipe sections 1022a, 1022b (including at the weld joint 1026). While
the embodiment
of FIGS. 112A and 112B show the pump 2312 located exterior to the pipe
sections 1022a,
1022b, it is noted that the cooling section 2316 with alignment of the spray
nozzles 318 may
also be readily implemented for the embodiment of FIGS. 104 ¨ 107 (i.e., where
the manifold
2320 and the spray nozzles 2318 receive coolant from coolant source 2012). The
cooling
procedures of the internal cooling system 2310 may be performed in a similar
manner as
described for the previous embodiments, where the pump 2312 may be controlled
via the
controller of the internal cooling system 2310 and/or externally and where
coolant flow may
be implemented based upon measured temperature information provided by
temperature
sensors disposed on the internal cooling system 2310.
[001036] Thus, the internal cooling system of the present patent application
is configured to
provide improvements for pipeline welding procedures, including enhancement of
cooling of
connected pipe sections upon formation of weld joints by providing controlled
cooling
internally within the pipe sections and reducing production time (since
cooling can occur
faster and more efficiently, increasing the number of weld joins between pipe
sections that
can occur in a given time period). Further, the number of work stations
associated with
welding procedures and also resources associated with such welding procedures
can be
reduced. For example, the work space required for welding pipe sections
together can be
reduced, and this can become particularly beneficial in scenarios in which
work space is
limited (e.g., on barges or other water vessels).
[001037] In one embodiment, a method for welding a pair of insulated pipes
(e.g., pipes
1022a, 1022b as shown in FIG. 113) to one another is provided. As shown in
FIG. 113, each
pipe 1022a, 1022b includes the metal pipe interior 5244 surrounded by the
insulator material
5246. In one embodiment, the end portions 5248, 5250 of the pipes 1022a, 1022b
to be
welded have the metal pipe interior 5244 exposed.
[001038] In one embodiment, referring to FIGS. 113-134, the method includes
aligning the
exposed metal pipe ends 5248, 5250 to be welded, welding the exposed metal
pipe ends 5248,
5250 to one another, heating the exposed end portions 5248, 5250 of the welded
pipes 1022a,
1022b, applying an insulator 5246 to the heated exposed end portions 5248,
5250 of the
welded pipes such that the insulator 5246A (as shown in FIG. 118) is adhered
to the exterior
surface 5254 of the metal pipe interior 5244, thus insulating the formerly
exposed end
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portions 5248, 5250 of the pipes 1022a, 1022b, and applying cooling energy
from within the
pipes 1022a, 1022b to an interior surface 5130a, 5130b of the metal pipes
1022a, 1022b.
[001039] In one embodiment, the applying cooling energy from within the pipes
to the
interior surface of the metal pipes is performed after applying the insulator.
In one
embodiment, the method also includes performing a pipeline deployment
procedure. In one
embodiment, applying the cooling energy reduces a wait time between applying
the insulator
and performing the pipeline deployment procedure. In one embodiment, the
pipeline
deployment procedure is a spooling procedure. In one embodiment, the pipeline
deployment
procedure is a S-lay procedure.
In one embodiment, the pipeline development procedure is a pipeline lowering
procedure. In
one embodiment, the pipe deployment procedure is described with respect to
FIG. 1B of the
present patent application.
[001040] In one embodiment, the cradles 5330 (as shown in FIGS. 10A and 10B)
or cradles
6010A and 6010B (as shown in FIG. 73) are used for carrying and moving the
pipes 1022a
and 1022b and for providing the exposed metal pipe end 5248 of the incoming
pipe 1022a at
the exposed metal pipe end 5250 of the pipe 1022b. That is, the cradles 5330
or
6010A/6010B are used to align of the exposed metal pipe ends 5248, 5250 to be
welded.
[001041] In one embodiment, the alignment of the exposed metal pipe ends 5248,
5250 to be
welded may be automatically performed by the one or more processors 5140
controlling the
cradles 5330 (or 6010A or 6010B), may be performed by hydraulically
controlling cradles
5330 (or 6010A or 6010B), or may be performed by an operator using a crane and
a clamp
(internal or external) arrangement. In one embodiment, after the alignment of
the pipes 1022a,
1022b, the pipes 1022a, 1022b may be clamped using the external clamps 5302
(as shown in
FIGS. 7A and 7B) and/or internal clamps 5142 or 5144. In one embodiment, as
described in
this application, one or more external or internal clamps may be used during
the alignment of
the exposed metal pipe ends 5248, 5250 (to be welded). That is, the one or
more external or
internal clamps may be used independently and/or in combination with the
cradles. In one
embodiment, the operation of the one or more external or internal clamps and
the cradles may
be controlled by the one or more processors 5140.
[001042] In one embodiment, the one or more processors 5140 are configured to
operate the
cradles 5330 (or 6010A and 6010B) to adjust the relative positioning of the
pipes 1022a,
1022b based on the pre-weld profile data. In one embodiment, the pre-weld
profile data may
be obtained for one or more inspection detectors that are operatively
connected to the one or
more processors 5140. In one embodiment, the adjustment of the relative
positioning of the
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pipes 1022a, 1022b (based on the pre-weld profile data) may include an
adjustment along the
longitudinal axis of the pipes 1022a, 1022b, and/or an adjustment along the
radial axis of the
pipes 1022a, 1022b. In one embodiment, after the adjustment of the pipes
1022a, 1022b, the
pipes 1022a, 1022b are clamped back using the external and/or internal clamps.
FIG.113
shows the pipes 1022a, 1022b with their exposed metal pipe ends 5248, 5250
correctly
aligned and ready for the welding procedure.
[001043] FIG. 114 shows the pipes 1022a, 1022b with the weld joint 1026 formed
between
their exposed metal pipe ends 5248, 5250. In one embodiment, an internally
positioned (e.g.,
inside the pipes 1022a, 1022b) weld torch 5502 may be configured to weld the
exposed metal
pipe ends 5248, 5250 to one another. In one embodiment, an externally
positioned (e.g.,
outside/external the pipes 1022a, 1022b) weld torch 7502 may be configured to
weld the
exposed metal pipe ends 5248, 5250 to one another. In one embodiment, a
combination of the
internally positioned weld torch 5502 and externally positioned weld torch
7502 may be used
to weld the exposed metal pipe ends 5248, 5250 to one another. In one
embodiment, the
externally positioned weld torch 7502 and/or the internally positioned weld
torch 5502 are
operatively connected to the one or more processors 5140.
[001044] In one embodiment, referring to FIGS. 115A and 115B, a heater 5304
may be
configured to heat the exposed end portions 5248, 5250 of the welded pipes
1022a, 1022b. In
one embodiment, the heater 5304 may be an induction heating system used to
heat the
exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b of the
pipeline 1024 in
preparation for application of the coating material(s) or the insulator. In
one embodiment, the
heater 5304 may include Ultra high frequency (UHF) induction coils that are
configured to
rapidly heat the exposed end portions 5248, 5250 of the welded pipes 1022a,
1022b of the
pipeline 1024 up to the required coating temperature. In one embodiment, the
heater 5304
may use two induction coils. In one embodiment, the heater 5304 may be an
electrical
heating system. In one embodiment, the heater 5304 may be a radiant heating
system. In one
embodiment, induction coils 5307 of the heater 5304 are shown in FIG. 115A.
[001045] As shown in FIGS. 115A and 115B, the heater 5304 is configured to
circumferentially surround the exposed end portions 5248, 5250 of the welded
pipes 1022a,
1022b of the pipeline 1024. In one embodiment, the heater 5304 may include two
half round,
annular heater members 5304a and 5304b. In one embodiment, the two half round,
annular
heater members 5304a and 5304b are pivotally connected to each other by a
joint 5305 at the
top and are releasably connected to each other via one or more connector
members (not
shown) at the bottom.
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[001046] In one embodiment, the heater 5304 is also configured to regulate the
temperature
of the exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b of the
pipeline
1024 to maintain a suitable coating application temperature. In one
embodiment, the heater
5304 may also include a heater feedback system configured to enable the heater
5304 achieve
and maintain the required coating temperature and a temperature sensor
operatively coupled
to the heater feedback system. In one embodiment, the temperature sensor may
be a contact
or a non-contact temperature sensor. In one embodiment, the heater feedback
system may
include other sensors that are configured to sense other parameters of the
heating procedure,
for example, heating time, etc. In one embodiment, through the feedback
signals from the one
or more sensors, the heater feedback system is configured to regulate the
current in the
inductor coils to achieve the required coating temperature. In one embodiment,
the heater
5304 and its feedback system may be operatively connected to the one or more
processors
5140. In one embodiment, the one or more processors 5140 may be configured to
control the
operation of the heater 5304 and its feedback system.
[001047] In one embodiment, referring to FIG. 116A, 116B, 117A and 117B, an
insulator
supply 5306 configured to apply insulator material 5312 to the heated exposed
end portions
5248, 5250 of the welded pipes 1022a, 1022b such that the insulator 5246A (as
shown in FIG.
118) is adhered to the exterior surface 5254 of the metal pipe interior 5244,
thus insulating
the formerly exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b.
In one
embodiment, the insulator supply 5306 comprising a container 5310 configured
to contain the
insulator material 5312 and an output nozzle 5308 configured to spray the
insulator material
5312 onto the exposed end portions 5248, 5250 of the welded pipes 1022a,
1022b. In one
embodiment, the container 5310 configured to contain the insulator material
5312 may be
pressurized.
[001048] In one embodiment, the insulator supply 5306 may include a feedback
system
configured to enable the insulator supply 5306 to achieve the desired coatings
on the pipeline
1024 and one or more sensors operatively connected to the feedback system. In
one
embodiment, the one or more sensors may be configured to sense the following
parameters of
the insulator application procedure ¨ insulator material temperature,
insulator material
volume, etc.
[001049] In one embodiment, referring to FIGS. 116A and 116B, the insulator
supply 5306 is
an automated system and includes a coating frame 5393 that is configured to be
positioned on
the weld joint 1026 area. In one embodiment, the coating frame 5393 of the
insulator supply
5306 is configured to be pre-programmed to rotate around the weld joint 1026
area so as to
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achieve the desired dry film thickness of the insulator material. That is, the
coating frame
5393 is constructed and arranged to move evenly around the weld joint 1026
area. In one
embodiment, the spray head (including the container 5310 and the output nozzle
5308) is
mounted on the coating frame 5393 in a specific position (e.g., perpendicular
to the heated
exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b).
[001050] In one embodiment, the insulator supply 5306, shown in FIGS. 116A and
116B, is
configured to apply Fusion Bonded Epoxy insulator material to the heated
exposed end
portions 5248, 5250 of the welded pipes 1022a, 1022b such that the Fusion
Bonded Epoxy
insulator 5246A (as shown in FIG. 118) is adhered to the exterior surface 5254
of the metal
pipe interior 5244, thus insulating the formerly exposed end portions 5248,
5250 of the
welded pipes 1022a, 1022b.
[001051] In one embodiment, the insulator supply 5306, shown in FIGS. 117A and
117B, is
configured to apply Injection Molded Polypropylene insulator material to the
heated exposed
end portions 5248, 5250 of the welded pipes 1022a, 1022b such that the
Injection Molded
Polypropylene insulator 5246 is adhered to the exterior surface 5254 of the
metal pipe interior
5244. In one embodiment, the insulator supply 5306 of FIGS. 117A and 117B may
be used to
apply Injection Molded Polyurethane insulator material to the heated exposed
end portions
5248, 5250 of the welded pipes 1022a, 1022b such that the Injection Molded
Polyurethane
insulator 5246 is adhered to the exterior surface 5254 of the metal pipe
interior 5244.
[001052] Referring to FIGS. 117A and 117B, in one embodiment, the insulator
supply 5306
is an automated system and includes a mold 5381 that configured to
circumferentially
surround the welded joint 1026 area and to create an annular gap 5383 for the
injection
molded insulator material 5246 to fill. In one embodiment, a hydraulically
operated valve
(not shown) is configured to supply/inject the molten insulator material 5385
into the annular
gap 5383. The supplied/injected molten insulator material 5385 enters the mold
5381 (and the
annular gap 5383) encasing the welded joint 1026 area and forming the
inner/inside profile of
the mold 5381. In one embodiment, chilled water may be supplied to the mold to
cool the
outer profile of the insulator material such that the Injection Molded
Polyurethane insulator
5246 is adhered to the exterior surface 5254 of the metal pipe interior 5244,
thus insulating
the formerly exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b.
[001053] In one embodiment, the insulator supply 5306 shown and described
above with
respect to FIGS. 116A and 116B may be used for onshore pipeline applications.
In one
embodiment, the insulator supply 5306 shown and described above with respect
to FIGS.
117A and/or 117B may be used for offshore pipeline applications.
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[001054] In one embodiment, the insulator supply 5306 shown and described
above with
respect to FIGS. 116A, 116B, 117A and/or 117B may also be used to apply other
insulator
materials, described elsewhere in this application, and/or other insulated
materials as would
be appreciated by one skilled in the art to the heated exposed end portions
5248, 5250 of the
welded pipes 1022a, 1022b.
[001055] In one embodiment, the insulator supply 5306 and its corresponding
feedback
system may be operatively connected to the one or more processors 5140. In one
embodiment,
the one or more processors 5140 may be configured to control the operation of
the insulator
supply 5306 and its corresponding feedback system.
[001056] In one embodiment, FIG. 118 shows the pipeline 1024 in which the
insulator
material is applied to the heated exposed end portions 5248, 5250 of the
welded pipes 1022a,
1022b such that the insulator 5246A is adhered to the exterior surface 5254 of
the metal pipe
interior 5244, thus, insulating the formerly exposed end portions of the pipes
1022a, 1022b.
[001057] In one embodiment, referring to FIGS. 119 and 120, a cooler system
6500 is
configured to be positioned within the pipes 1022a, 1022b. In one embodiment,
the cooler
system 6500 includes a frame, a plurality of rollers 6530, a drive motor 6532,
and a brake
system. In one embodiment, a forward-most frame 6618, a center frame 6634, and
a rear
frame 6522 of the cooler system 6500 may be together referred to as the frame
of the cooler
system 6500.
[001058] For example, the frame is configured to be placed within welded pipes
1022a,
1022b, the plurality of rollers 6530 is configured to rotatably support the
frame, the drive
motor 6532 drives the rollers 6530 to move the frame within the pipes 1022a,
1022b, and the
brake system secures the frame from movement at a desired location within the
pipes 1022a,
1022b. The structure, configuration and operation of the plurality of rollers,
the drive motor,
and the brake system of the cooler system 6500 are similar to the plurality of
rollers, the drive
motor, and the brake system of the internal weld systems described in this
application, and
therefore they will not be described in detail here. For example, in one
embodiment, the brake
system of the cooler system 6500 may include one or more clamps that clamp
circumferentially spaced locations on the interior surface 5130, 5132 of the
welded pipes
1022a, 1022b. In another embodiment, the brake system of the cooler system
6500 may
include a wheel lock that prevents rotation of the rollers 6530.
[001059] In one embodiment, the cooler system 6500 includes a cooler carried
by the frame
and applies cooling energy to the interior surface 5130a, 5132a of the metal
pipes 1022a,
1022b to facilitate cooling of the welded metal pipes 1022a, 1022b. In one
embodiment, the
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cooler includes a heat exchanger 6502 that carries cooling fluid therein and
has a pipe
contacting surface 6572 that contacts the interior surface 5130a, 5132a of the
pipe 1022a,
1022b to facilitate cooling of the welded pipes 1022a, 1022b. In one
embodiment, the cooler
system 6500 includes a heat exchanger motor 6552 configured to move the heat
exchanger
6502 radially outwardly so that the pipe contacting surface 6572 can be moved
outwardly to
engage the interior surface 5130a, 5132a of the welded pipes 1022a, 1022b
after the frame is
positioned at the desired location within the pipes 1022a, 1022b.
[001060] In one embodiment, the cooler system 6500 includes one or more
processors that
are operatively connected with the drive motor 6532, the brake system and the
cooler 6502.
In one embodiment, the one or more processors are configured to operate the
cooler 6502 to
reduce the temperature of the welded pipes 1022a, 1022b to a predetermined
level. For
example in one embodiment, the cooler system includes one or more temperature
sensors
2017a that are operatively communicated (wired or wirelessly) with the one or
more
processors to determine a temperature of the pipes. In one embodiment, cooling
power can be
continued until a predetermined threshold temperature is detected.
[001061] In one embodiment, the one or more processors are communicatively
connected to
the brake system, the drive motor 6532 or the cooler 6502 via one or more
wired or wireless
connections. Wireless connections may comprise, for example, a Wi-Fi
connection, a
Bluetooth connection, an NFC connection, a cellular connection, or other
wireless connection.
[001062] In one embodiment, the one or more processors, which receive pipe
temperature
information from the temperature sensor 2017a, are communicatively connected
to a remote
computer system and configured to transmit pipe cooling data to the remote
computer system.
In one embodiment, the cooling data transmitted by the one or more processors
includes
cooling time curve information. In one embodiment, the cooling time curve
information
includes change of pipe temperature over time. In one embodiment, the remote
computer
system contains cooling data from other weld systems, and calculates expected
time until the
temperature of the welded pipes is below a threshold. In one embodiment, the
expected time
is sent to the one or more processors.
[001063] In one embodiment, the cooler system 6500 may include a user
interface, and
wherein the expected time and/or pipe temperature is sent to the user
interface by the one or
more processors. The user interface can be a computer, for example, having a
display.
[001064] In one embodiment, the expected time for the pipe (at least the
portion of the pipe
at issue) being cooled to a certain threshold temperature is calculated, at
least in part, based
on the size (for example, the circumference, thickness, thermal mass, or any
combination
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thereof) of the welded pipe. In another embodiment, the calculation is further
based upon a
cooling energy output of the cooler. For example, this cooling energy output
may be based on
the volume of water or gas being directed at the pipe surface, the starting
temperature of the
pipe or gas, etc. As another example, cooling energy for a closed fluid system
heat exchanger
may be known in advance, or calculated based upon its operating parameters
(fluid speed,
fluid temperature, thermal transfer efficiency, etc.).
[001065] In another embodiment, the cooling energy output of the cooling
system, and/or
expected cooling time, is based upon information received from the remote
cloud based
computer system which contains a large central data base of information
obtained from
several remotely operated cooler systems. In one embodiment, the cooling
energy output is
predetermined. In one embodiment, the one or more processors are
communicatively
connected to a remote computer system and configured to transmit coolant
consumption data
(e.g., the amount of water used to cool the pipe of a known size needed to
reach the threshold
temperature.
[001066] In one embodiment, the cooler system 6500 may be entirely untethered.
Specifically, the cooler system 6500 need not include the reach rod or the
umbilical and all
the communications to and from the cooler system 6500 are entirely wireless.
In one
embodiment, the cooler system 6500 may include a transmitter that is
configured to transmit
all the communication signals entirely wirelessly from the cooler system 6500
to the remote
uLog processing system and a receiver that is configured to receive all the
communication
signals entirely wirelessly from the remote uLog processing system. In one
embodiment, the
one or more processors and/or all the electronic modules of cooler system 6500
are
configured to communicate entirely wirelessly with the remote uLog processing
system. In
one embodiment, all the sensors, all the motors, all the valves and/or other
components/elements of the cooler system 6500 are configured to communicate
entirely
wirelessly with the remote uLog processing system.
[001067] In one embodiment, any information from the cooler system 6500 can be
communicated wirelessly with systems outside the pipe by WiFi, Bluetooth, NFC,
by radio
frequency, or through cell tower transmissions, just for example. In some
embodiments
where appropriate, the information is communicated by use of repeaters or
extenders, where
the transmission signal is to travel long distances or through curved areas.
[001068] In one embodiment, the one or more processors and one or more sensors
of the
cooler system 6500 are configured to monitor the charge levels of the on-board
cooling
power supply, on-board locomotion power supply, and other on-board power
supplies. For
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example, the voltage output by these power supplies may be (continuously or at
regular
intervals) monitored. In one embodiment, the transmitter of the cooler system
6500 transmits
the monitored battery life/charge level information entirely wirelessly to the
remote uLog
processing system for further processing. For example, the monitored charge
level
information of the on-board power supplies may be used to determine an
estimated remaining
operating time of the cooler system 6500. In one embodiment, the one or
processors of the
cooler system 6500 may be configured to determine the estimated remaining
operating time
of the cooler system 6500 locally on the cooler system 6500. In one
embodiment, the remote
uLog processing system may be configured to determine the estimated remaining
operating
time of the cooler system 6500 based on the wirelessly transmitted battery
life/charge level
information. In one embodiment, the remote uLog processing system may be
configured to
transmit the estimated remaining operating time of the cooler system 6500 to
the one or more
processors of the cooler system 6500. In one embodiment, the remote uLog
processing
system may also be configured to transmit (entirely wirelessly to the cooler
system 6500)
further instructions about the operation of the cooler system 6500 based on
the estimated
remaining operating time of the cooler system 6500.
[001069] In one embodiment, the one or more processors and one or more sensors
of the
cooler system 6500 are configured to monitor the levels of the on-board
coolant supply/tank.
For example, the pressure and/volume of the coolant supply tanks may be
(continuously or at
regular intervals) monitored. In one embodiment, the transmitter of the cooler
system 6500
transmits the monitored coolant consumption data entirely wirelessly to the
remote uLog
processing system for further processing.
[001070] For example, the monitored coolant consumption data may be used to
determine an
estimated remaining operating time of the cooler system 6500 before the
coolant
refill/recharge. In one embodiment, the one or processors of the cooler system
6500 may be
configured to determine the estimated remaining operating time of the cooler
system 6500
(e.g., before the coolant recharge) locally on the cooler system 6500. In one
embodiment, the
remote uLog processing system may be configured to determine the estimated
remaining
operating time of the cooler system 6500 (e.g., before the next coolant
recharge) based on the
wirelessly transmitted coolant consumption data. In one embodiment, the remote
uLog
processing system may be configured to transmit the estimated remaining
operating time of
the cooler system 6500 (e.g., before the coolant recharge) to the one or more
processors of
the cooler system 6500. In one embodiment, the remote uLog processing system
may also be
configured to transmit (entirely wirelessly to the cooler system 6500) further
instructions
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about the operation of the cooler system 6500 based on the estimated operating
time of the
cooler system 6500 (e.g., before the coolant recharge).
[001071] In one embodiment, the remote uLog processing system receives battery
charge
data from numerous cooler systems at different locations (for example,
different locations
across a country or across the globe) and establishes a data base thereon.
That database is
used by the uLog processing system to determine, based on a large data set,
expected battery
life times based on different operating parameters of the cooler system. This
can used by the
uLog and/or by one or more processors of the cooler system 6500 to anticipate
battery life
times for various components based upon present operating conditions of those
components.
This information can be used by the one or more processors to reduce or
regulate power
consumption of one or more components by modifying one or more operating
parameters.
For example, cooling rate, voltage, and/or current can all be regulated (e.g.,
lowered) to
conserve battery life if the one or more processors determine that such
operating conditions
can be modified without adversely affecting the associated operation being
performed.
[001072] In one embodiment, the battery life, voltage output, coolant levels
and any of the
operating parameters are sent wirelessly to a user interface, such as a
computer monitor
having computer display, so that they can be monitored by a user.
[001073] In one embodiment, like the cooler system 6500, all other cooler
systems (e.g.,
2010, 2110, 2210, 2310) described in the application are configured to
communicate wireless
with the remote uLog processing system.
[001074] In one embodiment, referring to FIG. 120, the cooler system 6500 is
configured to
apply cooling energy to the interior surface 5130a, 5132a of the metal pipes
1022a, 1022b to
facilitate cooling of the metal pipes 1022a, 1022b after the insulator
material 5312 is applied.
In one embodiment, the cooler system 6500 comprises a heat exchanger or cooler
6502
configured to carry a movable fluid therethrough. That is, the cooling energy
is applied by the
moveable fluid disposed within the heat exchanger 6502. In one embodiment, the
movable
fluid may be a gas or liquid.
[001075] For example, in one embodiment, as shown in FIGS. 119-122, the heat
exchanger
6502 may have liquid passage lines 6593 therein that carry the movable liquid
therethrough
and the cooling energy is applied by the moveable liquid disposed within the
fluid passage
lines 6593 of the heat exchanger 6502. In one embodiment, as shown in FIGS.
124-125, the
heat exchanger 6502 may have air channels 6576 therein that carry the moveable
air
therethrough and the cooling energy is applied by the moveable air disposed
within the air
channels 6576 of the heat exchanger 6502.
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[001076] In one embodiment, a contact surface 6572 of the heat exchanger 6502
is
configured to be positioned in contact with the interior surface 5130a, 5132a
of the welded
pipes 1022a, 1022b to remove heat from the welded pipes 1022a, 1022b.
[001077] In one embodiment, the contact surface 6572 of the heat exchanger
6502 may be a
conformable, thermally conductive surface. For example, in one embodiment, the
contact
surface 6572 of the heat exchanger 6502 is constructed and shaped to conform
closely to the
interior surfaces of the welded pipes 1022a, 1022b to remove heat from the
welded pipes
1022a, 1022b. In one embodiment, the contact surface 6572 of the heat
exchanger 6502 is
constructed and arranged to be thermally conductive.
[001078] In one embodiment, the cooling energy is applied by a fluid released
within the
interior of the pipes 1022a, 1022b such that the fluid directly contacts the
interior surface
5130a, 5132a of the pipes 1022a, 1022b. In one embodiment, the fluid includes
a liquid. In
one embodiment, the fluid includes a gas. For example, in one embodiment, the
fluid nozzles
6562 (as shown in FIG. 123) are configured to apply (or spray) a cooling fluid
(directly) onto
the interior surface 5130a, 5132a of the welded pipes 1022a, 1022b to remove
heat from the
welded pipes 1022a, 1022b. In one embodiment, the blower 6505 (as shown in
FIG. 133) is
configured to apply (or blow) a cooling gas (directly) onto the interior
surface 5130a, 5132a
of the welded pipes 1022a, 1022b to remove heat from the welded pipes 1022a,
1022b.
[001079] In one embodiment, the contact surface 6572 of the heat exchanger
6502 is
configured to be positioned in contact with the interior surface 5130a, 5132a
of the welded
pipes 1022a, 1022b to remove heat from the welded pipes 1022a, 1022b. For
example, as
shown in FIGS. 119-121, 124, 130 and 132, the contact surface(s) 6572 of each
of these
different types of heat exchangers 6502 are configured to be positioned in
contact with the
interior surface 5130a, 5132a of the welded pipes 1022a, 1022b to remove heat
from the
welded pipes 1022a, 1022b.
[001080] Referring to FIGS. 119-122, the heat exchanger 6502 of the cooler
system 6500
may include a plurality of heat exchanger elements or fins 6580 positioned at
circumferentially spaced apart locations on a center frame 6634. In one
embodiment, each
heat exchanger element 6580 may have one or more coolant lines 6593 passing
therethrough.
In one embodiment, each heat exchanger element or fin 6580 is supported on the
center frame
6634 and is operatively connected to an actuator mechanism 6582. In one
embodiment, the
actuator mechanism 6582 is configured to move each heat exchanger element or
fin 6580
between its extended position (as shown in FIGS. 120 and 121) and its
retracted position (as
shown in FIG. 122). In one embodiment, as shown in FIG. 122, there is a radial
gap G
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between the contact surfaces 6572 of the heat exchanger elements 6580 and the
inner surfaces
5130a, 5132a of the pipes 1022a, 1022b, when the heat exchanger elements 6580
are in their
retracted positions.
[001081] In one embodiment, the actuator mechanism 6582 may include a piston
6586, a
cylinder 6584, a plurality of first members 6588 and a plurality of second
members 6590. In
one embodiment, the number of the first and second members may depend on the
number of
heat exchanger element 6580 being used.
[001082] In one embodiment, there may be two actuator mechanisms, where one
actuator
mechanism is positioned (axially along the pipe axis) on one side of the heat
exchanger
element 6580 and the other actuator mechanism is positioned (axially along the
pipe axis) on
the other side of the heat exchanger element 6580. In one embodiment, the two
actuator
mechanisms may operate simultaneously to move the heat exchanger elements 6580
between
their extended and retracted positions. In one embodiment, there may be only
one actuator
mechanism that is configured to move each heat exchanger element or fin 6580
between its
extended position (as shown in FIGS. 120 and 121) and its retracted position
(as shown in
FIG. 122).
[001083] In one embodiment, each second member 6590 is constructed and
arranged to be
connected to the heat exchanger element 6580 on one end and to the first
member 6588 on
the other end. In one embodiment, each first member 6588 is constructed and
arranged to be
connected to the second member 6590 on one end and to a portion of the positon
6586 (or a
member moveable by the piston 6586) on the other end.
[001084] In one embodiment, the second member 6590 is constructed and arranged
to
positioned in a radially extending opening 6592 in a (fixed) frame member 6594
such that the
radially extending opening 6592 facilitates a radial movement (e.g., up and
down radial
movement) of the second member 6590 therein.
[001085] In one embodiment, the piston 6586 is configured to be movable
axially in the
cylinder 6584. In one embodiment, the first members 6588 moved by the axially,
reciprocating piston 6586, for example, driven by fluid (hydraulic or
pneumatic) pressure
inside the cylinder 6584.
[001086] The heat exchanger elements 6580 are moved from their retracted
positions (as
shown in FIG. 122) where the contact surfaces 6572 of the heat exchanger
elements 6580 are
not in contact with the inner surfaces 5130a, 5132a of the pipes 1022a, 1022b
to their
extended positions (as shown in FIGS. 120 and 121) where the contact surfaces
6572 of the
heat exchanger elements 6580 are configured to be in contact with the inner
surfaces 5130a,
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5132a of the pipes 1022a, 1022b, by activating the cylinder 6584 so that the
piston 6586 is
axially moved in the cylinder 6584. The compressed air entering a port 6503
pushes the
piston 6586 to move the heat exchanger elements 6580 to their extended
positions.
[001087] In one embodiment, the axial movement of the piston 6586 is
translated to radial
movements of the second members 6590 via the first members 6588. Thus, the
radial contact
forces are generated by fluid pressure of the compressed air acting on the
piston 6586. The
piston 6586 drives the first members 6588 that convert the axial movement of
the piston 6586
to radial movements of the second members 6590. As each heat exchanger element
6580 is
operatively connected to the second members 6590, the radial movements of the
second
members 6590 cause the radial movement of the heat exchanger element 6580
between its
extended and retracted positions.
[001088] In one embodiment, the size of the cylinder, the applied fluid
pressure, and the
sizes of various components of the actuator mechanism 6582 may be changed to
control the
extension and retraction of the heat exchanger elements 6580.
[001089] In one embodiment, as shown in FIG. 123, the cooler system 6500 may
include a
fluid nozzle 6562 configured to apply a cooling liquid onto the interior
surface 5130a, 5130b
of the welded pipes 1022a, 1022b to remove heat from the welded pipes 1022a,
1022b. In one
embodiment the fluid nozzle 6562 is a water nozzle that blows/sprays water
onto the interior
surface 5130a, 5132a of the pipe 1022a, 1022b to facilitate cooling of the
welded pipes 1022a,
1022b.
[001090] In one embodiment, the heat exchanger 6502 may include a plurality of
fluid
nozzles 6562 that are positioned circumferentially and axially (along the pipe
axis) spaced
apart locations. In one embodiment, each fluid nozzle 6562 is configured to
receive the
cooling liquid from a coolant source 6564 via a coolant supply line 6566 and
via one or more
valves. In one embodiment, the coolant is gas or liquid. In one embodiment,
the received
coolant is sprayed by the fluid nozzles 6562 onto the interior surface 5130a,
5132a of the
welded pipes 1022a, 1022b to remove heat from the welded pipes 1022a, 1022b.
[001091] FIGS. 124 and 125 show a heat exchanger element or fin 6574 that is
configured to
be extendable, for example, using the actuator mechanism 6582 shown and
described with
respect to FIGS. 120-122. In one embodiment, the contact surface 6572 of the
heat exchanger
element or fin 6574, when the heat exchanger element or fin 6574 is in
extended position, is
configured to be positioned in contact with the interior surface 5130a, 5132a
of the welded
pipes 1022a, 1022b to remove heat from the welded pipes 1022a, 1022b. In one
embodiment,
the heat exchanger may include a plurality of such heat exchanger element or
fin 6574
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positioned at circumferentially spaced apart locations and that may be
extended and retracted
by an actuating mechanism (e.g., a pneumatic or other). In one embodiment, the
heat
exchanger element or fin 6574 may include a plurality of fluids (air) channels
6576 therein
that are configured to allow the fluid to pass therethrough. In one
embodiment, the channels
6576 may be radially extending and circumferentially spaced apart.
[001092] Referring to FIGS. 126-128, in one embodiment, the cooler system 6500
may
include a drive system 6602. In one embodiment, the drive system 6602 may
include a cable
structure 6604 that extends from the internal cooler system 6500 and through
one or more
pipes 1022a, 1022b to an open end 6606 of a pipe 1022a. In one embodiment, the
cable
structure 6604 is used to facilitate a forward movement of the internal cooler
system 6500
within the pipes 1022a, 1022b.
[001093] In one embodiment, the one or more cable/winch systems 6608 and 6604
may be
implemented, in which one or more winches 6608 may be provided as part of the
internal
cooler system 6500 and/or located at one or more anchor points (e.g., 6610)
that are external
to the pipes 1022a, 1022b. In one embodiment, a winch structure may be
provided within the
internal cooler system 6500 frame.
[001094] For example, in one embodiment, a winch structure 6608 is provided at
an
anchored location 6610 exterior to the pipes 1022a, 1022b and connected to the
cable
structure 6604. That is, referring to FIGS. 127 and 128, one end 6612 of the
cable structure
6604 is connected to the winch structure 6608 and the other end 6614 of the
cable structure
6604 is connected to a member 6616 of a forward-most frame 6618 of the cooler
system 6500.
This configuration of the cable structure 6604 and the winch structure 6608
facilitate a
forward movement of the internal cooler system 6500 within the pipes 1022a,
1022b.
[001095] In one embodiment, another cable structure may be connected to a
member 6620 of
a rear frame 6622 (as shown in FIG. 119) of the cooler system 6500 to
facilitate reverse
movement internal cooler system 6500 within the pipes 1022a, 1022b. This cable
structure
may be operated by another winch structure (e.g., provided at an anchored
location
rearwardly and exterior to the pipes 1022a, 1022b) to facilitate a reverse
movement internal
cooler system 6500 within pipe sections 1022a, 1022b.
[001096] Thus, the cable structure 6604 extends between the winch 6608 and a
connection
point (either at the internal cooler system 6500 or a connection point
external to the pipes
1022a, 1022b) to facilitate placement of the internal cooler system 6500
within and/or
withdrawal of the internal cooler system 6500 from the pipes 1022a, 1022b
during procedures.
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[001097] In one embodiment, as shown in FIG. 129, the cooler system 6500 may
include a
plurality of rollers 6530 configured to engage the interior surface 5130, 5132
of one or more
of the pipes 1022a, 1022b and a drive motor 6532 configured to drive the
rollers 6530 so as
to move a frame assembly 6503 (including the forward-most frame 6618, the
center frame
6634, and the drive frame 6622) of the cooler system 6500.
[001098] In one embodiment, the cooler electronics module 6528 is configured
to control
operation of the drive system 6602 (e.g., by controlling one or more motors
6532 (which
move the rollers 6530 in contact with internal wall portions of pipe)) to
facilitate
advancement of the internal cooling system 2010 within the pipe 1022a and
toward the weld
location. In one embodiment, the cooler electronics module 6528 of the
internal cooler
system 6500 are configured to communicate with the one or more processors 5140
and one or
more other processors or electronic modules (e.g., operatively connected with
the different
weld systems, operatively connected with the cradles, the clamps or other pipe
alignment
systems and/or positioned at a remote location from these systems) as
described in this
application.
[001099] In the illustrated embodiment, each roller 6530 of the cooler system
6500 is
operatively connected with its corresponding drive motor 6532. That is, four
drive motors
6532 are connected to four rollers 6330 as shown. In another embodiment, two
rollers 6530
may be directly connected to two drive motors 6532, and the other two rollers
6530 may be
operatively connected to the two rollers 6530 that are directly connected to
the drive motors
6532.
[001100] In one embodiment, as shown in FIGS. 130 and 131, the cooler system
6500 may
include a power supply source 6526 to provide electrical power to the cooler
electronics
module 6528 of the cooler system 6500, the drive system 6602, the electronic
sensors, the
valve structure (e.g., to electronically control one or more valves 6522 and
thus control flow
of the coolant from the coolant supply source 6524 to the heat exchanger
6502). In one
embodiment, the power supply source 6526 is carried by the frame assembly of
the cooler
system 6500. In one embodiment, the power supply source 6526 includes a
plurality of
battery cells or battery packs that are carried by the rear frame 6622 of the
cooler system
6500. In one embodiment, seven batteries are shown. In one embodiment, the
number of
batteries may vary. In one embodiment, the number of batteries may depend on
the type of
the heat exchanger being used and/or other power requirements of the cooler
system 6500. In
the illustrated embodiment, the power supply source 6526 is shown in a cooler
system having
a thermo electric heat exchanger. It is contemplated, however, that the power
supply source
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6526 may be used with the cooler systems having any type of heat exchanger as
described in
this application.
[001101] In one embodiment, the one or more battery cells carried by the frame
of the cooler
system 6500 are configured to power the drive motor 6532 and the brake system
of the cooler
system 6500. In one embodiment, the one or more battery cells carried by the
frame of the
cooler system 6500 are configured to power the cooler 6502 of the cooler
system 6500.
[001102] In one embodiment, as shown in FIGS. 130 and 132, the heat exchanger
6502 of
the cooler system 6500 may be a thermo electric heat exchanger 6502. For
example, the
thermo electric heat exchanger may be a Peltier device.
[001103] In one embodiment, the thermo electric heat exchanger 6502 may have a
plurality
of frame members 6538 positioned at circumferentially spaced apart locations
on a shaft
member 6542 of the cooler system 6500. In the illustrated embodiment, six
frame members
6538 are shown. In one embodiment, the number of the frame members 6538 may
vary. In
one embodiment, each frame member 6538 may have a plurality of thermoelectric
heat
transfer elements 6544 positioned thereon. In illustrated embodiment, six
thermoelectric heat
transfer elements 6544 are positioned on each frame member 6538. In one
embodiment, the
number of the thermoelectric heat transfer elements 6544 positioned on each
frame member
6538 may vary.
[001104] In one embodiment, the frame members 6538 may be supported on the
shaft
member 6542 of the cooler system 6500 via support members 6540 (e.g., two). In
one
embodiment, the support members 6540 may be extended and retracted by an
actuating
mechanism. In one embodiment, the actuating mechanism is configured to extend
the support
members 6540 such the frame members 6538 and the thermoelectric elements 6544
positioned thereon are positioned in contact with the interior surface 5130a,
5132a of the
welded pipes to remove heat from the welded pipes 1022a, 1022b. In one
embodiment, the
actuating mechanism may be pneumatically controlled or may be controlled in
any other way
as would be appreciated by one skilled in the art.
[001105] In one embodiment, as shown in FIG. 133, the heat exchanger 6502 of
the cooler
system 6500 may be a blower 6505 configured to blow a cooling gas onto the
interior surface
5130a, 5132a of the welded pipes 1022a, 1022b to remove heat from the welded
pipes 1022a,
1022b. In one embodiment, the blower blows air onto the interior surface
5130a, 5132a of the
pipe 1022a, 1022b to facilitate cooling of the welded pipes 1022a, 1022b. In
one embodiment,
the blower 6505 may include a frame member 6550 have a plurality of holes 6552
thereon. In
one embodiment, the frame member 6550 is constructed and arranged to receive
air from the
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outlet of a compressed air (e.g., high pressure) source 6554. In one
embodiment, the frame
member 6550 is constructed and arranged to receive air from the outlet of a
motor driven fan.
In one embodiment, the holes 6552 formed on the frame member 6550 are
configured to
function as outlets for delivering received air to the interior surface 5130a,
5132a of the
welded pipes to remove heat from the welded pipes 1022a, 1022b.
[001106] In one embodiment, as shown in FIG. 134, a camera 6556 mounted at a
location CL
on the first section 6558 and is controlled by the cooler electronics module
6528 may provide
video images to a remote control device so that a user may determine how close
the internal
cooler system 6500 is to the weld joint 1026.
[001107] In one embodiment, as shown in FIGS. 135 and 136, the cooler system
6500
includes a blower 6650 configured to blow a cooling gas onto the interior
surface 5130a,
5132a of the welded pipes 1022a, 1022b to remove heat from the welded pipes
1022a, 1022b.
In one embodiment, the blower 6505 includes a fan. In one embodiment, the
structure,
positioned and operation of the blower 6505 may be similar to the fan 2122 as
described in
detail elsewhere in this application.
[001108] In one embodiment, referring to FIGS. 135 and 136, the heat exchanger
elements
6580 are moved from their retracted positions (as shown in FIG. 136) where the
contact
surfaces 6572 of the heat exchanger elements 6580 are not in contact with the
inner surfaces
5130a, 5132a of the pipes 1022a, 1022b to their extended positions where the
contact
surfaces 6572 of the heat exchanger elements 6580 are configured to be in
contact with the
inner surfaces 5130a, 5132a of the pipes 1022a, 1022b, by operating an
actuating mechanism
6664.
[001109] In one embodiment, the actuator mechanism 6664 may be a linear
actuator. In one
embodiment, the actuator mechanism 6664 may include a motor 6652, a lead screw
6654, a
lead nut 6656, a plurality of first members 6664 and a plurality of second
members 6666. In
one embodiment, the number of the first and second members may depend on the
number of
heat exchanger element 6580 being used. In one embodiment, each second member
6666 is
constructed and arranged to be connected to the heat exchanger element 6580 on
one end and
to the first member 6664 on the other end. In one embodiment, each first
member 6664 is
constructed and arranged to be connected to the second member 6666 on one end
and to a
member 6662 moveable by the motor 6652 on the other end.
[001110] In one embodiment, the motor 6652 is configured (e.g., mechanically
connected) to
rotate the lead screw 6654. In one embodiment, the motor 6652 is configured to
rotate either
clockwise or counter clockwise direction so as to cause the raising or
lowering of the heat
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transfer elements 6580 substantially perpendicular to the pipe axis of the
pipes 1022a, 1022b.
In one embodiment, the motor 6652 is configured to be directly connected to
rotate the lead
screw 6654. In another embodiment, the motor 6652 is configured to be
indirectly connected,
e.g., through a series of gears or a gearbox, to rotate the lead screw 6654.
[001111] In one embodiment, the lead screw 6654 includes threads machined on
its outer
surface and extending along its length. In one embodiment, the lead nut 6656
is constructed
and arranged to be threaded onto the lead screw 5514 and includes
complimentary threads
machined on its inner surface.
[001112] In one embodiment, the lead nut 6656 is configured to interlock with
a portion of a
member 6662 so that the rotation of the lead nut 6656 is prevented along with
the lead screw
6654. That is, the lead nut 6656 is restrained from rotating along with the
lead screw 6654,
therefore the lead nut 6656 is configured to travel up and down the lead screw
6654. In one
embodiment, the lead nut 6656 is interlocked and positioned in an opening of
the member
6662. In one embodiment, the lead screw 5514 is configured to pass through an
opening of
the interlocked lead nut 5516.
[001113] The operation of the actuator mechanism 6664 is discussed in detail
below. When
the lead screw 6654 is rotated by the motor 6652, the lead nut 6656 is driven
along the
threads. In one embodiment, the direction of motion of the lead nut 6656
depends on the
direction of rotation of the lead screw 6654 by the motor 6652. As the lead
nut 6656 is
interlocked in the opening of the member 6662, the member 6662 is configured
to travel the
lead screw 6654 along with the lead nut 6656. That is, the member 6662
translates linearly
(right to left or left to right) as the motor 6652 rotates. Also, as the
member 6662 is connected
to the first members 6658, the movement of the member 6662 causes the movement
of the
first members 6658. As the second members 6660 are connected to the first
members 6658,
the movement of the first members 6658 causes the radial (up or down) movement
of the
second members 6660. That is, the linear translation of the member 6662 is
converted to the
radial (up or down) movement of the second members 6660 through the first
members 6658.
[001114] As the heat exchanger element 6580 is connected to the second members
6660, the
radial (up or down) movement of the second members 6660 causes the radial (up
or down)
movement in the heat exchanger element 6580. Thus, the motor 6652 is
configured to move
the contact surfaces 6572 of the heat exchanger elements 6580 outwardly into
engagement
with the interior surface 5130a, 5132a of the metal pipes 1022a, 1022b.
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[001115] In one embodiment, the time that the cooler system takes to cool the
pipes (e.g.,
after the coating procedure and before the spooling procedure) may be in the
range between
90 and 150 minutes.
[001116] Because the cooler system can be used to apply the cooling energy to
an interior
surface of the metal pipes, from within the pipes, the time for cooling of the
metal pipes can
be reduced (for example, in comparison to permitting natural cooling of the
metal pipes, or in
comparison to applying a coolant on top of the insulator material). This, for
example, can
facilitate cooling of the metal pipes after the insulator material is applied
to a welded pipe,
which should be pre-heated prior to application of the weld material. As a
result, the welded
pipe can be put into service or otherwise further processed more quickly.
Specifically, after
the welded pipe has been heated to apply the insulator material, and insulator
applied, it
should not be subjected to high stresses that may take place in a deployment
procedure. For
example, in some embodiments, the welded pipe and its insulation (which
insulation is
applied only after the welded pipe temperature is heated to a temperature of
at least 160 C) is
intended to be wound on a spool in a spooling operation. Such spooling
operation is
conducted ideally only after the welded and insulated metal pipe has been
cooled to below a
threshold level (e.g., below 50 C). The use of the internal cooler can
expedite achieving
cooling of the metal pipe to below the threshold level. In another application
of the internal
cooler system, after the pipes are welded (and before application of the
insulator).
[001117] The spooling operation is one of a number of deployment procedures
that may be
conducted ideally only after the welded pipe is below a threshold temperature
(e.g., by
operation of the internal cooler). Other deployment procedures may include an
S-lay
procedure and/or J-lay procedure on a pipe laying barge. The welded pipe
should be below a
threshold temperature before the pipe should be submerged into the water
(e.g., sea or ocean).
[001118] In addition, in another application, it may be desirable to inspect
the weld with an
ultrasound detector, in an ultrasound inspection system. The ultrasound
inspection station is
configured to operate ideally below a threshold temperature (e.g., below 80
C), which can
more quickly be obtained (after the pipe is heated as a result of the welding
operation) by use
of the cooler system. Thus, in one system, the cooler can be used prior to an
ultrasound
inspection system operation, which would be conducted after welding and before
the pipe is
re-heated for application of the insulation material.
[001119] In one embodiment, referring to FIG. 136A, an ultrasound inspection
station 6801
that is configured to inspect the weld between the welded metal pipes 1022a,
1022b is
provided. In one embodiment, the cooler system 6500 is configured to
facilitate cooling of
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the metal pipes 1022a, 1022b after the pipes 1022a, 1022b are welded and
before inspection
of the weld by the ultrasound inspection station 6801.
[001120] In one embodiment, a temperature sensor (e.g., 2017a as shown in
FIGS. 104-109)
may be used to determine the temperature of the pipe 1022a, 1022b in the
vicinity of the weld
1026. For example, referring to FIG. 107, the temperature sensor 2017a is
configured to be
positioned on the internal cooler system and in the vicinity of the weld 1026.
In one
embodiment, the temperature sensor 2017a may be positioned near the heat
transfer elements
or fins of the internal cooler system to measure the temperature of the (inner
diameter) inner
surfaces 5130, 5132 of the pipe 1022a, 1022b. In another embodiment, the
temperature
sensor may be positioned at the ultrasound inspection station 6801. In one
embodiment, the
temperature sensor may be a contact or a non-contact temperature sensor.
[001121] In one embodiment, the temperature sensor 2017a that senses a
temperature of the
pipes 1022a, 1022b may be operatively communicating with the one or more
processors. In
one embodiment, the one or more processors send operating instructions to the
cooler 6502
based on signals received from the temperature sensor 2017a. In one
embodiment, the one or
more processors operate the cooler until the sensor 2017a and the processor
determines that
the temperature of the pipes 1022a, 1022b is below a threshold temperature.
[001122] In one embodiment, one or more processors may be configured to
determine that
temperature of the pipe 1022a, 1022b in the vicinity of the weld 1026 is below
a
predetermined temperature threshold. In one embodiment, the temperature sensor
may be
configured to detect that temperature of the pipe 1022a, 1022b in the vicinity
of the weld
1026 is below a predetermined temperature threshold.
[001123] In one embodiment, the inspection by the ultrasound inspection
station 6801
commences after the temperature sensor 2017a detects that the temperature of
the pipe 1022a,
1022b in the vicinity of the weld 1026 is below a predetermined temperature
threshold.
[001124] FIG. 136B shows a method for the pipeline deployment. FIGS. 136C and
136D
show schematic views of the S-lay pipe deployment system and J-lay pipe
deployment
system. FIG. 136E shows S-lay and J-lay unspooling barges.
[001125] In one embodiment, pipes 1022a, 1022b (e.g., about 40 feet or 80 feet
long) are
manufactured during the pipe manufacturing procedure 6902. In one embodiment,
the
manufactured pipes are stored at pipe storage 6904 before sending the pipes
for further
processing, for example, to a S-lay barge 6942 (as shown in FIG. 136C), a
spool base or a J-
lay barge 6944 (as shown in FIG. 136D). In one embodiment, the pipe storage
may include a
plurality of storage racks.
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[001126] In one embodiment, at the spoolbase procedure 6914, the manufactured
pipe
sections are received by the spoolbase, these pipe sections are joined, at the
spoolbase, to
form long pipe sections, and these long pipe sections are then spooled and
loaded on to a
vessel, ship, or barge. In one embodiment, the spoolbase may include semi-
automatic or
automatic welding systems, field joint coating systems, nondestructive
inspection and
testing systems, storage racks, roller systems, and/or other pipe handling
equipment for the
fabrication, spooling, and loading of rigid pipeline before installation.
[001127] In one embodiment, the pipe stalks are reeled onto big spools on
barges (as shown
in FIG. 136E) and unspooled when the barge arrives at the job location. In one
embodiment,
the spooled pipe stalks are unspooled on the vessel, ship, or barge at
procedure 6916 and the
pipe sections are then deployed at procedure 6918. In one embodiment, the
"unspooling"
vessel, ship, or barge may be a J-lay barge or a S-lay barge. FIG. 136E shows
S-lay and J-lay
unspooling barges.
[001128] In one embodiment, the S-lay barge 6942 receives the stored pipe
sections from the
pipe storage. In one embodiment, at procedure 6906, the S-lay barge 6942 uses
its on-board
systems to produce long pipe sections. In one embodiment, at procedure 6906,
automatic
weld systems, pipe facing systems, backup clamps, purge clamps and/or other
support
equipment are used on the S-lay barge 6942 to produce long pipe sections. In
one
embodiment, the S-lay pipe deployment procedure is used for offshore pipeline
applications.
In one embodiment, the S-lay pipe deployment procedure is used shallow and
intermediate
waters. In one embodiment, the S-lay pipe deployment procedure allows the pipe
leave the
vessel in a horizontal position. In one embodiment, the S-lay pipe deployment
procedure
provides high production rates. As shown in FIG. 136C, the S-lay barge 6942 is
constructed
and arranged to deploy the pipe sections in a S-shaped pipe configuration.
[001129] In one embodiment, the J-lay barge 6944 receives the stored pipe
sections from the
pipe storage. In one embodiment, at procedure 6908, the J-lay barge 6944 uses
its on-board
systems to produce long pipe sections. In one embodiment, at procedure 6908,
automatic
weld systems, pipe facing systems, J-lay clamps, and/or other support
equipment are used on
the J-lay barge 6944 to produce long pipe sections. In one embodiment, the J-
lay pipe
deployment procedure is used for offshore pipeline applications. In one
embodiment, the J-
lay pipe deployment procedure is used for deep-water work. In one embodiment,
the J-lay
pipe deployment procedure allows the pipe to leave the lay system in a
position which is very
close to vertical. This means that a pipeline is installed with much reduced
stresses on the
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pipe. As shown in FIG. 136D, the J-lay barge 6944 is constructed and arranged
to deploy the
pipe sections in a J-shaped pipe configuration.
[001130] Control, positioning and communication with the internal welder
system, the tie-in
welder system, and/or the pipe cooler systems, when located within a pipe can
be
accomplished in a variety of ways, as described herein. In yet another
embodiment, position
of the system within the pipe can be detected by a low frequency
electromagnetic signal
transmission from a coil placed in close proximity parallel to the pipe outer
surface. This
signal is detected by a pair of orthogonal receiving coils mounted on the
system in the pipe,
in close proximity to the pipe inner surface. The phases of the received
signals with respect to
the transmitted signal and the ratio of the amplitudes of the two received
signals is used to
estimate the relative position of the transmitter and the receivers. Control
of the system
within the pipe (i.e., internal welder, tie-in welder, or cooler system, etc.)
along with
transmission of information can also accomplished via a high frequency direct
sequence
spread spectrum radio link between one or more processors (e.g., within a
computer console)
outside the pipe and one or more processors mounted on the system in the pipe.
The details of
this deployment can be appreciated from US Patent 6,092,406, incorporated
herein by
reference in its entirety.
[001131] In one embodiment, the internal weld system 5004, 3001 may include a
weld
material consumption device. In one embodiment, the external weld system 7500
may
include a weld material consumption device. In one embodiment, the weld
material
consumption device may be a part of the wire feed assembly 5020 of the
internal weld system
5004.
[001132] In one embodiment, the weld consumption device may have structure and
operation
similar to the device(s) as shown in and described with respect to 161A-165 of
this
application. For example, in one embodiment, the structure, configuration and
operation of
the spool 5272 (as shown in FIG. 22A) used the internal weld system 5004 may
be similar to
the spool 14480 as shown and described with respect to FIG. 161A. In one
embodiment, the
structure, configuration and operation of the motors of the wire feed assembly
5020 of the
internal weld system 5004 may be similar to the motor 14490 as shown in and
described with
respect to FIGS. 162, 164A, and 164B. Also, in one embodiment, the wire feed
assembly
5020 of the internal weld system 5004 may include a weight sensor that is
configured to
sense the depletion of the consumable material. The structure, configuration
and operation of
the weight sensor of the internal weld system 5004 may be similar to the
weight sensor 14484
as shown in and described with respect to FIG. 161C. In one embodiment, the
internal weld
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system 5004 may include other sensors (e.g., shown in 161B) to determine an
amount of
consumable weld material used by the internal weld system 5004 for a given
period of time.
[001133] In one embodiment, the one or more processors 5140 operatively
associated with
the internal weld system 5004 may be configured to determine the wire feed
speed from the
speed of the motors of the wire feed assembly 5020 as described in elsewhere
in this
application. In one embodiment, the one or more processors 5140 operatively
associated with
the internal weld system 5004 may be configured to determine an amount of
consumable
weld material used by the internal weld system 5004 for a given period of time
and generate
weld material consumption data based thereon. In one embodiment, a transmitter
of the
internal weld system 5004 may transmit the weld material consumption data
entirely
wirelessly to the remote uLog processing system for further processing. In one
embodiment,
the remote uLog processing system may also be configured to transmit (entirely
wirelessly to
the internal weld system, the external weld system and/or the tie-in internal
weld system)
further instructions about the operation of the internal weld system, the
external weld system
and/or the tie-in internal weld system based on the processed weld material
consumption data.
For example, the instructions may include correcting a slippage of the motors
of the wire feed
assembly by increasing the speed of the motor of the wire feed assembly of the
internal weld
system, the external weld system and/or the tie-in internal weld system. In
one embodiment,
the one or more processors 5140 of the internal weld system 5004 may use the
procedures
shown in and described with respect to FIGS. 163 and 165 to determine weld
material
consumption data, the processed weld material consumption data, etc.
[001134] In one embodiment, the structure and operation of the weld
consumption device is
described above with respect to the internal weld system 5004. In one
embodiment, the
external weld system 7500 and the tie-in internal weld system 3001 may include
a weld
consumption device with similar structure and operation. That is, in one
embodiment, the hub,
electronics, software and pictures being sent by the weld material consumption
devices of the
internal weld system and the external weld system are generic to both the
devices. However,
the shape and size the weld material consumption devices of the internal weld
system 5004,
3001 and the external weld system 7500 may change. In one embodiment, the weld
material
consumption devices of the internal weld system 5004, 3001 and the external
weld system
7500 may have different shaped configurations and/or different geometries. In
one
embodiment, the weld material consumption device may be configured to detect
unauthorized
wire spool being used in the internal weld system 5004, 3001 or the external
weld system
7500.
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