BR112017020431B1 - SYSTEMS AND METHODS FOR USE IN WELDING PIPE SEGMENTS - Google Patents

Abstract

systems and methods for use in welding pipe segments in a pipeline. A field system for welding two tubes includes a first tube coupling structure, a second tube coupling structure, one or more welding torches, a motor and one or more processors. o One or more welding torches are configured to be positioned inside the tubes to create an internal weld at an interface region between the tubes. the motor is operatively associated with the one or more welding torches to rotate the one or more welding torches along the interface region between the tubes. the one or more processors control the motor and the one or more welding torches to generate a complete circumferential weld along the interface region by rotating the one or more welding torches along the interface region in a single direction of rotation until the complete circumferential weld is performed.

Description

FUNDAMENTALS CROSS REFERENCE TO RELATED ORDERS

[0001] This application is a continuation in part of PCT/US2015/047603, filed August 28, 2015, which claims priority to Provisional Application US No. 62/043,757, filed August 29, 2014. This application is also a continuation in part of PCT/US2015/022665, filed March 26, 2015 and US Patent Application No. 14/228,708, filed March 28, 2014. PCT/US2015/022665 claims the benefit of US Patent Application No. ° 14/228,708. This application is also a continuation in part of PCT/US2014/039148, filed May 22, 2014 and US Patent Application No. 14/272,914, filed May 8, 2014, both claiming priority to US Provisional Application No. 61/826,628, filed May 23, 2013. PCT/US2014/039148 claims the benefit of US Patent Application No. 14/272,914. This application also claims priority to US Provisional Application No. 62/175,201, filed June 12, 2015 and US Provisional Application No. 62/189,716, filed July 7, 2015. The contents of all such applications are incorporated herein. in its entirety for reference.

FIELD OF INVENTION

[0002] The present patent application refers to various field systems and methods that are used for the purpose of welding pipe segments of a pipe.

[0003] Piping systems, which may include long stretches of sections or segments of pipe (for example, miles of pipe) comprising iron, stainless steel or other types of metal, are used to transport fluids such as water, oil and gas between two locations (eg from a source source which may be land based or water based to a suitable storage location). The construction of piping systems generally involves connecting pipe segments of suitable diameter and longitudinal dimensions, through solder joints, for example, capable of providing a liquid seal for the connected pipe segments.

[0004] During formation of a weld joint between two pipe segments (for example, two pipe segments with the same or different cross-sectional dimensions in similar cross-sections), one end of a pipe section or segment is placed in close proximity or contacting one end of a second tube section or segment. The pipe segments are held in relation to each other and a solder joint is formed to connect the two ends of the pipe segments using a suitable soldering process. After the weld is completed and cleaned, the weld can be inspected. After inspection, it may be desirable to apply external protective coatings to the solder joint.

[0005] Conventional internal welders often include internal alignment mechanisms that expand radially outward to contact the interior of the tube. Alignment of the two tube segments is accomplished from the inside when the extension members of a central member contact the inside of the tube relatively close to the joint faces of the tube segment on both sides of the joint as shown in US Pat. ° 3,461,264; 3,009,048; 3,551,636; 3,612,808 and GB 1261814 (which is incorporated herein by reference in its entirety). To weld the joint, the expander frame must be configured to allow enough space to accommodate a rotating torch. Therefore, it would be advantageous to provide an internal alignment that allows sufficient space for a rotating or connecting torch or to externally align the tube segments so as to eliminate the need for an internal expander that can create significant internal clutter.

[0006] In addition, the conventional internal welding process usually involves internal or external alignment and an insertion of the internal welder so that the torches align with the face seam. In this process it is sometimes difficult to assess the accuracy of the placement of the internal welder in general and the torch in particular. It is even more difficult to assess the accuracy of the torch position as the torch traverses the interior of the tube along its orbital path during welding. Therefore, it would be advantageous to provide a frame tracking system or positioning the tube edges at the tube interface to control the torch by using the interface tracking condition. Specifically, it would be advantageous to first track an interface profile 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 tube interface profile.

[0007] In addition, conventional pipe welding systems employing external alignment mechanisms generally support two segments on rollers and manipulate the position and orientation of the segments until alignment is satisfactory. Whether an alignment is satisfactory will usually depend on, for example, industry acceptable indicators and acceptable lows, which are quite accurate but are manually operated and positioned in discrete locations rather than across the entire pipe interface. In either case, the profile or structure of the interface, as viewed from within the tube, is usually not a consideration for the quality of the alignment. Therefore, it would be advantageous to provide an alignment system in which the interface profile information as read by the laser is used as an input parameter during the external alignment process. Specifically, it would be advantageous to provide the information from the torch control laser to the controller that would use the information to control external alignment mechanisms.

[0008] In addition, conventional piping systems for welding pipe segments typically do not have the capability to visually inspect the weld applied by the torch. Therefore, it would be advantageous to provide a camera that follows the welding application of the torch and a screen to show an image of the weld, for an operator to visually verify the weld quality. Other advantages of the present disclosure will be evident by reviewing this disclosure. The patentable advantages are not limited to those highlighted in this section. In addition, the benefits discussed in this document are to be considered independent of each other and not dependent on each other, unless specifically noted in this document. Additional advantages are also described in the claims provided in this application.

[0009] In a welding operation, tubes are normally preheated to a suitable temperature before welding, and a significant amount of heat is also generated during the welding process.

[0010] Some time after the weld is completed and cleaned, the weld can be inspected. It is desirable to inspect the weld at a temperature closer to the pipe operating temperature than to the elevated weld temperature. Therefore, cooling after the welding process may be desired prior to inspection. After inspection, it may be desirable to apply external protective coatings to the joint. To facilitate this coating, heat can be added to the tube in order to raise the tube temperature needed for the application of certain external coatings (eg polypropylene).

[0011] After such heating, the pipe connection is ideally allowed to cool to a suitable temperature before additional processing steps are performed (for example, before winding connected pipe sections or handling/putting pipe sections in water or in any other suitable location on the ground).

[0012] During some pipe fabrication steps (eg after welding and before inspection), outer portions of the joined pipe are easily accessible, and cooling on the outer surface is an option. However, during some portions of the process (for example, after certain materials have been externally applied to the outer surface of the tube) the outer surface is not available, on which a tube cooling process is conducted.

[0013] Internal cooling can be useful during certain portions of the manufacturing process (ie, even when external cooling is available). Internal cooling inside the tubes can be challenging due to the size of the tubes and the difficulty of accessibility to the inner portion of the tube section that is located at or near the weld joint. Therefore, it would be especially desirable to provide internal cooling, so that during portions of the process where external surfaces of the tube are inaccessible, cooling can be implemented to more quickly condition the tube for future steps that require lower temperatures (eg, winding ).

[0014] Existing pipe weld inspection processes such as ultrasonic testing and X-ray radiography can be challenging. For example, some processes may require a large team (eg 4 or more staff) of highly trained personnel to travel to remote locations where the pipeline is being built; may require a rugged computer to be transported by dedicated truck and used in remote locations with harsh environments; provide; use inspection equipment that is connected by network wires ("tethered") to a robust computer equipment and specialized truck; it may be inefficient because each team member may only be needed for certain steps in the process; requires a highly trained technician on site to interpret test results; and require the desired analysis to be completed and the results written on the tube before the team can move to inspect an upcoming weld. These are, of course, generalities, and not all of these issues are present in all systems.

[0015] Currently, pipe joining technology remains a technique that is based on the prevention of error by a worker applying a solder. Some welding technologies require proper data management, work control and activity supervision. As a result of such challenges, weld 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 employed in the application of tube welding. The field system provides many modalities related to tube welding systems and methods, which can be used in combination with each other or individually. Such welding systems and methods include, for example, internal welding systems and methods, tie-in welding systems and methods, pipe inspection systems and methods, pipe treatment systems and methods, pipe cooling systems and methods systems, systems and non-destructive testing methods, as well as remote database and interface (uLog) systems and methods, to name a few. The order also refers to welded tubes that result from some or all of these processes.

[0018] One aspect of the present patent application provides for a field system for soldering two tubes. The field system includes a first tube engagement structure; a second tube coupling structure; an inspection detector; an engine; one or more processors; and a welding torch. The first tube engagement structure is configured to engage the interior surface of a first tube to allow the first tube engagement structure to be secured relative to the first tube. The second tube engaging structure is configured to engage the interior surface of a second tube to allow the second tube engaging structure to be secured relative to the second tube. The inspection detector is positioned between the first tube engaging structure and the second tube engaging structure, the inspection detector configured to emit a beam of inspection radiation. The motor is operatively associated with the inspection detector to direct the inspection radiation beam along a region of interface between the tubes. One or more processors are operatively associated with the inspection detector to profile the region of interface between the tubes. The welding torch is configured to create a weld between the tubes based on the profile of the interface region between the tubes.

[0019] Another aspect of the present patent application provides for a field system to weld two tubes. The field system includes a first tube engagement structure; a second tube coupling structure; an inspection detector; one or more guidance engines; one or more processors; and a welding torch assembly. The first tube engagement structure is configured to engage the interior surface of a first tube to allow the first tube engagement structure to be secured relative to the first tube. The second tube engaging structure is configured to engage the interior surface of a second tube to allow the second tube engaging structure to be secured relative to the second tube. The inspection detector is positioned axially between the first pipe engaging structure and the second pipe engaging structure, the inspection detector configured to inspect a region of interface between the pipes and generate profile data based thereon. One or more guidance motors are operatively associated with the inspection detector to direct the inspection radiation beam along the region of interface between the tubes. One or more processors are operatively associated with the inspection detector and configured to receive profile data from the inspection detector to determine one or more characteristics of the interface region between the tubes. The welding torch assembly includes a welding torch and at least one welding torch motor, with the welding torch and at least one welding torch motor being driven by one or more processors to create a weld between the tubes. based on one or more characteristics of the interface region between the tubes.

[0020] Yet another aspect of the present patent application providing for a field system for soldering two tubes is provided. The field system includes a frame configured to be placed inside the tubes; a plurality of rollers configured to rotatably support the frame; a drive motor that drives the rollers to move the frame within the tubes; a brake system that protects the frame from movement at a desired location within the tubes; a frame-borne inspection detector, the inspection detector configured to detect a characteristic of an interface region between the tubes; a welding torch carried by the frame; one or more battery cells carried by the frame, one or more battery cells configured to power the drive motor, inspection detector and welding torch; and one or more processors operatively connected with the drive motor, inspection detector, and welding torch.

[0021] Yet another aspect of the present patent application provides for a method for soldering a pair of insulated tubes to one another. Each tube includes a metal tube interior surrounded by an insulating material. The end portions of the tubes to be welded have the inside of the metal tube exposed. The method includes aligning the ends of exposed metal tubes to be welded, welding the exposed metal tube ends together, heating the exposed end portions of the welded tubes, applying an insulator to the heated exposed end portions of the welded tubes so that the insulator is adhered to an outer surface of the interior of the metal tube, thereby insulating the previously exposed end portions of the tubes and applying cooling energy within the tubes to an inner surface of the metal tubes.

[0022] Yet another aspect of the present patent application provides for a system for soldering a pair of insulated tubes to one another. Each tube comprises a metal tube interior surrounded by an insulating material. The end portions of the tubes to be welded have the inside of the metal tube exposed. The system includes a welding torch configured to weld exposed metal tube ends together; a heater configured to heat the exposed end portions of the welded tubes; an insulator supply configured to apply the insulating material to the heated exposed end portions of the welded tubes so that the insulator is adhered to an outer surface of the interior of the metal tube, thereby insulating the previously exposed end portions of the tubes; and a cooler system configured to be positioned within the tubes, the cooling system applying cooling energy to an interior surface of the metal tubes to facilitate cooling of the metal tubes after insulating material is applied.

[0023] Yet another aspect of the present patent application provides for a method for soldering a pair of insulated tubes to one another. Each tube includes a metal tube interior surrounded by an insulating material. The end portions of the tubes to be welded have the inside of the metal tube exposed. The method includes aligning the ends of exposed metal tubes to be welded, welding the exposed metal tube ends together, heating the exposed end portions of the welded tubes, applying an insulator to the heated exposed end portions of the welded tubes so that the insulator is adhered to an outer surface of the interior of the metal tube, thereby insulating the previously exposed end portions of the tubes and applying cooling energy within the tubes to an inner surface of the metal tubes after applying the insulator; and perform a pipe laying procedure. The application of cooling energy reduces a waiting time between application of the insulator and carrying out the piping procedure.

[0024] Yet another aspect of the present patent application provides for a welded tube assembly. The weld tube assembly includes a first metal tube having a length of at least 30' and an outside diameter of less than 24"; a second metal tube having a length of at least 30' and an outside diameter of less than 24"; solder material connecting the first tube with the second tube, the solder material comprising a plurality of solder pass layers, the plurality of solder pass layers including a root pass layer and a hot pass layer arranged on top of the root pass layer, the pass layer is positioned closer to an interior longitudinal axis of the first and second welded tubes of the root pass layer.

[0025] Yet another aspect of the present patent application provides for a welded tube assembly. The assembly includes a first metal tube having a length of at least 30' and an outside diameter of less than 24"; a second metal tube having a length of at least 30' and an outside diameter of less than 24"; a welded joint connecting the first metal tube and the second metal tube, the welded joint comprising a first inner bevel formed in the first metal tube and a second inner bevel formed in the second metal tube and a root pass layer of the Weld material disposed in a region defined by the first inner bevel and the second inner bevel.

[0026] Yet another aspect of the present patent application provides a pipe cooling system. The tube 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 inside the welded tubes. The plurality of rollers are configured to rotatably support the frame. The drive motor drives the rollers to move the frame within the tubes. The brake system that secures the movement frame to a desired location within the tubes. The cooler is cooler carried by the frame, the cooler applying cooling power to an interior surface of the metal tubes to facilitate the cooling of the welded metal tubes. One or more processors are operatively connected with the drive motor, brake system and cooler. One or more processors that operate the cooler to reduce the temperature of the welded tubes to a predetermined level.

[0027] Yet another aspect of the present patent application provides for a welded tube assembly. The welded tube assembly includes a first metal tube; a second tube of metal and solder material connecting the first metal tube with the second metal tube. The first metal tube is at least 30 feet long and has an outside diameter of less than 24 inches. The second metal tube is at least 30 feet long and has an outside diameter of less than 24 inches. The solder material includes a plurality of solder pass layers. The plurality of solder 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 first and second welded tubes than to the root pass layer.

[0028] Yet another aspect of the present patent application provides for a welded tube assembly. The weld tube assembly includes a first metal tube, a second metal tube, and a weld joint connecting the first metal tube and the second metal tube. The first metal tube is at least 30 feet long and has an outside diameter of less than 24 inches. The second metal tube is at least 30 feet long and has an outside diameter of less than 24 inches. The weld joint includes a first inner bevel formed in the first metal tube and a second inner bevel formed in the second metal tube and a root pass layer of the weld material disposed in a region defined by the first inner bevel and the second inner bevel .

[0029] Yet another aspect of the present patent application provides for a field system for welding two tubes. The field system includes a first tube engaging structure configured to engage the interior surface of a first tube to allow the first tube engaging structure to be secured relative to the first tube; a second tube engaging structure configured to engage the interior surface of a second tube to allow the second tube engaging structure to be secured relative to the second tube; one or more welding torches configured to be positioned within the tubes to create an internal weld at an interface region between the tubes; a motor operatively associated with the one or more welding torches for rotating the one or more welding torches along the region of interface between the tubes; and one or more processors that control the motor and one or more welding torches, one or more processors that operate the motor and one or more welding torches to generate a complete circumferential weld along the interface region by rotating one or more welding torches. weld along the interface region in a single direction of rotation until the complete circumferential weld is completed.

[0030] Yet another aspect of the present patent application provides for an inspection system for pre-inspection of an interface region between two tubes to be welded end to end. The system includes a frame configured to be placed inside the tubes; a plurality of rollers configured to rotatably support the frame; a drive motor that drives the rollers to move the frame within the tubes; a brake system that protects the frame from movement at a desired location within the tubes; a movable sensor with the frame that detects the region of interface between the tubes; an inspection detector configured to generate signals based on a profile of the interface region between the tubes; a motor that routes the inspection detector along the interface region; and one or more processors operatively associated with the drive motor, sensor, inspection detector and motor, one or more processors that operate the drive motor to move the frame through at least one of the tubes until the sensor detects the region of the interface, one or more processors that operate the brake system to protect the structure from motion at a location within the tubes that positions the inspection detector in relation to the interface region to allow the inspection detector to detect the profile of the inspection region. interface between the tubes; one or more processors operating the inspection detector and motor to check the interface region between the tubes, and in response to detecting one or more undesirable characteristics of the interface region, one or more processors sending instructions based thereon.

[0031] Yet another aspect of the present patent application provides for a field system for pre-inspection of an interface region between two tubes to be welded end to end. The system includes a frame configured to be placed inside the tubes; a plurality of rollers configured to rotatably support the frame; a drive motor that drives the rollers to move the frame within the tubes; a brake system that protects the frame from movement at a desired location within the tubes; an inspection detector configured to generate signals based on a profile of the interface region between the tubes; one or more guidance motors that rotatably move the inspection detector along the interface region; and one or more processors operatively associated with the drive motor, the inspection detector and the motor, one or more processors that operate the brake system to protect the armature from motion at a location within the tubes that positions the inspection detector in relation to the interface region to allow the inspection detector to detect the profile of the interface region between the tubes; one or more processors operating the inspection detector and motor to verify the interface region between the tubes to generate pre-weld profile data and in response to detecting one or more undesirable characteristics of the pre-weld profile data, one or more processors sending instructions based on that.

[0032] Yet another aspect of the present patent application provides for a method for pre-inspection of an interface region between two tubes to be welded end to end. The method includes moving a frame within at least one of the tubes to be welded; detect the region of the interface between the tubes; protecting the frame from movement in the region of the interface between the tubes; detect a profile of the interface region between the tubes; and in response to detecting one or more undesirable features of the interface region between the tubes, generating instructions based thereon.

[0033] Yet another aspect of the present patent application provides a pipe cooling system. The tube cooling system includes a frame configured to be placed inside welded tubes; a plurality of rollers configured to rotatably support the frame; a drive motor that drives the rollers to move the frame within the tubes; a brake system that protects the frame from movement at a desired location within the tubes; a frame carried cooler, the cooler applying cooling energy to an interior surface of the metal tubes to facilitate cooling of the welded metal piping; and one or more processors operatively connected with the drive motor, brake system and cooler, one or more processors that operate the cooler to reduce the temperature of the welded tubes to a predetermined level.

[0034] One aspect of the present patent application provides a method of welding two tubes. The method includes internally clamping a first tube with a first clamp; internally clamping a second tube with a second clamp, the first and second tubes 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 tubes and between the clamps to obtain profile data of the interface region; welding the two tubes in end-to-end relationship based on the profile data; and internally inspecting the welded tubes from a location within the tubes and between the clamps

[0035] One aspect of the present patent application provides a weld processing system to facilitate tube welding remote from a field system to perform tube welding operations between a first tube and a second tube. For example, the remote field system comprises an inspection detector configured to emit a radiation inspection beam to scan a profile of an interface region between the first and second tubes and a welding torch configured to create a weld between the first. and the second tube based on the profile of the interface region between the first and second tube. The welding processing system comprises: a receiver configured to receive, from the remote welding system, profile data determined from the scanning of the interface region between the tubes by the inspection detector; one or more processors configured to compare one or more profile data characteristics of the interface region scan to one or more predefined profile data characteristics of predetermined interface regions and configured to determine control operation data for the field system remote based on comparison; and a transmitter configured to transmit the control operation data to the remote field system. Control operation data is configured to cause the welding torch to perform one or more weld operations in the tube-to-tube interface region.

[0036] One aspect of the present application provides a method of welding pipes. The method comprises: aligning the ends of the two tubes to be welded, the tubes comprising a metallic tube interior surrounded by an insulating material, the metallic tube interior being exposed in portions of the tubes adjacent to the ends of the tubes to be welded; welding the aligned ends of the tubes together within the tubes to form a solder joint; generating weld data while welding the aligned ends, the weld data corresponding to the weld parameters associated with the weld; inspecting the weld joint with an inspection laser from inside the welded tubes to obtain internal weld inspection data; inspect the weld joint with a radiation inspection source to obtain radiation inspection data; transmitting the weld data, internal weld inspection data, and radiation inspection data to a remote computer system to derive additional weld data; and receiving the derived additional weld data. Additional weld data is derived from data transmitted and additional inspection data received by the remote inspection system for other tubes.

[0037] One aspect of the present patent application provides a field system to facilitate 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 scanning the object from the inspection device. One or more processors are communicatively connected to a remote computer system and configured to transmit inspection data to the remote computer system. One or more processors are configured to receive data related to the performance of the operation from the remote computer system responsive to the transmission of inspection data, and to cause, based on the data related to the operation, the field device to perform the operation that physically affects the object. Operation-related data is derived from inspection data and other inspection data associated with a separate check of another object.

[0038] One aspect of the present patent application provides a method to facilitate 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 scanning the object to one or more processors; transmitting, by one or more field system processors, the inspection data to a remote computer system; receiving, by one or more processors, data related to the performance of an operation that physically affects an object of the remote computer system responsive to the transmission of inspection data; and causing, by one or more processors, based on data related to the operation, a field device of the field system to perform the operation that physically affects the object. Operation-related data is derived from inspection data and other inspection data associated with a separate check of another object.

[0039] One aspect of the present patent application provides a computer system to facilitate field testing and physical operations based thereon remotely from a field system in which the field testing and physical operations take place. The remote field system comprises an inspection device configured to verify 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 scanning of the object by the inspection device; one or more processors configured to process the inspection data to generate data related to the performance of 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, whereby the operation is performed based on the data related to the operation.

[0040] One aspect of the present patent application provides a method to facilitate field testing and physical operations based thereon remotely from a field system in which field testing and physical operations take place. The remote field system comprises an inspection device configured to verify 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 object scanning by the inspection device; processing, by one or more processors, the inspection data to generate data related to the performance of 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, whereby the operation is performed based on the data related to the operation.

[0041] One aspect of the present patent application provides a computer system to facilitate the field testing of a field system and the 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 remote field system, inspection data associated with the inspection of the object by the inspection device. Object verification by the inspection device is subsequent to a performance of one or more operations by one or more field devices that physically affected the object. 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 inspection data, a defect related to the object; generating an operating protocol associated with at least one type of operation from one or more operations responding to defect detection, wherein the operating protocol comprises a second set of input parameters with at least one input parameter different from the first set of input parameters; select the operation protocol to perform a subsequent operation similar to at least one of the one or more operations; and generating, based on at least one input parameter of the operation protocol, data related to carrying out the subsequent operation. The computer system further comprises a transmitter configured to transmit data relating to the operation to one or more field systems to cause one or more field systems to perform the subsequent operation. The subsequent operation is performed based on the data related to the operation.

[0042] One aspect of the present patent application provides a method to facilitate field testing of a field system and the physical operations based thereon. The field system comprises an inspection device configured to verify the object and one or more field devices configured to perform one or more operations that physically affect an object. The method comprises receiving, by a receiver, from the remote field system, inspection data associated with the verification of the object by the inspection device. Object verification by the inspection device is subsequent to a performance of one or more operations by one or more field devices that physically affected the object. 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 inspection data, a defect related to the object; generating, by one or more processors, an operating protocol associated with at least one type of operation of one or more operations sensitive to defect detection, wherein the operating protocol comprises a second set of input parameters with at least one parameter different input from the first set of input parameters; selecting, by one or more processors, the operating protocol to perform a subsequent operation similar to at least one of the one or more operations; generating, by one or more processors, based on at least one input parameter of the operation protocol, data related to the performance of the subsequent operation; and transmits, by a transmitter, the data relating to the operation to one or more field systems to cause the one or more field systems to carry out the subsequent operation. The subsequent operation is performed based on the data related to the operation.

[0043] One aspect of the present patent application provides a computer system to facilitate the field testing of a field system and the physical operations based thereon. The field system comprises an inspection device configured to verify the object and one or more field devices configured to perform one or more operations that physically affect the object. The computer system comprises a receiver configured to receive, from the remote field system, inspection data associated with the object verification. Object verification is subsequent to a performance of one or more operations that physically affected the object. 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 inspection data, whether the quality of one or more aspects of the object resulting from 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 one or more operations, where the operation protocol is generated to understand one or more of the sets of input parameters that respond to the quality of one or more aspects of the object that exceed the quality standard indicated by the predefined quality profile; select the operation protocol to perform a subsequent operation similar to at least one of the one or more operations; and generating, based on at least one input parameter of the operation protocol, data related to carrying out the subsequent operation. The computer system further comprises a transmitter configured to transmit data relating to the operation to one or more field systems to cause one or more field systems to perform the subsequent operation. The subsequent operation is performed based on the data related to the operation.

[0044] One aspect of the present patent application provides a method to facilitate the field testing of a field system and the physical operations based thereon. The field system comprises an inspection device configured to verify the object and one or more field devices configured to perform one or more operations that physically affect the object. The method comprises reception, by a receiver, from the remote field system, of inspection data associated with the verification of the object. Object verification is subsequent to a performance of one or more operations that physically affected the object. One or more operations are performed using a first set of input parameters. The method also comprises: determining, by one or more processors, based on inspection data, whether the quality of one or more aspects of the object resulting from one or more operations exceeds a quality standard indicated by a predefined quality profile; generate, by one or more processors, an operation protocol associated with at least one type of operation of one or more operations, wherein the operation protocol is generated to comprise one or more of the sets of input parameters that respond to the quality of one or more aspects of the object that exceed the quality standard indicated by the predefined quality profile; selecting, by one or more processors, the operation protocol to perform a subsequent operation similar to at least one of the one or more operations; generate, by one or more processors, based on at least one input parameter of the operation protocol, data related to the performance of the subsequent operation; and transmitting, by one or more processors, the data relating to the operation to one or more field systems to cause one or more field systems to perform the subsequent operation. The subsequent operation is performed based on the data related to the operation.

[0045] One aspect of the present patent application provides a computer system to facilitate 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 one or more observed operations and (ii) one or more objects without the defect. One or more processors are also configured to: compare, based on 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 plus other objects without the defect; determine, based on the comparison, a common difference that the first set of observations has with one or more other sets of observations; and, 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 to facilitate field testing and physical operations based thereon. The method comprises the obtaining, by one or more processors, from one or more field systems, data related to the 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 one or more observed operations and (ii) one or more objects without the defect. The method also comprises: comparing, by one or more processors, based on data related to the observation, 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, by one or more processors, based on the comparison, a common difference that the first set of observations has with one or more other sets of observations; and cause, by one or more processors, based on the common difference, an operation trigger to be implemented such that a field system is made 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.

[0047] One aspect of the present patent application provides a system for aligning and welding 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 a connecting torch, a laser sensor to read a face joint profile, and an electronic controller for receiving information signals. the laser sensor to control torch position and/or orientation; an alignment mechanism for manipulating the longitudinal axis orientation 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 to the tube and a welding portion capable of rotation relative to the support portion within the tube; and wherein the torch and laser sensor are rotatably supported by the welding portion so that, during welding, the torch follows the laser sensor along the face joint.

[0048] One aspect of the present patent application provides a method for aligning and welding two segments of a pipe. The method includes the steps of: placing a first pipe segment on an alignment device; insert an internal welding machine with a laser and welding torch into the first tube segment; generally aligning a second tube segment with the first tube segment and internal welding machine; taking an outer portion of the first and second pipe segments to adjust an axial position of the inner welding machine so as to generally align with a face joint of the first and second pipe segments; adjust a relative alignment of the first and second pipe segments through the alignment device based on a signal from the internal welder; begin a root weld cycle in which the laser sweeps the face joint, the torch follows the laser and the laser output is used to control the position of the articulated torch, where the position and orientation of the torch relative to the face joint is controlled to produce a quality weld; determining a laser face join profile; releasing the alignment device and removing the inner welding machine from one end of the open pipe segment; and repositioning a next sequential pipe segment on the outer alignment mechanism in preparation for welding a next joint.

[0049] One aspect of the present patent application provides an internal heat exchanger (IHEX) for pipe welding. The internal heat exchanger includes a drive system configured to move the IHEX to a position within at least one pipe section close to a position of solder joint with another pipe section; a cooling section including a 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 in position within the at least one pipe section.

[0050] One aspect of the present patent application provides a welding system. A soldering system including a plurality of soldering stations, each soldering station including a soldering station computer and the soldering system in communication with the soldering station computer, each soldering station including one or more sensors, the one or more sensors configured to measure weld data, including lead wire velocity data; a plurality of wireless devices in communication with the one or more of the soldering station computers to receive solder data, including lead wire speed data; and a cloud server in communication with the wireless devices, the cloud server being configured to process the solder data including the wire speed data and speed, and configured to determine an amount of consumable solder material used by the plurality of soldering stations for a certain period of time, in which the cloud server is configured to communicate the amount of consumable soldering material used for one or more of the wireless devices.

[0051] One aspect of the present patent application provides a welding system. A soldering system including a soldering station, the soldering station including a soldering station computer and a soldering system in communication with the soldering station computer, the soldering system including a soldering material source, a welding device and a welding supply motor assembly which moves the weld material to the welding device; a weighing device operatively connected to the soldering station computer and configured to measure a weight of the supply of solder material and to communicate the weight of the supply of solder material to the solder station computer in the form of weighting data; and a sensor operatively connected to the solder supply motor assembly and the soldering station computer so as to communicate the speed of the solder supply motor assembly to the solder station computer as speed data; where the soldering station computer is operatively connected for mounting the solder supply motor and is configured to control motor assembly speed 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 solder material for the first time; measuring, using the weight measuring device, a second weight of the supply of solder material at a second time later than the first time; calculate, using a computer, a difference in measured weight between the first weight and the second weight, the difference in measured weight corresponding to the measured weld material used; calculating, using the computer, a theoretical weight of the used weld material based on the speed of a motor assembly that feeds the weld material to a welding device; comparing, by computer, the theoretical weight of the solder material used with the measured weight of the solder material used; and adjusting, by the computer, the speed of the power train so as to correct for a slip of the power train.

[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 welding station computer and a welding system in communication with the welding station computer, each welding station including one or more sensors, one or more sensors configured to measure weld data including lead wire speed data; a plurality of wireless devices in communication with one or more of the computers of the soldering station to receive the soldering data, including the measured lead wire speed data; and each soldering station computer is configured to process the soldering data, including the binding wire speed data, to the soldering system in communication therewith, the soldering station computer configured to determine a quantity of material of consumable welding used by the welding system for a set period of time and generating consumption data based on that.

[0054] One aspect of the present patent application provides a system for pipe testing. The system includes a testing device adapted to generate non-destructive test data with respect to at least a weld portion; said testing device communicating said non-destructive test data to a second device that is adapted to receive said non-destructive test data; and said testing device adapted to operate remotely from a means for analyzing said non-destructive test data.

[0055] One aspect of the present patent application provides a system for non-destructive pipe testing. The system includes imaging equipment adapted to generate non-destructive test data with respect to a portion of a welded tube; a remote processing device adapted to receive and process inspection data in relation to said portion of said welded tube.

[0056] One aspect of the present patent application provides a non-destructive pipe testing method. The method includes the steps of: providing an imaging equipment; generate non-destructive test data; providing a means to provide said non-destructive test data for analysis; and said non-destructive test data provided for analysis at a remote location of the tested portion of a tube and the equipment near the tested portion of a tube.

[0057] One aspect of the present patent application provides a system for constructing piping. The system includes a system for real-time recording of weld data; and welding data is provided for analysis by computerized means and/or subject matter 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 medium that provides a computer memory with welding data; a computer-readable program code that supplies said memory with data from a data set comprising pipe data; a computer readable program code that processes said weld data and said pipe data to provide a log output.

[0059] One aspect of the present patent application provides a method of data management running on a computer. The method includes the steps of: communicating first data from a first device to a second device, said first data being data relating to a pipeline construction; processing said first data by a cloud-based network means.

[0060] One aspect of the present patent application provides a welding computer. The system includes a first device having a processor that processes pipeline construction data, the first device communicating said pipeline construction data to a cloud-based memory, said pipeline construction data processed by a processor based on the a cloud.

[0061] These and other aspects of the present patent application, as well as the methods of operation and function of the related elements of structure and the combination of parts and manufacturing economies, will become more apparent when considering the following description and the appended claims with reference to the accompanying figures, all of which form a part of this descriptive report, in which reference numerals designate corresponding parts in the various figures. In one embodiment of the present application, the structural components illustrated in this document are drawn to scale. It is to be expressly understood, however, that the figures are for illustrative and descriptive purposes only and are not intended as a definition of the limits of the present application. It should also be appreciated that features of one modality described in this document can be used in other modalities described in this document. As used in the specification and claims, the singular forms of "a", "an" and "the" include plural referents, unless the context clearly indicates otherwise. Furthermore, as used in the specification and 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 in this document may be discussed in connection with only one (single) of such components and that additional components that may be disclosed in this document cannot be discussed in detail because of redundancy reduction. For example, when a single welding torch head is described, the same configuration can be used for additional welding torch heads provided in the same system (for example, in an internal welding system) and can also be used in other systems. (such as internal plug-in welders) described in this document. Similarly, various components such as clamps, seals, brakes, solder consumption detection systems or other components described in this document can be used, with various embodiments described in this document. For example, the braking system, motors, clamping seals, as described in one embodiment, can be applied to other embodiments described in this document, as will be appreciated by experts in the art.

BRIEF DESCRIPTION OF THE FIGURES

[0062] FIGS. 1A and 1B show block diagrams of a method for welding pipe segments, in which FIG. 1A shows a high-level block diagram of the method and FIG. 1Bshows a more detailed block diagram description of the method, in accordance with an embodiment of the present patent application;

[0063] FIG. 2 shows a cross-sectional view of a weld joint connecting a first tube and a second tube according to an embodiment of the present patent application;

[0064] FIGS. 2A and 2B show bevel details for a single pipe segment and for a joint (before welding) between two pipe segments in accordance with an embodiment of the present application;

[0065] FIGS. 2C-2F show a front view, a perspective view, a side view, and a detailed view of a bevel gauge used to calibrate the tube bevel in accordance with an embodiment of the present application;

[0066] FIGS. 2G-2I show cross-sectional views of pipes with solder joints formed between their pipes, where FIG. 2G shows a solder joint in which the root pass and hot pass layers are formed by an inner solder system and the filler and finish solder layers are formed by an outer solder system, FIG. 2H shows a solder joint in which a root pass solder layer is formed by an inner solder system and the heat pass, filler, and finish solder layers are formed by an outer solder system, and FIG. 2I shows a solder joint formed by an external soldering system in accordance with an embodiment of the present patent application;

[0067] FIGs. 3-7 show block diagrams of methods for welding pipe segments for different welding situations according to an embodiment of the present application;

[0068] FIGS. 7A and 7B show views of an external clamp being used to secure the tubes together from the outside in accordance with one embodiment of the present application;

[0069] FIG. 8 shows a perspective view of a system for welding two segments of tubes according to 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;

[0071] FIG. 9A shows a partial cross-sectional view of tubing in which an ideal alignment of a welding torch to an inner bevel (along longitudinal axes of the tubes) in accordance with an embodiment of the present application;

[0072] FIG. 10-1 shows the system of FIG. 8 in which an internal welding system is inserted into a first segment of tube in accordance with an embodiment of the present patent application;

[0073] FIGs. 10-2 and 10-3 show the system of FIG. 8 wherein the internal soldering system is inserted into the first tube segment and a second tube segment is being aligned with the first tube segment in accordance with an embodiment of the present application;

[0074] FIGS. 10A and 10B show views of the inner welding system being constructed and arranged to be positioned on tubes with an outer diameter of 26 to 28 inches outside diameter and on tubes with an outside diameter of less than 24 inches, respectively, according to one embodiment of the present patent application;

[0075] FIGS. 10C and 10D show a left side perspective view and a bottom perspective view of a support for transporting and moving the first tube and second tube according to an embodiment of the present application;

[0076] FIGS. 10E and 10F show two pipe alignment errors, while FIG. 10E shows an angular tube alignment error and FIG. 10F shows a position tube alignment error;

[0077] FIG. 11 shows the internal welding system for welding two segments of tubes according to an embodiment of the present patent application;

[0078] FIG. 11A shows a view of an umbilical operatively connected to the inner welding system in accordance with an embodiment of the present application;

[0079] FIG. 12 shows a detailed view of a further section of the inner welding system according to an embodiment of the present patent application;

[0080] FIGs. 13-22 show views of various components of the forward section of the internal welding system in accordance with an embodiment of the present patent application;

[0081] FIG. 22A shows an example of a coil with solder wire according to an embodiment of the present patent application;

[0082] FIG. 22B shows an example solder 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 central section of the inner welding system according to an embodiment of the present patent application;

[0084] FIGs. 25-31 show views of various components of the forward section of the internal welding system in accordance with an embodiment of the present patent application;

[0085] FIGS. 32A and 32B show side and top views of a drive section of the internal welding system according to an embodiment of the present patent application;

[0086] FIG. 33 shows a view of the center section of the inner welding system being positioned within 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 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 inner welding system being positioned within the pipe segments, where some components of the center section are not shown for clarity, according to an embodiment of the present patent application;

[0088] FIG. 35 shows a view of the center section of the inner welding system being positioned within the pipe segments, where only the clamps are engaging the inner surfaces of the pipes and where some components of the center section are not shown for clarity, accordingly with an embodiment of the present patent application;

[0089] FIGS. 35A and 35B show cross-sectional views of the center section of the internal welding system, where the clamps are in their extended and retracted positions, respectively, and where some components of the center section are not shown for reasons of clarity, in accordance with an embodiment of the present. patent application;

[0090] FIG. 35C shows a side (front) view of the inner welding system in accordance with an embodiment of the present patent application;

[0091] FIG. 36 shows a view of a clamp of the inner welding system according to an embodiment of the present patent application;

[0092] FIG. 37 shows a view of a spider member of a clamp of the inner welding system in accordance with an embodiment of the present patent application;

[0093] FIG. 38 shows a view of a shoe clamp member of the inner welding system in accordance with an embodiment of the present patent application;

[0094] FIGs. 39 and 40 show views of a clamp hub of the inner welding system with the shoe clamp member and the connecting member attached 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 inner welding system in accordance with an embodiment of the present application;

[0096] FIG. 43 shows another rear perspective view of the weld head assembly internal welding system in which a welding torch of the weld head assembly has been raised to a desired welding position, in accordance with an embodiment of the present application;

[0097] FIGs. 44-46 show a left side perspective view, a perspective view and a sectional view of the solder head assembly, in which some components of the solder head assembly are not shown for the sake of clarity, according to a modality of the present patent application;

[0098] FIGs. 47, 48 and 49 show perspective views of the welding head assembly, where the welding torch is positioned, by an axial positioning system, in its axial position centered in FIG. 47, and the welding 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 expanded view of the solder head assembly, in which some components of the solder head assembly are not shown for the sake of clarity, in accordance with an embodiment of the present application. ;

[0100] FIG. 52 shows a bottom perspective view of an upper positioning member of the solder head assembly in accordance with an embodiment of the present application;

[0101] FIG. 53 shows a top elevation view of the solder head assembly, in which some components of the solder head assembly are not shown for the sake of clarity, in accordance with an embodiment of the present application;

[0102] FIG. 54 shows a cross-sectional view of the welding head assembly, wherein the welding torch is positioned in a normal, uninclined position in accordance with an embodiment of the present application;

[0103] FIGs. 55 and 56 show a rear perspective view and a sectional view of the welding head assembly, respectively, in which the welding torch is positioned by a tilt positioning system to +5° angular tilt according to an embodiment. of the present patent application;

[0104] FIG. 56A shows a cross-sectional view of the solder head assembly in accordance with an embodiment of the present patent application.

[0105] FIGs. 57 and 58 show a rear perspective view and a sectional view of the welding head assembly, respectively, in which the welding torch is positioned by a tilt positioning system to -5° angular tilt according to an embodiment. of the present patent application;

[0106] FIG. 59 shows an exploded view of the solder head assembly, in which some components of the solder head assembly are not shown for the sake of clarity, in accordance with an embodiment of the present application;

[0107] FIGS. 60A-63 show schematic views of the internal welding system with a welding torch, an inspection camera and two inspection detectors in accordance with an embodiment of the present application;

[0108] FIGs. 64-69 show schematic views of the internal welding system with two welding torches, an inspection chamber and an inspection detector in accordance with an embodiment of the present application;

[0109] FIG. 70 shows a schematic diagram showing the flow of compressed air through the internal soldering system in accordance with an embodiment of the present application;

[0110] FIG. 71 shows a schematic diagram showing energy flow including solder energy, communication data and control data through the internal soldering system in accordance with an embodiment of the present patent application;

[0111] FIG. 72 shows a schematic diagram showing the flow of shielding gas through the internal welding system in accordance with an embodiment of the present application;

[0112] FIGS. 72A, 72B and 72C show close-up views of an inner welding torch used in a prior art system and the inner welding system, respectively, where the tubes have a space and radial displacement (Hi¬Lo) alignment;

[0113] FIG. 72D shows exemplary welding parameters that are used for up and down welding procedures in accordance with an embodiment of the present application;

[0114] FIG. 73 shows a perspective view of a system for welding two externally aligned tube segments supported on alignment mechanisms in accordance with an embodiment of the present patent application;

[0115] FIG. 74 shows an enlarged outside 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;

[0116] FIG. 75 shows the system in which a solder system is inserted into a tube segment in accordance with an embodiment of the present patent application, wherein one of the tube segments is not shown for clarity;

[0117] FIG. 76 shows an enlarged view of a section of FIG. 75 showing a solder portion of the soldering system positioned to solder to a pipe segment in accordance with an embodiment of the present patent application, wherein one of the pipe segments is not shown for clarity.

[0118] FIG. 77 shows a cross-sectional view of FIG. 76 taken along axis BB showing the arrangement of various members of the solder portion according to an embodiment of the present application;

[0119] FIGs. 78 and 79 show side views of the welding system of FIG. 75, in which the tube segment is not shown for clarity, in accordance with an embodiment of the present application;

[0120] FIG. 80 shows a perspective view of the system of FIG. 73 in an embodiment showing a first procedure in which a segment of tube is placed in an external alignment mechanism in accordance with an embodiment of the present application;

[0121] FIG. 81 shows a perspective view of the system of FIG. 73 in a configuration showing a procedure subsequent to FIG. 80 wherein the soldering system is inserted into a pipe segment in accordance with an embodiment of the present application;

[0122] FIG. 82 shows a side view of the solder portion of the system of FIG. 73 in accordance with an embodiment of the present patent application;

[0123] FIG. 83 shows an enlarged perspective view of a section of the solder portion of the system of FIG. 73 in accordance with an embodiment of the present patent application;

[0124] FIG. 84 shows another enlarged perspective view of a section of the solder portion of the system of FIG. 73 in accordance with an embodiment of the present patent application;

[0125] 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;

[0126] FIG. 86 shows a purge and inspection system in accordance with an embodiment of the present patent application;

[0127] FIG. 87 shows a detailed view of a further section of the purge and inspection system according to an embodiment of the present patent application;

[0128] FIG. 88 shows a purge assembly and inspection system in accordance with an embodiment of the present patent application;

[0129] FIGs. 89 and 90 show a front view and a cross-sectional view of a central section of the purge and inspection system in accordance with an embodiment of the present patent application;

[0130] FIG. 91 shows a purge seal and inspection system in accordance with an embodiment of the present patent application;

[0131] FIG. 92 shows the rotating hub of the purge and inspection system in accordance with an embodiment of the present patent application;

[0132] FIG. 93 shows a detailed view of an actuation section of the purge and inspection system according to an embodiment of the present patent application;

[0133] 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 application;

[0134] 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;

[0135] FIG. 96 shows a schematic diagram showing the flow of purge gas through the purge and inspection system in accordance with an embodiment of the present application;

[0136] FIG. 97 shows a partial view of a purge and inspection system according to an embodiment of the present patent application;

[0137] FIG. 98 shows a close-up view of an external welding torch of an external welding system used in the purge and inspection system in accordance with an embodiment of the present application;

[0138] FIGs. 99 and 100 show close-up views of the external welding torch of the external welding system used in a prior art system and the purge and inspection system, respectively, where the tubes have a clearance and radial displacement (Hi-Lo) alignment;

[0139] FIG. 101 shows a plug-in soldering system in accordance with an embodiment of the present application;

[0140] FIG. 102 shows a detailed view of a power section plug-in internal welding system in accordance with an embodiment of the present patent application;

[0141] FIG. 103 shows a schematic diagram showing energy flow including solder energy, communication data and control data through the internal plug-in soldering system in accordance with an embodiment of the present patent application;

[0142] FIGS. 103A shows a cross-sectional view of the center section of the internal plug-in welding system, where the clamps are in their retracted positions, and where some components of the center section are not shown for reasons of clarity, in accordance with an embodiment of the present application;

[0143] FIG. 103B shows a method for aligning two tubes, pre-inspecting an interface region between the two tubes to be welded end to end, welding the two tubes together, post-welding inspecting the weld joint formed between the two tubes in accordance with an embodiment of the present patent application;

[0144] FIG. 103C shows a side view of a plug-in soldering system in accordance with another embodiment of the present application;

[0145] FIG. 103D shows a perspective view of the plug-in soldering system according to another embodiment of the present patent application;

[0146] FIG. 103E shows a perspective view of the inset welding system of weld head assemblies according to another embodiment of the present application;

[0147] FIG. 103F shows a front view of the plug-in welding system of the weld head assemblies according to another embodiment of the present application;

[0148] FIGS. 103G-103J show a procedure in which one or more sets of weld heads are operated in a clockwise and counterclockwise direction to perform a welding operation on the plug-in welding system in accordance with another embodiment of the present application;

[0149] FIG. 104 shows a perspective view of an exemplary internal cooling system for use in pipe welding in accordance with an embodiment of the present application;

[0150] FIG. 105 shows a perspective view of the internal cooling system of FIG. 104 immediately prior to insertion into an end of a tube section in accordance with an embodiment of the present application;

[0151] FIG. 106 shows a perspective view of the internal cooling system of FIG. 104 located within a first section of pipe that is secured via a solder joint to a second section of pipe in accordance with an embodiment of the present application;

[0152] FIG. 107 shows another view of FIG. 106 wherein the internal cooling system is located within the first and second pipe segments at a suitable location relative to the solder joint to facilitate internal cooling in the solder joint in accordance with an embodiment of the present application;

[0153] FIG. 108 shows a perspective view of the internal cooling system of FIG. 104 connected with a snap clamp in accordance with an embodiment of the present patent application;

[0154] FIG. 109 shows a perspective view of the internal cooling system of FIG. 104 connected with a snap clamp in accordance with another embodiment of the present patent application;

[0155] FIGS. 110A and 110B show perspective and partial perspective views, respectively, of the internal cooling system for use in pipe welding in accordance with another embodiment of the present application;

[0156] FIGS. 111A and 111B show partial perspective views of portions of the internal cooling system for use in pipe welding in accordance with another embodiment of the present application, wherein the portion of the internal heat exchanger is within two tube segments secured to each other. to others by means of a solder joint and a water pump is provided at the end of a portion of a pipe section;

[0157] FIGS. 112A and 112B show partial perspective views of portions of the internal cooling system for use in pipe welding in accordance with another embodiment of the present application, in which the portion of the internal heat exchanger is within two tube segments secured to a with the other through a solder joint and a water pump is provided at the end of a portion of a pipe section;

[0158] FIG. 113 shows a cross-sectional view of tubes with exposed metal tube ends aligned in accordance with an embodiment of the present application;

[0159] FIG. 114 shows a cross-sectional view of tubes with the solder joint formed between their exposed metal tube ends in accordance with an embodiment of the present application;

[0160] FIGS. 115A and 115B show a sectional view and a perspective view of the tubes with the solder joint formed between their exposed metal tube ends and a heater positioned on the tubes to heat the exposed end portions of the welded tubes, respectively. with an embodiment of the present patent application;

[0161] FIGS. 116A and 116B show a sectional view and a perspective view of the tubes with the solder joint formed between their exposed metal tube ends and a supply of insulator positioned on the tubes to apply an insulating material to the heated exposed end portions of the tubes. welded, respectively, in accordance with an embodiment of the present patent application;

[0162] FIGS. 117A and 117B show a sectional view and a perspective view of the tubes with the solder joint formed between their exposed metal tube ends and a supply of insulator positioned on the tubes to apply an insulating material to the heated exposed end portions of the tubes. soldiers, in accordance with one embodiment of the present patent application;

[0163] FIG. 118 shows a cross-sectional view of the tubes with the solder joint formed between their exposed metal tube ends and an insulator adhered to the outer surface of the metal tube interior, thereby isolating the previously exposed end portions of the tubes in accordance with an embodiment of the present patent application;

[0164] FIG. 119 shows a perspective view of a cooling system configured to apply cooling energy to an interior surface of the tubes to facilitate cooling of the tubes after insulating material is applied in accordance with an embodiment of the present application;

[0165] FIG. 120 shows a partial cross-sectional view of the cooling system being positioned within the tubes in accordance with an embodiment of the present application;

[0166] FIGs. 121 and 122 show partial and cross-sectional views of the cooling system being positioned within the tubes, where FIG. 121 shows a cooling system heat exchanger placed in contact with the inner surface of the welded tubes to remove heat from the welded tubes, and FIG. 122 shows that the heat exchanger is in its retracted position and is not in contact with the inner surface of welded tubes in accordance with an embodiment of the present patent application;

[0167] FIG. 123 shows a perspective view of the cooling system, in which fluid nozzles configured to apply a coolant to the inner surface of the welded tubes to remove heat from the welded tubes are shown in accordance with another embodiment of the present application. ;

[0168] FIGs. 124 and 125 show a perspective view and a front view of a heat exchanger element or a fin member of the cooling system according to another embodiment of the present patent application;

[0169] Figures 126-128 show perspective views of a system that is configured to facilitate the placement of the cooling system within and/or removal of the tube refrigeration system according to another embodiment of the present patent application;

[0170] FIG. 129 shows a partial perspective view of the cooling system, in which a plurality of rollers configured to engage the inner surface of one or more of the tubes and a drive motor configured to drive the rollers to move a frame assembly of the assembly. cooling systems are shown in accordance with another embodiment of the present application;

[0171] FIG. 130 shows a perspective view of a cooling system according to another embodiment of the present patent application;

[0172] FIG. 131 shows a top view of an engine power source carried by the frame assembly of the cooling system in accordance with another embodiment of the present patent application;

[0173] FIG. 132 shows a cooling system heat exchanger positioned in contact with the inner surface of the welded tubes to remove heat from the welded tubes in accordance with another embodiment of the present application;

[0174] FIGs. 133 and 134 show perspective views of a cooling system according to another embodiment of the present patent application;

[0175] FIGs. 135 and 136 show a perspective view and a partial cross-sectional view of a cooling system according to another embodiment of the present application;

[0176] FIG. 136A shows a perspective view of an ultrasound inspection station that is configured to inspect the weld between welded metal tubes in accordance with an embodiment of the present application;

[0177] FIG. 136B shows a method showing procedures for deploying tubing in accordance with an embodiment of the present patent application;

[0178] FIGS. 136C and 136D show schematic views of the S-shaping procedure and the J-shaping procedure according to one embodiment of the present application;

[0179] FIG. 136E shows S-shape and J-shape release barges in accordance with one embodiment of the present application;

[0180] FIG. 137A shows a system for facilitating the testing of the field system or its operations under another embodiment of the present application;

[0181] 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 application;

[0182] FIG. 137C shows communication links between the remote computer system and field system components without the field computer system in accordance with another embodiment of the present application;

[0183] FIG. 138 shows a flowchart of a method for facilitating, by a field system, field trials and physical operations based thereon in accordance with another embodiment of the present application;

[0184] FIG. 139-142 show flow diagrams of methods for facilitating, by a computer system, field tests and physical operations based thereon in accordance with other embodiments of the present application;

[0185] FIG. 143 represent an example of a tubing according to another embodiment of the present patent application;

[0186] FIG. 144 shows a soldering station in accordance with another embodiment of the present application;

[0187] FIG. 145 show a plurality of pipe welding stations in accordance with another embodiment of the present patent application;

[0188] FIG. 146 is a schematic diagram of a system with a plurality of soldering stations in communication with a plurality of control and record collection stations in accordance with another embodiment of the present application;

[0189] FIG. 147 is a schematic diagram of a system with a plurality of soldering stations in communication with a plurality of control and recording collection stations in accordance with another embodiment of the present application;

[0190] FIG. 148 is a schematic diagram of the soldering station in communication with a network via a WiFi connection in accordance with another embodiment of the present application;

[0191] FIG. 149 is a schematic diagram of a plurality of workplaces in communication with a cloud server over a worldwide network (internet) in accordance with another embodiment of the present application;

[0192] FIG. 150 is a schematic diagram of a plurality of soldering stations in communication with intermediate computing devices (technicians, inspectors, engineers, etc.) which in turn are in communication with a cloud server over the internet according to another modality of the present patent application;

[0193] FIG. 151 is a schematic diagram of a plurality of soldering stations in communication with an intermediate computer system (engineering, quality and technology terminals) via a wireless communication channel (eg WiFi) according to another modality of the present patent application;

[0194] FIG. 152 is a schematic diagram of a plurality of soldering stations in communication with a computer system via a wireless communication channel (e.g., WiFi) in accordance with another embodiment of the present application;

[0195] FIG. 153 is a schematic diagram of a plurality of soldering stations in communication with a plurality of intermediate computer systems (engineering, quality and technology terminals) which in turn are in communication with a cloud server, in accordance with an embodiment of the present. invention;

[0196] FIG. 154 shows an example graphical user interface ("GUI") for a "home screen" of a cloud-based universal data logging (uLog) application implemented by a computer system in the welding station, in the intermediate computer system or on the cloud server in accordance with another embodiment of the present patent application;

[0197] FIG. 155 shows an example GUI for a "Live Log" screen of the cloud-based universal data logging (uLog) application showing voltages versus time at a welding station according to another embodiment of the present application;

[0198] FIG. 156 shows a GUI example for a "Get Log" screen of the cloud-based universal data logging (uLog) application that shows the weld data parameters including weld event type, time, zone, travel speed welding, transmission speed of the main wire according to another embodiment of the present patent application;

[0199] FIG. 157 shows an example GUI for a cloud-based universal data logging (uLog) application summary report screen displaying various weld parameters including weld time, weld station identification number, weld arc voltage, etc., according to another embodiment of the present patent application;

[0200] FIG. 158 shows an example GUI for a "Save Data on Log" screen of the cloud-based universal data logging (uLog) application displaying various according to another embodiment of the present patent application;

[0201] FIG. 159 shows an example GUI for an "Analytics" screen of the application for universal data logging (uLog) showing two icons to select a type of analysis performed (eg trends, moving average) according to another modality of the present patent application;

[0202] FIG. 160 shows an example GUI for a "Welding Parameter" screen of the application for universal data logging (uLog) showing two variants for selecting a type of function to be performed according to another embodiment of the present patent application;

[0203] FIG. 161A schematically depicts an example of a spool that is configured to carry a solder wire in accordance with another embodiment of the present application;

[0204] FIG. 161B schematically represents a side view of a hub transducer that is configured to measure a coil weight in accordance with another embodiment of the present patent application;

[0205] FIG. 161C is another side view of the transducer-hub showing the placement of transducer elements or strain sensors/meters for measuring weight tension when the coil is mounted on the hub in accordance with another embodiment of the present application;

[0206] FIG. 162 schematically depicts an arrangement in which a solder wire on the hub mounted spool is pulled by a motor assembly to feed wire 82 to the solder device (not shown) in accordance with another embodiment of the present application;

[0207] FIG. 163 is a flow diagram describing a method of comparing measured weight and determined theoretical weight based on yarn feed speed in accordance with another embodiment of the present application;

[0208] FIGS. 164A and 164B represent enlarged lateral cross-sections of the motor assembly according to another embodiment of the present patent application;

[0209] FIG. 165 is a diagram of a welding system configuration representing the interconnections of various system components in accordance with another embodiment of the present application;

[0210] FIG. 166 shows an overview of the non-destructive testing system in accordance with another embodiment of the present patent application;

[0211] FIG. 167 shows a generic embodiment of a non-destructive testing system in accordance with another embodiment of the present application;

[0212] FIG. 168 shows an ultrasonic testing embodiment of a non-destructive testing system in accordance with another embodiment of the present application; and

[0213] FIG. 169 shows a radiographic test embodiment of a non-destructive test system in accordance with another embodiment of the present application. DETAILED DESCRIPTION

[0214] FIGS. 1A and 1B show block diagrams of a method 1000 for welding sections or segments of pipe 1022 (for example, 1022a and 1022b as shown in Figure 2) of a pipe 1024 (as shown in Figure 2) together. For example, FIG. 1A shows a high-level block diagram of method 1000, while FIG. 1B shows a more detailed description of the block diagram of method 1000.

[0215] FIG. 2 shows a cross-sectional view of a solder joint 1026 connecting tube segments 1022 (e.g., 1022a and 1022b) of tubing 1024. Tube segments 1022 (e.g., 1022a and 1022b) may interchangeably referred to. in this document as tubes or tube sections. In one embodiment, solder joint 1026 is a complete circumferential solder that connects tube segments 1022 (e.g., 1022a and 1022b) end-to-end circumferentially. In one embodiment, the weld joint 1026 may be referred to as a circumference weld or an butt weld. In one embodiment, as described in detail below, tube segments 1022a and 1022b are welded together at their beveled end portions.

[0216] In one embodiment, the first tube segment 1022a and the second tube segment 1022b are at least 30 feet long. In one embodiment, first tube segment 1022a and second tube segment 1022b are at least 31.5 feet long. In one embodiment, first tube segment 1022a and second tube segment 1022b are at least 33 feet long. In one embodiment, first tube segment 1022a and second tube segment 1022b are at least 34.5 feet long. In one embodiment, first tube segment 1022a and second tube segment 1022b are at least 36 feet long.

[0217] In one embodiment, the first segment of tube 1022a and the second segment of tube 1022b have an outside diameter of 24 inches or less. In one embodiment, the outside diameter of the tube segment may also be referred to as the outside diameter of the tube segment.

[0218] In one embodiment, the first segment of tube 1022a and the second segment of tube 1022b have a nominal outside diameter of 24 inches or less. In one embodiment, first tube segment 1022a and second tube segment 1022b each have an outside diameter of 24.1875 inches or less. In one embodiment, first tube segment 1022a and second tube segment 1022b have an outside diameter of 23.8125 inches or less.

[0219] In one embodiment, the first segment of tube 1022a and the second segment of tube 1022b have an outside diameter of 22.8 inches or less. In one embodiment, first tube segment 1022a and second tube segment 1022b have an outside diameter of 21.6 inches or less. In one embodiment, first tube segment 1022a and second tube segment 1022b each have an outside diameter of 20.4 inches or less. In one embodiment, first tube segment 1022a and second tube segment 1022b each have an outside diameter of 19.2 inches or less.

[0220] In one embodiment, the first segment of tube 1022a and the second segment of tube 1022b each have an outside diameter in the range of 26 to 28 inches.

[0221] In one embodiment, the first tube segment 1022a and the second tube segment 1022b are made of a metal material. In one embodiment, first tube segment 1022a and second tube segment 1022b are made of a carbon steel material. In one embodiment, the first tube segment 1022a and the second tube segment 1022b are made of an alloy steel material. In one embodiment, first tube segment 1022a and second tube segment 1022b are made of a low-alloy steel material. In one embodiment, first tube segment 1022a and second tube segment 1022b are made of a stainless steel material. In one embodiment, the first tube segment 1022a and the second tube segment 1022b may be made of an American Petroleum Institute (API) 5L grade X52 specification material (i.e., 52000 PSI of minimum drag force and 66000 PSI of minimum tensile strength). In one embodiment, the first tube segment 1022a and the second tube segment 1022b can be made of an API 5Lgrade X60 (that is, 60000 PSI minimum tensile strength and 75000 PSI minimum tensile strength).

[0222] In one embodiment, the first segment of tube 1022a and the second segment of tube 1022b may be made completely or in part from a corrosion resistant alloy (CRA). In one embodiment, the corrosion resistant alloy can include both iron-based alloys, such as various grades of stainless steel or nickel-based alloys (ie, typically known by the trade name, Inconel).

[0223] In one modality, some CRA materials may require shielding gas on both sides of the weld. In one embodiment, in such a case, a purge and inspection system 7001 (as will be described in detail in relation to FIGS. 86-100) may be used within tubes 1022a, 1022b to provide an inward purge gas chamber ( at the interface region) of the tubes to be welded and an external welding system 7500 (as shown in Figure 97) can be used outside the tubes 1022a, 1022b. In one embodiment, the 7500 external welding system can be configured to supply shielding gas to the outside (eg at the joint of) of the pipes to be welded.

[0224] In one embodiment, the first tube segment 1022a and the second tube segment 1022b may be made of the same material. In one embodiment, the first tube segment 1022a and the second tube segment 1022b can be made of different materials.

[0225] In one embodiment, the first tube segment 1022a and the second tube segment 1022b may be made of bi-metallic materials, wherein the inner portion of the tube segment is an ARC material and the outer portion of the tube segment is tube can be carbon steel or a different CRA material than the inner part.

[0226] In an embodiment as shown in FIG. 2G, first tube segment 1022a and second tube segment 1022b include a metallic tube interior 5244 surrounded by an insulator/liner material 5246. In one embodiment, the end portions of the first tube segment 1022a and the second Tube segment 1022b to be welded has the 5246 insulator/liner material removed and the inside of the 5244 metal tube exposed.

[0227] In one embodiment, the first tube segment 1022a and the second tube segment 1022b may be coated on their outer surface with a coating/corrosion resistant material when the first tube segment 1022a and the second tube segment 1022b they are used in corrosive environments (eg sea/salt water/ocean, chemical, etc.). In one embodiment, first tube segment 1022a and second tube segment 1022b may be coated on their outer surface with a coating/wear resistant material. In one embodiment, the first tube segment 1022a and the second tube segment 1022b may be coated on their outer surface with a coating/insulator material. In one embodiment, the first tube segment 1022a and the second tube segment 1022b may be coated on their inner surface with the coating/corrosion resistant material, the coating/wear resistant material, the coating/insulator material or a combination of these. In one embodiment, the first tube segment 1022a and the second tube segment 1022b may be coated on their inner and outer surfaces with the coating material/corrosion resistant, the coating material/wear resistant, the coating material/ insulator or a combination thereof.

[0228] In one embodiment, as shown in FIGS. 2A and 2B, one end 1038a of tube 1022a is welded to a second end 1038b of tube 1022b. In one embodiment, end 1038a of tube 1022a has an inner bevel surface 5228 and an outer bevel surface 5230. In one embodiment, end 1038b of tube 1022b has an inner bevel surface 5232 and an outer bevel surface 5234. In one embodiment, as will be clear from the discussions below, a root pass solder layer of solder material is disposed in an IBR region defined by the first inner bevel surface 5228 and the second inner bevel surface 5232 when it is used an internal solder system 5004 for depositing the root pass solder layer of tubes 1022a, 1022b.

[0229] In one embodiment, outer bevel surfaces 5230 and 5234 may each include first outer bevel surfaces 5230a and 5234a and second outer bevel surfaces 5230b and 5234b, respectively. In one embodiment, the first outer bevel surfaces 5230a and 5234a are beveled at an angle EB1 with respect to an axis NN that is perpendicular to a longitudinal axis AA of the tube segments 1022a, 1022b. In one modality, the EB1 angle can be 5°.

[0230] In one embodiment, the second outer bevel surfaces 5230b and 5234b are chamfered at an angle EB2 with respect to the NN axis. In one modality, the EB2 angle is greater than the EB1 angle. In one modality, the EB2 angle can be 45°.

[0231] In one embodiment, outer bevel surfaces 5230 and 5234 may include a single bevel surface. In one embodiment, outer bevel surfaces 5230 and 5234 may include a single continuous surface having a J-shaped configuration.

[0232] In one embodiment, the inner bevel surfaces 5228 and 5232 are chamfered at an angle IB with respect to the NN axis. In one embodiment, the IB angle can be 37.5°. In one embodiment, the inner bevel surfaces 5228 and 5232 may have a distance B measured along the NN axis from the respective inner tube surfaces 5130 and 5132. In one embodiment, the distance B measured along the NN axis from of the respective inner tube surfaces 5130 and 5132 is 0.05 inches.

[0233] In one embodiment, the outer bevel surfaces 5230 and 5234 and the inner bevel surfaces 5228 and 5232 may be separated from each other by a non-conical surface. In one embodiment, the non-conical surface may have a distance NB measured along the NN axis. In one modality, the distance NB measured along the NN axis is 0.05 inches. In one embodiment, the non-tapered surface is optional and outer bevel surfaces 5230 and 5234 and the corresponding inner bevel surfaces 5228 and 5232 may be close to (and touch) each other.

[0234] In one embodiment, the inner bevel surfaces 5228 and 5232 of tube segments 1022a, 1022b may have the same bevel angle. In one embodiment, outer bevel surfaces 5230 and 5234 of tube segments 1022a, 1022b may have the same bevel angle(s). In another embodiment, the bevel angle of inner bevel surfaces 5228 and 5232 of tube segments 1022a, 1022b can be varied. In another embodiment, the bevel angle(s) of outer bevel surfaces 5230 and 5234 of tube segments 1022a, 1022b may vary.

[0235] In one embodiment, the B dimensions of the inner bevel surfaces, the NB dimension of the non-conical surface, and the bevel angles IB, EB1 and EB2 can vary and depend on the thickness T of the tube segments 1022a, 1022b.

[0236] In one embodiment, end 1038a of tube 1022a and end 1038b of tube 1022b are joined to have a solder groove 5236 formed therebetween. In one embodiment, solder groove 5236 may have a V-shaped cross section. In one embodiment, end 1038a of tube 1022a and end 1038b of tube 1022b are constructed and arranged to have J-shaped configurations such that the The solder 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 solder groove depends on the soldering parameters or conditions.

[0237] Referring to FIG. 2, in one embodiment, a solder material 1034 is configured to bond the first segment of tube 1022a and the second segment of tube 1022b. In one embodiment, solder material 1034 may include Inconel material or Inconel alloy material. In one embodiment, the weld material 1034 can include a material that has a higher strength than the material of the tubes. In one embodiment, the solder material 1034 may be a material other than the material of the tubes. For example, in one embodiment, the weld material can include Inconel material or Inconel alloy material and the material of the first tube segment 1022a and the second tube segment 1022b can include a stainless steel material.

[0238] In one embodiment, the solder material 1034 and/or the solder joint 1026 includes a plurality of pass solder layers 1014, 1016, 1018 and 1020. For example, in one embodiment, the plurality of solder layers 1014, 1016, 1018, and 1020 may include the root pass solder layer 1014, the hot pass solder layer 1016, one or more fill pass solder layers 1018, and the root pass solder layer 1020 finish as will be explained in detail below. The pass weld layer(s) may interchangeably, referred to in this document as the pass layer(s). In one embodiment, the weld pass (eg, root pass, heat pass, fill pass, finish pass) can be a single advance of the welding tool or welding system along the 1026 weld joint. In one embodiment, a weld bead or layer of weld is formed as a result of each weld pass.

[0239] In one embodiment, referring to FIGS. 1A, 1B and 2, 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 root pass weld procedure fill and finish 1006, a weld inspection procedure 1008, a heat process 1010, and a coating procedure 1012. In one embodiment, the fill and finish pass weld process 1006 may include one or more of the weld weld procedures. 1006a fill pass and a 1006b finish pass weld procedure. In one embodiment, method 1000 is generally a multi-pass or multi-layer soldering procedure that includes, for example, the root pass solder procedure 1002, the hot pass solder procedure 1004, and the solder procedure of filling and finishing 1006.

[0240] In one modality, one or more of the solder passes (for example, root pass, hot pass, fill pass, boundary pass) a multilayer soldering method or 1000 multipass soldering can be performed by the same. welding system or tool at different times. In one modality, the welding is carried out sequentially by the same welding system or tool. For example, in one embodiment, the root and hot-pass welding procedures can be carried out sequentially by an internal 5004 welding system (as will be described in detail below) from the interior of the tubes. In one embodiment, the fill and finish pass welding operations can be carried out sequentially by an external welding system 7500 from the outside of the tubes.

[0241] In one embodiment, the inner welding system 5004 is generally configured to weld the tube segments 1022a and 1022b from the interior of the pipe 1024 and the outer welding system 7500 is generally configured to weld the tube segments 1022a and 1022b from the outside of the tubing 1024. In one embodiment, welding performed by the 5004 internal welding system may result in a K-shaped weld bead or layer and welding performed by the 7500 external welding system may result in a K-shaped weld bead or layer of J.

[0242] In one modality, the finish and fill pass welding procedures can be performed sequentially by the 7500 external welding system from the outside of the tubes, while only the root pass welding procedure is performed by the welding system 5004 (as will be described in detail below) of the inside of the tubes.

[0243] In an embodiment, one or more of the weld passes (eg, root pass, hot pass, fill pass(s), finish pass) of the 1000 multipass or multilayer welding method can be performed by different welding systems or tools at the same or different times. In one embodiment, solder passes can be carried out sequentially by different soldering systems or tools.

[0244] In one modality, each of the hot fill and finish pass soldering procedures can be performed on its corresponding solder bar from the outside of the tubes. In one embodiment, the welding tent is a relatively small compartment, for example, about 12 feet wide, 10 feet long and 8 feet high, where an external welding system is assembled and transported from a pipe joint to the next by a rear platform. The welding tent is typically a light metal frame covered with thin sheets. The welding tent has a special floor designed to swivel up to allow the welding tent to be lowered onto the pipes and then swivel down to allow easy access to the pipe. In one embodiment, each of the one or more fill pass soldering procedures can be performed on different soldering tents each having an external soldering system.

[0245] In one embodiment, the 1002 root pass welding procedure is the first welding procedure of the 1000 multipass or multilayer welding method. In one embodiment, the 1002 root pass welding procedure is performed by the system of internal weld 5004. In one embodiment, the root pass weld procedure 1002 may be performed by an internal socket weld system 3001 (as will be described in detail below) with onboard weld power.

[0246] In one embodiment, the 1002 root pass soldering procedure, when performed with the 5004 internal soldering system, can take up to 1.03 minutes. In one modality, the cycle time for the root pass weld procedure is 4 minutes (this time is calculated from when a reach rod or a 5034 umbilical is set to auto travel). In one embodiment, the total cycle time for three cycles of the root pass soldering procedure (performed by the 5004 internal soldering system) is 13.15 minutes (including a 2.30 minute time for the changeover procedure wire/coil) and the average cycle time for the root pass welding procedure (performed by the 5004 internal welding system) is 4.42 minutes.

[0247] In one embodiment, the 1002 root pass welding procedure can be performed by an external 7500 welding system. In one embodiment, the 1002 root pass welding procedure can be performed by the 7500 external welding system with the 7001 purge and inspection system. In one embodiment, the 1002 root pass welding procedure can be performed by the external welding system with internal snap-on clamps. In one embodiment, the root pass welding procedure 1002 can be performed by the external welding system 7500 with internally disposed clamps 7050, 7052. In one embodiment, the internally disposed clamps can be standard clamps or bleed clamps (e.g., the purge and inspection system 7001).

[0248] In one embodiment, the root pass solder procedure 1002 forms the root pass solder layer 1014. In one embodiment, as shown in FIGS. 1A 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 ruler or root sealant layer. In one embodiment, the 1002 root pass welding process is performed by gas metal arc welding (GMAW). In one embodiment, the 1002 root pass welding procedure is performed by Tungsten Gas Arc Welding (GTAW). In one embodiment, the 1002 root pass welding procedure is performed by short circuit gas metal arc welding (GMAW-S). In another embodiment, the root pass welding procedure 1002 is performed by other welding processes as would be appreciated by one of ordinary skill in the art.

[0249] In one embodiment, the 1004 hot pass welding procedure is the second welding procedure of the 1000 multipass or multilayer welding method. In one embodiment, the 1004 root pass welding procedure is performed by the system of internal welding 5004. In one embodiment, the hot pass welding process 1004 can be performed by the internal plug-in welding system 3001 with on-board welding power.

[0250] In another embodiment, the hot pass welding process 1004 is performed by the external welding system 7500. In one embodiment, the hot pass welding procedure 1004 is performed by the external welding system with internally arranged clamps. In one embodiment, the internally arranged clamps can be standard clamps or purge and inspection clamps. In another embodiment, the hot pass welding process 1004 can be performed by a manual welder. In such an embodiment, the ends of the tube are configured to include a 30° bevel angle.

[0251] In one embodiment, the 1004 hot pass welding process, when performed with the external welding system (in a welding tent) and in a ditch side location, can take up to 1.06 minutes. In one embodiment, the 1004 hot pass soldering procedure, when performed with the external soldering system (in a soldering tent) and at a side job location, can take up to 58 seconds. In one embodiment, the cycle time for the hot-pass soldering procedure is 2.38 minutes (this time is calculated from when the hot-pass soldering tent is fitted to the tube). In one modality, the total cycle time for three cycles, the hot pass welding procedure performed by the external welding system in a welding booth is 11.35 minutes and the average cycle time for the welding process of hot ironing performed by the external soldering system in a soldering tent is 3.45 minutes.

[0252] In one embodiment, the hot-pass soldering procedure 1004 forms the hot-pass solder layer 1016. In one embodiment, as shown in FIG. 2, the hot-pass solder layer 1016 is the second solder bead or layer deposited in the multiple-pass or multi-layer 1000 soldering method. In one embodiment, the hot-pass soldering procedure 1004 immediately follows the procedure of 1002 root pass welding. In one embodiment, the 1004 hot pass welding process is performed by gas metal arc welding (GMAW). In one embodiment, the 1004 hot pass welding procedure is performed by Tungsten Gas Arc Welding (GTAW). In one embodiment, the hot pass welding procedure 1004 is performed by short circuit gas metal arc welding (GMAW-S). In another embodiment, the hot pass soldering procedure 1004 is performed by other soldering processes as would be appreciated by one skilled in the art.

[0253] In one embodiment, one or more of the fill weld procedures 1006a and the fill pass and fill 1006b weld procedure of the fill and finish pass weld procedure 1006 are performed by the 7500 external weld system. In one embodiment, the fill and finish pass weld procedure 1006 can be performed at multiple stations. In another embodiment, the fill and finish pass welding procedure 1006 can be performed by a manual welder. In such an embodiment, the ends of the tube are configured to include a 30° bevel angle.

[0254] In one embodiment, one or more 1006a fill pass weld procedures follow (or are performed later) the 1004 hot pass weld procedure. In one embodiment, one or more 1006a fill pass weld procedures form the fill pass solder layer(s) 1018. The fill pass solder layer(s) 1018 are configured to fill the solder groove and be substantially flush with the surfaces of the segments of tube 1022a and 1022b of tube 1024. In one embodiment, the number of fill pass weld procedures 1006a in the multiple or multilayer weld method 1000 may vary. In one embodiment, the number of fill pass weld procedures 1006a in the multi-pass or multi-layer weld method 1000 may depend on the thickness of the tube segments 1022a and 1022b of the tube 1024 being welded together.

[0255] In one embodiment, the 1006a fill pass welding procedures are performed by gas metal arc welding (GMAW). In one embodiment, the 1006a fill pass welding procedures are performed by Tungsten Gas Arc Welding (GTAW). In one embodiment, the 1006a fill pass welding procedures are performed by pulsed metal gas arc welding (GMAW-P). In another embodiment, the fill pass 1006a soldering procedures are performed by other soldering processes as would be appreciated by one of ordinary skill in the art.

[0256] In one embodiment, the finish pass weld procedure 1006b is the last or last weld process of the multipass or multilayer weld method 1000. In one embodiment, the finish pass weld procedure 1006b follows (or is performed after) the 1006a fill pass soldering procedure(s). In one embodiment, as shown in FIG. 2, the finish pass weld layer 1020 is the weld bead or layer deposited subsequent to the fill pass weld procedures 1006a. In one embodiment, the finish weld procedure 1006b may also be referred to as a cover pass weld procedure. In one embodiment, the finish weld procedure 1006b forms the finish pass weld layer 1020. In one embodiment, as shown in FIG. 2, the finish pass weld layer 1020 is the last or last weld bead deposited in the multiple pass or a multi-layer weld method 1000. In one embodiment, the finish pass weld layer 1020 is configured to be substantially larger than the surfaces of tube segments 1022a and 1022b of tube 1024.

[0257] In one embodiment, the 1006b finish pass weld procedure is performed by gas metal technique welding (GMAW). In one embodiment, the 1006b finish pass weld procedure is performed by Tungsten gas welding (GTAW) technique. In one embodiment, the 1006b finish pass welding procedure is performed by pulsed gas metal arc welding (GMAW-P). In another embodiment, the finishing pass welding procedure 1006b is performed by other welding processes as would be appreciated by one skilled in the art.

[0258] In one embodiment, the 1002 root pass welding procedure may be the only pass welding procedure of the 1000 multipass or multilayer welding method that is performed by the 5004 internal welding system, while the 5004 internal welding procedure. hot pass 1004 and the 1006 fill and finish pass weld procedure are all performed with the 7500 external weld system.

[0259] In another embodiment, both the 1002 root pass welding procedure and the 1004 hot pass welding procedure of the 1000 multipass or multilayer welding method are performed by the internal welding system 5004, while the welding procedure of 1006 fill and finish pass welding is performed with the 7500 external welding system.

[0260] In yet another modality, the 1002 root pass welding procedure, the 1004 hot pass welding procedure and the 1006 fill and finish pass welding procedure is performed with the 7500 external welding system. In this modality, the purge and inspection clamps are used inside the tubes 1022a, 1022b, while the external welding system 7500 performs the root pass welding procedure 1002, the hot pass welding procedure 1004 and the welding procedure of fill and finish pass 1006.

[0261] FIGS. 2G-2I show cross-sectional views of conduits 1024 with solder joints 1026 formed between them.

[0262] FIG. 2G shows a cross-sectional view of tubing 1024 with solder joint 1026 formed therebetween. For example, the solder joint 1026 of FIG. 2G includes root pass solder layer 1014 and hot pass solder layer 1016 formed by inner solder system 5004 from the interior of tubes 1022a, 1022b while the one or more fill pass solder layers 1018 and the Finish pass solder layer 1020 are formed by external solder system 7500 from the outside of tubes 1022a, 1022b.

[0263] The individual solder pass layers (eg root pass solder layer 1014, hot pass solder layer 1016, fill and finish pass solder layers 1018 and 1020) can also be clearly seen in FIG. 2. The edge 1032 between the solder material 1034 and the tube material 1036 can be easily and clearly distinguished in FIG. 2. In one embodiment, the shape of the edge 1032 (as illustrated by the ABCDE line) is unique to the 1024 tubing that is welded (for example, the 1002 root pass welding procedure and/or the hot pass welding process 1004) from inside the pipe 1024.

[0264] In one embodiment, when both the 1002 root pass welding procedure and the 1004 hot pass welding procedure of the 1000 multipass or multilayer welding method are performed by the internal welding system 5004 of the interior of the pipe 1024, the positions of the root pass solder layer 1014 and the hot pass solder layer 1016 will exchange (for example, when compared to the solder joint in which the root pass solder procedure is performed by the internal solder system 5004 of the inside the pipe 1024 and the hot pass welding procedure 1004 is performed by the external welding system outside the pipe 1024). In one embodiment, as shown in FIGS. 2 and 2G, hot pass solder layer 1016 is positioned closer to an interior longitudinal axis AA of first and second solder tubes 1022a and 1022b than root pass solder layer 1014.

[0265] In one embodiment, the hot pass solder layer 1016 of solder material 1034 has at least a portion 5238 thereof disposed closer to the longitudinal axis AA than inner surfaces 5130, 5132 of solder tubes 1022a and 1022b in regions 5240 and 5242 of the weld, tubes 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 1002 root pass welding procedure and the 1004 hot pass welding procedure of the 1000 multipass or multilayer welding method 1000 are performed by the internal welding system 5004 of the interior of the pipe 1024, the area retention 1028 of the 1026 weld joint occurs more from the inner walls 5130, 5132 of the 1024 pipe.

[0266] In one embodiment, the root pass solder layer 1014 is disposed on the inner bevel surfaces 5228, 5232 of the first and second tubes 1022a and 1022b and the hot pass solder layer 1016 is disposed on top of the layer of root weld 1014 (ie, closer to the inner longitudinal axis AA). In one embodiment, inner welding system 5004 is constructed and arranged to perform more than one weld pass from the interior of pipe 1024. In one embodiment, inner welding system 5004 is constructed and arranged to be direction driven. radial so that the internal welding system 5004 can adjust the height of welding torch 5502 between the two passes (for example, root pass welding procedure 1002 and hot pass welding procedure 1004).

[0267] In one embodiment, an additional solder pass layer(s) may be disposed over the hot pass layer (1016) and positioned closer to the inner longitudinal axis (AA) of the first and second weld tubes 1022a, 1022b than hot pass layer 1016. For example, in one embodiment, the one or more fill pass solder layers 1018 can be made by inner solder system 5004 such that the one or more solder layers of fill pass 1018 are disposed on top of the hot pass layer 1016 and positioned closer to the inner longitudinal axis AA of the first and second welded tubes 1022a, 1022b than the hot pass layer 1016. For example, in one embodiment , the one or more fill pass solder layers 1018 and the finish pass solder layers 1020 can be made by the inner solder system 5004 such that the one or more fill pass solder layers 1018 and the layers. Finish pass weld layers 1020 are disposed over the hot pass layer 1016 and positioned closer to the inner longitudinal axis AA of the first and second weld tubes 1022a, 1022b than the hot pass layer 1016.

[0268] In another embodiment, the one or more fill pass solder layers 1018 and finish pass solder layer 1020 are disposed on outer bevel surfaces 5230, 5234 of the first and second tubes 1022a and 1022b and can be made by the 7500 external welding system from the outside of the 1024 pipe.

[0269] FIG. 2H shows a cross-sectional view of tubing 1024 with solder joint 1026 formed therebetween. For example, the solder joint 1026 of FIG. 2H includes the root pass solder layer 1014 formed by the inner solder system 5004 from the interior of tubes 1022a, 1022b, while the hot pass solder layer 1016, while the one or more fill pass solder layers 1018 and the finishing pass layer 1020 are formed by the external welding system 7500 from the outside of the tubes 1022a, 1022b. In one embodiment, the root pass solder layer 1014 is disposed on the inner bevel 5228, 5232 of the first and second tubes 1022a and 1022b. In one embodiment, the hot pass solder layer 1016, the one or more fill pass solder layers 1018, and the finish pass solder layer 1020 are disposed on outer bevel surfaces 5230, 5234 of the first and second. tubes 1022a and 1022b.

[0270] FIG. 2I shows a cross-sectional view of tubing 1024 with solder joint 1026 formed therebetween. For example, the solder joint 1026 of FIG. 2I includes root pass solder layer 1014, hot pass solder layer 1016, one or more fill pass solder plates 1018 and 1020 formed by external solder system 7500 from outside tubes 1022a, 1022b. In one embodiment, the root solder layer 1014, the hot pass solder layer 1016, the one or more fill pass solder layers 1018, and the finish pass solder layer 1020 are all disposed on the surfaces of outer bevel 5230, 5234 of the first and second tubes 1022a and 1022b.

[0271] In one embodiment, after the 1026 weld joint is complete, the 1026 weld joint can be inspected during the 1008 weld inspection procedure. In one embodiment, the 1008 weld inspection procedure is performed after the 1008 weld process is completed. fill and finish pass weld 1006. In one embodiment, the 1026 weld joint can be cleaned prior to the 1008 weld inspection procedure. In one embodiment, a significant amount of heat can be generated during the welding procedures (by example, procedures 1002, 1004 and 1006). In one embodiment, weld inspection procedure 1008 is performed at a lower operating temperature than the highest weld temperature. In one embodiment, the 1026 weld joint may be cooled prior to the 1008 weld inspection procedure by a 2010 or 6500 internal cooling system (as described in detail below). In one embodiment, the 1008 weld inspection procedure may include any type of non-destructive testing/inspection of the 1026 weld joint.

[0272] In one embodiment, the 1008 weld inspection procedure may include an Automated Ultrasonic Test (AUT). In one embodiment, the 1026 Weld Joint Ultrasonic Automated Test can be used for both onshore and offshore pipe welding applications. In one modality, the AUT is configured to be used in high production environments. In one modality, the AUT is configured to be used to detect and scale weld failures.

[0273] In one embodiment, Automated Ultrasound Testing is performed by an AUT scanning system (eg 6801 as shown in FIG. 136A). In one embodiment, the AUT scanning system includes an ultrasonic sensor system. In one modality, the AUT scanning system can be portable. In one embodiment, the AUT scanning system may also include a data acquisition system that is operably linked to the ultrasonic sensor system. In one embodiment, the ultrasonic sensor system can include an emitter that is configured to send, for example, ultrasonic signals (e.g., wave pulses) in tube segments 1022a and 1022b and/or the circumference weld 1026 between them. In one modality, ultrasonic signals or pulses can be sent at a rate of 1 Hz to 20,000 Hz. In one modality, the frequency of the ultrasonic sound wave can range from 0.5 MHz to 23 MHz.

[0274] In one modality, the ultrasonic signals or pulses, sent by the emitter, are configured to reflect the thresholds where the density of the 1026 girth weld changes. In one embodiment, the ultrasonic sensor system may include a receiver that is configured to receive/detect the reflected pulses. In one modality, the receiver is configured to measure the strength of the reflected pulse and produce an electronic signal proportional to the strength of the reflected pulse. In one embodiment, the emitter and receiver of the ultrasonic sensor system can have multiple elements or components. In one modality, the emitter of the ultrasonic sensor system can be selectively activated to target the ultrasonic pulse at a specific location.

[0275] In one modality, a variety of automated ultrasonic testing (AUT) can include Time of Flight Diffraction (ToFD), In-phase Array (PA), corrosion mapping and/or complete weld inspection. In one modality, the ultrasonic Time of Flight Diffusion (ToFD) of weld inspection can be used when multiple bevels are to be evaluated.

[0276] In one embodiment, the AUT weld inspection procedure may include an ultrasonic full coverage weld inspection pulse echo. In one embodiment, eco-pulse ultrasonic inspection techniques utilize Phased array (PA) probes coupled with ToFD inspection to provide very accurate weld failure measurements. In one modality, welds can be divided into zones (zonal discrimination) that are evaluated individually, with the results being reassembled into a comprehensive weld analysis. In one modality, a linear and sector scan can provide a superior weld examination. In one embodiment, the ToFD ultrasound weld inspection can be used to complement the full coverage eco-pulse ultrasound weld inspection.

[0277] In yet another embodiment, the weld inspection procedure 1008 may include an X-ray radiography test. In one embodiment, the X-ray radiography test is performed by an X-ray radiography system. In one embodiment, the x-ray radiography system includes an emitter that is configured to send x-ray radiation into tube segments 1022a and 1022b and the circumference weld 1026 therebetween. In one embodiment, the intensity of the X-ray radiation can be attenuated by the material of tube segments 1022a and 1022b and circumference soldering 1026 between them. In one embodiment, the x-ray radiography system includes a receiver that is configured to measure the intensity of x-ray radiation as it passes through the material of tube segments 1022a and 1022b and circumference weld 1026 therebetween.

[0278] In one embodiment, the 1008 weld inspection procedure may include analysis of the Gamma and proximity radiography. In one embodiment, the 1008 weld inspection procedure may include Magnetic Particle Inspection (MPI) or Ink Penetration Inspection (DPI). In one embodiment, the 1008 weld inspection procedure may include any other Non-Destructive Test (NDT), for example, but not limited to Guided Wave Ultrasound Test, Eddy current tests, Hardness test, In-tank tests (MFL), positive material identification, corrosion mapping surveys, etc. In one embodiment, Non-Destructive Testing (NDT) can generally refer to any test configured to identify weld defects without damaging the tubes and/or the weld formed between them.

[0279] Referring to FIG. 2G, in one embodiment, as discussed above, each segment of tube 1022a, 1022b includes the interior of metal tube 5244, surrounded by external protective coatings (eg, an insulating material) 5246. In one embodiment, end portions 5248 and 5250 of the tube segments 1022a, 1022b to be welded have the metal tube interior exposed.

[0280] In one embodiment, after the 1008 weld inspection procedure, outer protective coatings are applied back to the 1026 weld joint. For example, an insulator is applied to the exposed end portions 5248, 5250 of the 1022a welded tube , 1022b such that insulator 5246A (as shown in FIG. 118) is adhered to an outer surface 5254 of the interior of metal tube 5244, thereby isolating previously exposed end portions 5248, 5250 of tubes 1022a, 1022b.

[0281] In one embodiment, to facilitate the application of the external protective coatings or insulator, the solder joint 1026 and the surrounding portions of the tube segments 1022a and 1022b of the tube 1024 are heated to a predetermined coating temperature. In one embodiment, exposed end portions 5248, 5250 of welded tubes 1022a, 1022b are heated. In one embodiment, the predetermined coating temperature is the temperature that is required to apply the outer protective coatings or insulator. In one embodiment, the predetermined coating temperature is set to provide a good adhesion or bond between the outer protective coatings or the insulator and tubing 1024.

[0282] In one embodiment, the 1010 heating procedure is performed after the 1008 weld inspection procedure. In one embodiment, an induction preheat procedure can be used to heat the 5248, 5250 exposed end portions of the tubes. welded 1022a, 1022b from tubing 1024 in preparation for application of the coating material(s) or insulator.

[0283] In one embodiment, the heating procedure 1010 is performed by a heating system 5304 (shown and explained in relation to Figures 115A and 115B). In one embodiment, the heating system may include an electrical heating system. In one embodiment, the heating system can include ultra high frequency (UHF) induction coils that are configured to rapidly heat the exposed end portions 5248, 5250 of welded tubes 1022a, 1022b of tube 1024 to the required coating temperature. In one embodiment, the heating system is also configured to regulate the temperature of exposed end portions 5248, 5250 of welded tubes 1022a, 1022b of tubing 1024 to maintain a suitable coating application temperature. In one embodiment, the heating system may include a heating feedback system configured to allow the heating system to reach and maintain the required coating temperature and a temperature sensor operatively coupled to the feedback system. In one modality, the temperature sensor can be a contact or a non-contact temperature sensor. In one embodiment, the heat feedback system may include one or more sensors that are configured to detect other parameters of the heat-up time, etc., heating procedure.

[0284] In one embodiment, the 1012 coating procedure is performed immediately after the 1010 heating process. In one embodiment, the 1012 coating procedure is performed on a coating tent (i.e., similar in construction to the welding tent) having a coating head that is constructed and arranged to apply/spray/supply an insulator/coating/epoxy mixture to the exposed end portions 5248, 5250 of welded tubes 1022a, 1022b of tubing 1024. In one embodiment, the coating head completes the coating procedure in less than one minute. In one embodiment, the coating head completes the coating procedure within 50 seconds.

[0285] In one embodiment, an insulator/liner is applied to the heated exposed end portions 5248, 5250 of the welded tubes such that the insulator/liner 5246A (as shown in FIG. 118) is adhered to the outer surface 5254 of the interior of the metal tube, thereby isolating the previously exposed end portions 5248, 5250 from the tubes 1022a, 1022b.

[0286] In one embodiment, coatings are applied to the external surfaces or areas of the tube segments 1022a and 1022b that surround the weld joint 1026 to provide an insulating barrier to prevent or minimize corrosion in the weld areas.

[0287] In one embodiment, coatings may include polypropylene coatings. In one embodiment, the coatings can include polyethylene coatings. In one embodiment, coatings can include polyurethane coatings. In one embodiment, coatings can include insulating coatings (eg, heat loss). In one embodiment, the coatings can include anti-corrosion coatings. In one embodiment, coatings can include wear resistant coatings. In one embodiment, coatings can include melt-bonded epoxy (FBE). In one embodiment, coatings can include melt-bonded epoxy (FBE) plus dual basecoats of polypropylene (CMPP) or chemically modified polyethylene (CMPE) powder. In one embodiment, the chemically modified polypropylene (CMPP) or polyethylene (CMPE) layer is immediately followed by the polypropylene (PP) or polyethylene (PE) tape. In one embodiment, the coatings can include Multicomponent Liquid (MCL) coatings (eg, urethane and epoxy based MCL coatings). In one embodiment, the coatings can include a field junction coating (FJC).

[0288] In one embodiment, coatings may include an injection molded polypropylene. In such an embodiment, tubing 1024 is preheated to a temperature of 180°C to receive the injection molded polypropylene coating.

[0289] In one embodiment, automated equipment may be used to apply coating materials to the 1026 weld joint. In one embodiment, the coating distribution system may include the Injection Molded Coating System as shown and described in detail in with respect to FIGS. 117A and 117B. In one embodiment, the coating delivery system can include a flame spray coating system. In one embodiment, the insulations/coatings can be applied to the exposed regions of the solder joint using a nozzle device. In one embodiment, the nozzle device is configured to spray insulation materials onto the exposed region of the tube in the region of the welds. In one embodiment, the mouthpiece device is shown and described in relation to FIGS. 116A-116B.

[0290] In one embodiment, an abrasive blasting procedure may be used to prepare 1024 tubing for coatings. In one embodiment, the abrasive blasting procedure may be performed prior to the 1010 heating procedure. In one embodiment, the oxidized tube solder joint is blasted to remove all contaminants.

[0291] In one embodiment, the coating system may include a coating feedback system configured to allow the coating system to obtain the desired coatings on pipe 1024 and one or more sensors operatively connected to the coating feedback system. In one embodiment, one or more sensors are configured to detect the following parameters of the coating procedure: heating time, heating temperature, coating material temperature, coating material volume, etc.

[0292] In one embodiment, method 1000 may include other procedures that are not shown in FIG. 1A. In one embodiment, these other procedures of method 1000 are shown and explained in relation to FIG. 1B.

[0293] In one embodiment, method 1000 may include a 1040 tube preparation procedure, a 1042 tube alignment procedure, an optional 1044 weld inspection procedure, a 1046 repair procedure, a 1048 cool down procedure, and a 1050 tubing deployment procedure. In one modality, each of these procedures is optional.

[0294] In one embodiment, the 1040 tube preparation procedure is performed prior to the 1002 root pass weld procedure. In one embodiment, the 1040 tube preparation procedure is performed prior to the 1042 tube alignment procedure.

[0295] In one embodiment, the tube 1040 preparation procedure may include a 1040a cutting procedure. In one embodiment, the cutting procedure 1040a is performed for preparing the end or end portions of tube segments 1022a, 1022b for welding. In one embodiment, during the cutting procedure 1040a, the tube segments 1022a and 1022b that are to be welded together are cut to the desired dimensions. In one embodiment, the 1040a cutting procedure can be performed at the manufacturer's location.

[0296] In one embodiment, the method may include a chaining procedure in which tubes are distributed according to a design plan (prior to the tube joining/welding procedure). In one embodiment, each pipe segment joint has a specific place in the pipe. The rope crew ensures that each piece of pipe is placed where it belongs. Inspectors check the assigned numbers to ensure the gaskets are in the correct order.

[0297] In one embodiment, the method may include a bending procedure in which the tubes are bent to suit the topography of the right of way. In one embodiment, the tube is inserted into a bender and a mandrel is then positioned on the tube. The mandrel is constructed and arranged to apply pressure within the tube to prevent buckling while bending. Operator positions tube and turns. The tube is removed from the bender after the bend is made. After the bending procedure, each piece of tube is placed in place.

[0298] In one embodiment, the 1040 tube preparation procedure may include a 1040b beveling procedure. In one embodiment, the beveling procedure 1040b is performed to prepare the end or end portions of tube segments 1022a and 1022b for welding. In one embodiment, during the beveling process 1040b, the end portions of tube sections or segments 1022a and 1022b that are to be welded together are chamfered to the desired dimensions. In one embodiment, the desired bevels can be machined into the end portions of the tube segments 1022. In one embodiment, a tube coating machine is inserted into the tube and is anchored to the tube (raising the internal clamping shoes). In one modality, the 1040b beveling procedure may take 10 seconds. In one embodiment, the operator may manually check the bevel formed using a 5801 flame gauge shown in FIGS. 2C-2F. FIGS. 2C-2E show a front view, a perspective view, and a side view of bevel gauge 5801, respectively, while FIG. 2F shows a detailed view of detail A in FIG. 2C. In one embodiment, beveling procedures 1040a, 1040b can be performed at the manufacturer's location.

[0299] In one embodiment, the default bevel depth for field welding from inside the tube is .050 inches. In one embodiment, the weld bead is about 3 millimeters high, so the weld bead rises from the surface by 0.05 to 0.07 inches. To make two weld passes (for example, hot and root pass welds) in one modality, the bevel can be cut to a depth of 0.150 to 0.170 inches.

[0300] In one embodiment, the 1042 tube alignment procedure is performed prior to the 1002 root pass weld procedure. In one embodiment, the 1042 tube alignment procedure is performed between the 1040 tube preparation procedure and the 1002 root pass soldering procedure. In one embodiment, a preheat procedure may be performed, prior to the soldering procedure (ie root pass soldering procedure), to heat the pipe to more than 100° C so as to evaporate all moisture from the surface of the tube.

[0301] In one embodiment, referring to FIG. 2G, the tube 1042 alignment procedure may include providing a second tube 1022a at the second end 1038b of the first tube 1022b and aligning the ends 1038a, 1038b of the first and second tubes 1022a, 1022b that are to be welded. In one embodiment, the 5004 internal welding system may include a feedback system (e.g., using inspection detector 5056, one or more 5140 processors, 5030, 5074 orientation motors, 5330 external support, 6010A, 6010B, internal clamps 5144, 5144, 7050, 7052 as will be explained in detail below) which is configured to detect whether the ends 1038a, 1038b of the first and second tubes 1022a, 1022b are properly aligned. The term "motor" as used in this document broadly refers to any type of electromechanical motor, such as an electric motor, hydraulic motor, pneumatic motor, for example only.

[0302] In one embodiment, the optional 1044 weld inspection procedure can be performed between the 1004 hot-pass weld process and the 1006 fill and finish weld procedure. In one embodiment, the optional weld inspection procedure 1044 may include X-ray radiography inspection. In one embodiment, 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 x-ray radiation into tube segments 1022a and 1022b and the hot and root pass solder layers formed therebetween. In one embodiment, the intensity of the X-ray radiation can be attenuated by the material of the tube segments 1022a and 1022b and the hot and root pass solder layers 1014, 1016 formed therebetween. In one embodiment, the x-ray radiography system includes a receiver that is configured to measure the intensity of x-ray radiation as it passes through the material of tube segments 1022a and 1022b and the hot and root pass solder layers 1014 , 1016 formed between them. In another embodiment, the 1044 weld inspection procedure may include analysis of the Gamma and proximity radiography.

[0303] In one embodiment, the 1046 repair procedure is performed after the 1008 weld inspection procedure and before the 1010 and 1012 heating and coating procedures. In one embodiment, the 1046 repair procedure is configured to repair any defects in weld that are detected during the 1008 weld inspection procedure.

[0304] The weld repair procedure outlined in this document can be one of a variety of types. In one embodiment, an additional weld operation is performed on top of the previous weld to remedy any weld defects. In another embodiment, the defective weld can be crushed or optionally cut off entirely (manually or automatically) before any subsequent repair welding operations are conducted.

[0305] In one embodiment, after the 1010 and 1012 heating and coating procedures, the 1024 tubing is allowed to cool to a suitable temperature before additional processing steps can occur (for example, before winding the connected tube segments or the handling/placement of the pipe segments in water or some other suitable location on land). In one embodiment, the 1048 cooling procedure is performed after the 1012 coating procedure. In one embodiment, the 1048 cooling procedure is performed by a 2010 cooling system, 2110, 2210, 6500 (as shown and described in relation to FIGS. 104-112B and 119-136) which is configured to remove heat from the welded tubes in order to reduce the temperature to an acceptable temperature for the effective coil. For example, the piping must be below a predetermined temperature (eg 50 to 70 °C) to perform the coil procedure, the S configuration procedure, etc. In one embodiment, the cooling system may be an internal cooling system that is configured to cool the welded tubes within the 1024 pipeline.

[0306] In one embodiment, welded tubes can also be left to cool-air over time. In one embodiment, welded pipes can be cooled by spraying or leaking water on the outside of the insulation/sheathing in the pipe. In one embodiment, the water spraying or pouring procedure can be carried out at one or more stations.

[0307] In one embodiment, the 1048 cooling procedure is performed, for example, for a barge welding procedure, a coil-based ply welding procedure, and a coil main line welding procedure. In one embodiment, the onshore mainline welding procedure and the onshore articulated welding procedure may not have a separate cooling procedure.

[0308] In one embodiment, the 1050 tubing deployment/lowering procedure is performed after the 1012 coating procedure. In one embodiment, the 1050 tubing deployment/lowering procedure is performed after the 1048 cooling procedure.

[0309] In one embodiment, the 1050 tubing deployment procedure may include a 1050a coil procedure, a 1050b S configuration procedure, or a 1050c tubing shortening procedure.

[0310] In one embodiment, the 1050a coil procedure is configured to coil the tubing to the container, which transports the tubing to its final destination or location. In one embodiment, the tubing must be below a predetermined temperature (eg, 50 to 70 °C) to perform the 1050a coil procedure. In one modality, the predetermined temperature (eg 50 to 70 °C) is set to avoid any damage during the 1050a coil procedure.

[0311] In one embodiment, the S configuration procedure is an offshore pipe configuration procedure in which the pipeline is lowered to the sea in a horizontal position. In one embodiment, during the S 1050b setup procedure, the tubing is pushed out of the end of the vessel in an S-shaped curve. In one embodiment, the tubing must be below a predetermined temperature (eg, 50 to 70 °C) to perform the setup procedure on S 1050a. In one modality, the predetermined temperature (eg 50 to 70 °C) is set to avoid any damage during the setting procedure in S 1050b.

[0312] The coil procedure, the S setting procedure and the J setting procedure are described in detail in relation to FIGS. 136B-E.

[0313] In one embodiment, the 1050c pipe lowering procedure is configured to position/lower the pipe in a pre-dug trench.

[0314] In one modality, the pipe welding condition/situations can be classified into five categories, namely, ground line welding procedure, ground connection welding procedure, coil main line welding procedure, welding procedure of coil fitting and barge welding procedure.

[0315] The ground main line welding procedure is shown in FIG. 3. The onshore mainline welding procedure is generally carried out at ground level and adjacent to a pre-dug trench into which the pipeline will be disposed. In one modality, the onshore pipelines are welded in sections, for example, up to 1 mile long. The onshore weld welding stations are next to each other. The welding procedures before and after the welding procedures of the onshore welding process are decoupled from the welding procedure itself, so that the welding procedures before and after can take place at their own pace. After the pipe segments are welded together, they are lowered into the pre-dug trench.

[0316] The onshore connection welding procedure is shown in FIG. 4. The onshore connection welding procedure usually takes place in a pre-dug trench where the pipeline will be disposed of. That is, the sections or segments are cut to length and welded together in the pre-dug trench.

[0317] The base of the main line welding procedure coil is shown in FIG. 5. The coil base main line welding procedure is usually performed in a similar factory setup. All procedures of the coil main line welding procedure take place within the factory connection and in a coordinated assembly line process. For example, pipes are welded, inspected and coated along a line of fire to form a pipe rod (eg sometimes up to 7 kilometers). Tube stalks are stored until they are placed on a vessel for transport to their final location. That is, when the ship/barge is far from the coil base, the welded tube is stored in long sections. Pipe stalks are towed in large coils on barges (typically J-connect) and not placed when the barge arrives at the job site.

[0318] The coil-based connection soldering procedure is shown in FIG. 6. The spool based connection weld procedure is used to join the pre-assembled pipe sections or segments as they are being placed on the vessel/ship, which generally transports the pipeline to its final location. It is the cooling of this gasket after coating that limits the coil rate. All spool procedures based on connection soldering are performed on the same station.

[0319] The barge welding procedure is shown in FIG. 7. The barge welding procedure is usually performed in a factory-like configuration aboard a floating ship. All barge welding procedures are generally performed within the factory setting and in a coordinated assembly line process. The pipeline is deployed at its final location as it leaves the vessel.

[0320] Each of these tube welding situations may have one or more welding procedures described in relation to FIGS. 1A and 1B. One or more systems described in this patent application (for example, 5004 internal welding system, 3001 internal welding system, 7001 purge and inspection system, 7500 external welding system, and 2010 internal cooling system) may be used in the operating procedures of these tube welding situations.

[0321] For example, referring to FIG. 3, the onshore mainline welding procedure starts with the tube preparation procedure in which an automated welding chassis is machined at each end of the tubes. This can be done by an advanced crew who are working a short distance ahead of the welding crew. After the tube preparation procedure, a root pass weld procedure is performed. In one embodiment, the root pass welding procedure may be performed by the 5004 internal welding system. In another embodiment, the root pass welding procedure may be performed by a 7500 external welding system with clamp(s) positioned internally (s) 7050, 7052. After the root pass soldering procedure, the hot pass soldering procedure is performed. The hot pass soldering procedure can be performed by the external soldering system or the 5004 internal soldering system.

[0322] In one embodiment, the hot pass and root welding procedures are performed by the 5004 internal welding system. In another embodiment, only the root pass welding procedure is performed by the 5004 internal welding system, while the hot pass soldering procedure is performed by the 7500 external soldering system.

[0323] In one embodiment, the fill and finish pass soldering procedure is performed after the hot pass soldering procedure. In one embodiment, the fill and finish pass weld procedure can be performed by the 7500 external welding system. In one embodiment, the fill and finish pass weld procedure can be performed at multiple stations.

[0324] After the fill and finish pass weld procedure, the weld inspection procedure is performed. For example, ultrasound, X-ray radiography or magnetic inspection can be used to inspect the weld area. All weld defects detected during the weld inspection procedure are repaired during the weld repair procedure. The welded tube is coated with Fusion Bonded Epoxy coating. Fusion Bonded Epoxy coating is applied to the final exposed (heated) portions of welded pipe so that the Fusion Bonded Epoxy coating is adhered to an outer surface of the interior of the pipe. The coating procedure can be done by an autonomous team working behind the repair team. The pipe is then lowered into the pre-dug trench. The pipe lowering procedure can be done by an autonomous team working behind the casing team.

[0325] Referring to FIG. 4, the grounding soldering procedure starts with the tube preparation procedure. The exact tube lengths are not known in advance, so the overlap is designed into the onshore connection weld procedure. Once the tubes are in the trench, a tube is cut to the correct length and the desired bevel is machined into the end of the tube. After the tube preparation procedure, a root pass weld procedure is performed.

[0326] In one embodiment, the root pass soldering procedure can be performed by the 3001 internal connection soldering system. In another embodiment, the root pass soldering procedure can be performed by the connection clamp system with a 7500 external welding system. In another embodiment, the root pass welding procedure can be performed by a manual welder with externally positioned clamps.

[0327] After the root pass soldering procedure, the hot pass soldering procedure is performed. In one embodiment, the hot pass welding procedure can be performed by the 3001 internal connection welding system. In another embodiment, the hot pass welding process can be performed by the 7500 external welding system. Hot pass welding can be performed by a manual welder.

[0328] In one embodiment, the hot pass and root weld procedures are performed by the internal connection welding system 3001. In another embodiment, only the root pass welding procedure is performed by the internal connection welding system 3001, while the hot pass soldering procedure is performed by the 7500 external soldering system.

[0329] The fill and finish pass welding procedure is performed after the hot pass welding procedure. In one embodiment, the fill and finish pass weld procedure can be performed by the 7500 external welding system. In another embodiment, the fill and finish pass weld procedure can be performed by a manual welder. The fill and finish pass welding procedure is done from the outside of the tubes. After the fill and finish pass weld procedure, the weld inspection procedure is performed. For example, ultrasound, X-ray radiography or magnetic inspection can be used to inspect the weld area. The weld inspection procedure is carried out by an autonomous team working behind the welding team. All weld defects detected during the weld inspection procedure are repaired during the weld repair procedure. The repair procedure is carried out by an autonomous team working behind the inspection crew. The welded tube is coated with Fusion Bonded Epoxy coating. Fusion Bonded Epoxy coating is applied to the final exposed (heated) portions of welded pipe so that the Fusion Bonded Epoxy coating is adhered to an outer surface of the interior of the pipe. The coating procedure can be done by an autonomous team working behind the repair team.

[0330] Referring to FIG. 5, the coil base main line welding procedure begins with the tube preparation procedure in which a suitable bevel is machined into the tube ends. After the tube preparation procedure, a root pass weld procedure is performed. In one embodiment, the root pass welding procedure can be performed by the 5004 internal welding system. In another embodiment, the root pass welding procedure can be performed by the 7001 purge and inspection system with the 7500 external welding system In another modality, the root pass welding procedure can be performed by the internal clamps with the external welding system.

[0331] After the root pass soldering procedure, the hot pass soldering procedure is performed. In one embodiment, the hot pass welding procedure can be performed by the 5004 internal welding system. In another embodiment, the hot pass welding process can be performed by the 7500 external welding system.

[0332] In one embodiment, the hot pass and root welding procedures are performed by the 5004 internal welding system. In another embodiment, only the root pass welding procedure is performed by the 5004 internal welding system, while the hot pass welding procedure is performed by the 7500 external welding system. In yet another modality, the root pass welding procedure is performed by the 7500 external welding system with 7001 internal bleed clamps, while the pass welding procedure Hot welding is carried out by the 7500 external welding system.

[0333] The X-ray X-ray weld inspection procedure is performed after the hot pass weld procedure. The X-ray X-ray weld inspection procedure is optional.

[0334] The fill and finish pass weld procedure is performed after the hot pass weld procedure and the X-ray radiography weld inspection procedure. In one embodiment, the fill pass weld procedure and Finishing can be performed by the external welding system. In one embodiment, the fill and finish pass weld procedure can be performed at multiple stations.

[0335] After the fill and finish pass weld procedure, the weld inspection procedure is performed to perform the weld inspection of the weld joint. For example, ultrasound, X-ray radiography or magnetic inspection can be used to inspect the weld area. All weld defects detected during the weld inspection procedure are repaired during the weld repair procedure. The welded tube is coated with an injection molded polypropylene coating. The injection molded polypropylene coating is applied to (preheated to 180°C) exposed end portions of the welded tubes so that the injection molded polypropylene coating is adhered to an outer surface of the interior of the tube. The cooling procedure is carried out after the coating procedure. Tubes can be allowed to air over time.

[0336] Referring to FIG. 6, the coil base connection weld procedure begins with the tube preparation procedure in which a suitable bevel is machined into the tube ends. After the tube preparation procedure, a root pass weld procedure is performed. In one embodiment, the root pass soldering procedure can be performed by the 3001 internal connection soldering system. In another embodiment, the root pass soldering procedure can be performed by the 7001 purge clamp system with a system of 7500 external welding. In another modality, the root pass welding procedure can be performed by the internal clamps with the external welding system.

[0337] After the root pass soldering procedure, the hot pass soldering procedure is performed. In one embodiment, the hot pass welding procedure can be performed by the internal connection welding system 3001. In another embodiment, the hot pass welding process can be performed by the external welding system.

[0338] In one embodiment, the hot pass and root welding procedures are performed by the 3001 internal connection welding system. In another embodiment, only the root pass welding procedure is performed by the welding system. internal connection 3001.

[0339] The X-ray X-ray weld inspection procedure is performed after the hot pass weld procedure. The X-ray X-ray weld inspection procedure is optional.

[0340] The fill pass and finish weld procedure is performed after the hot pass weld procedure. In one embodiment, the fill and finish pass welding procedure can be performed by the external welding system. In one embodiment, the fill and finish pass weld procedure can be performed at multiple stations.

[0341] After the fill and finish pass weld procedure, the weld inspection procedure is performed to perform the weld inspection of the weld joint. For example, ultrasound, X-ray radiography or magnetic inspection can be used to inspect the weld area. All weld defects detected during the weld inspection procedure are repaired during the weld repair procedure. The welded tube is coated with an injection molded polypropylene coating. The injection molded polypropylene coating is applied to (preheated to 180°C) exposed end portions of the welded tubes so that the injection molded polypropylene coating is adhered to an outer surface of the interior of the tube. The cooling procedure is carried out after the coating procedure. In one embodiment, the pipes can be cooled by pouring or spraying water on the outer surfaces of the insulation. In another embodiment, the tubes can be cooled by an internal cooling system. In one embodiment, tubes can be placed in the container after the cooling procedure. In one modality, the tubes must be below a temperature between 50 and 70 °C during the coiling procedure so as to avoid any damage during the coiling process. In one modality, all procedures of the coil base connection weld sequence can take place in the same location.

[0342] Referring to FIG. 7, the barge welding procedure begins with the tube preparation procedure in which a suitable bevel is machined into the tube ends. After the tube preparation procedure, a root pass weld procedure is performed. In one embodiment, the root pass soldering procedure can be performed by the 5004 internal soldering system. In another embodiment, the root pass soldering procedure can be performed by the 7001 bleed clamp system with an external soldering system 7500. In another modality, the root pass welding procedure can be performed by the internal clamps with the 7500 external welding system.

[0343] After the root pass soldering procedure, the hot pass soldering procedure is performed. In one embodiment, the tubes advance to the hot pass soldering procedure after the root pass soldering procedure is completed. In one embodiment, the hot pass welding procedure can be performed by the 5004 internal welding system. In another embodiment, the hot pass welding process can be performed by the external welding system.

[0344] In one embodiment, the hot pass and root welding procedures are performed by the 5004 internal welding system. In another embodiment, only the root pass welding procedure is performed by the 5004 internal welding system. The X-ray X-ray weld inspection procedure is performed after the hot pass weld procedure. The X-ray X-ray weld inspection procedure is optional.

[0345] The fill and finish pass weld procedure is performed after the hot pass weld procedure and the X-ray radiography weld inspection procedure. In one modality, the fill pass weld procedure and Finishing can be performed by the external welding system. In one embodiment, the fill and finish pass weld procedure can be performed at multiple stations.

[0346] After the fill and finish pass weld procedure, the weld inspection procedure is performed to perform the weld inspection. For example, ultrasound, X-ray radiography or magnetic inspection can be used to inspect the weld area. All weld defects detected during the weld inspection procedure are repaired during the weld repair procedure. The welded tube is coated with an injection molded polypropylene coating. The injection molded polypropylene coating is applied to (preheated to 180°C) exposed end portions of the welded tubes so that the injection molded polypropylene coating is adhered to an outer surface of the interior of the tube. The cooling procedure is carried out after the coating procedure. In one embodiment, the pipes can be cooled by pouring or spraying water on the outer surfaces of the insulation. In one embodiment, the cooling procedure can be performed at multiple stations. In another embodiment, the tubes can be cooled by an internal cooling system. In one embodiment, the tubes can be pushed out of the container end in an S-shaped configuration. In one embodiment, the tubes must be below a temperature of between 50 and 70 °C during the S configuration procedure of in order to avoid any damage during the configuration process in S.

[0347] In one embodiment, a 5000 field system for welding two tubes 1022a, 1022b is provided. The term "field system", as used herein, is a generic term intended to refer to the system(s) disclosed in this document as a whole, and/or any of the subsystems alone. For example, the "field system" can refer to the combination of the internal inspection system, external welder, internal tube cooler and ultrasonic non-destructive testing system together with the remote uLog processing system (eg system of remote computer 13704). In another example, the "field system" can only refer to the internal welding system, the internal inspection system, the internal cooling system, the connecting welder, for example. That is, the "field system" can only refer to the 5004 internal welding system, the 7001 internal inspection system, the 6500 internal cooling system alone, for example the 3001 connection welder.

[0348] As shown in FIGS. 8, 9, 10-1, 10-2, and 10-3, in one embodiment, each tube segment 1022a or 1022b has the longitudinal axis as shown by arrow A-A. As will be clear from the discussion below, the 5000 field system is configured to support multiple tube segments 1022a, 1022b and adjust their positions and/or orientations until the tube segments 1022a, 1022b are both aligned so that their axes longitudinal AA are collinear and one end of each of the tube segments 1022a, 1022b abuts the edges of the interface. FIG. 9 illustrates an enlarged detail view of the field system 5000 of FIG. 8 where the edges form a 5002 tube interface (also known as a "shaped" joint). In one embodiment, field system 5000 includes an internal solder system 5004 that applies a solder to the interior of interface 5002 from the interior of fitted tube segments 1022a, 1022b. To apply a solder to the interior of gasket 5002, inner solder system 5004 is wound onto the end of one of the tube segments 1022b as shown in FIG. 10-1. The second tube segment 1022a is then placed and manipulated until both tube segments 1022a, 1022b are satisfactorily aligned. In one embodiment, inner welding system 5004 applies a weld (e.g., a "GMAW" metal gas arc weld) from the interior of tube segments 1022a, 1022b to a face or edge joint of tube segment 1022a, 1022b and a v-shaped opening formed by beveled/beveled edges of the two tube segments 1022a, 1022b (other cross-sectional shapes other than a v-shaped opening may also be used).

[0349] FIG. 9A shows a partial cross-sectional view of tubing 1024 showing optimal alignment of a welding torch 5502 of inner welding system 5004 to inner bevel surfaces 5228 and 5232 (along longitudinal axes A-A of tubes 1022a, 1022b). In the illustrated embodiment, tubes 1022a, 1022b are perfectly aligned with one another and do not have Hi-Lo (i.e., a height difference between the bevel edges of tubes 1022a, 1022b after tube alignment).

[0350] In one embodiment, the 5000 field system may include 5302 external clamps that are used to secure pipes from outside joints (external to pipes). In one embodiment, the 5302 external clamps have bars on the solder joint and soldering can be done manually. In one embodiment, the external clamps 5302 can be hydraulically operated or can be mechanically operated (eg, using a hand lever). For example, in one embodiment, the outer clamps 5302 may be a tipton clamp as shown in FIGS. 7A and 7B.

[0351] In one embodiment, the internal welding system 5004 is connected to an external structure/system (ie, external to tubes 1022a, 1022b being welded) by an umbilical 5034 (as shown in FIG. 10-1). In one modality, the external system is the remote uLog processing system. In one embodiment, the umbilical 5034 can be between 40 and 80 feet long (for example, for a tube 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/umbilical rod 5034 can be fixedly connected to the inner welding system 5004. That is, the reach rod/umbilical 5034 is a permanent part of the inner welding system 5004. Umbilical 5034 includes a tubular structural member that protects all cables, wiring, and hoses (eg, connecting the outer frame/system and the 5004 inner welding system) from damage.

[0352] In one embodiment, when internal welding system 5004 moves from one tube joint (weld) to the next tube joint (weld), the umbilical 5034 is disconnected at a disconnect point, DP (as shown in FIG. 10-2). This disconnection facilitates the new/incoming tube segment 1022a to be placed in position relative to the first tube 1022b. FIG. 10-2 shows that the cables, hoses and wires (eg connecting the external frame/system and the internal welding system 5004) at the end of the reach/umbilical rod 5034 are disconnected and that the new/incoming tube segment 1022a is being placed in position relative to the first tube 1022b.

[0353] As shown in FIG. 10-3, in one embodiment, after inlet tube 1002a is placed in position with respect to first tube 1002b, umbilical 5034 may hang/extend outside inlet tube 1002a for a distance, HD. In one embodiment, the HD distance that the umbilical 5034 can hang/extend outside the 1002a inlet tube is between 1 and 5 feet.

[0354] The 5034 umbilical is generally used to transport fluids (compressed air), send electrical signals, and/or send communication signals between the external structure/system and the 5004 internal welding system. In one embodiment, the internal welding system 3001 does not include the reach rod or umbilical.

[0355] For example, the 5034 umbilical may include welding power lines configured to power the welding torches. In one embodiment, the 5034 umbilical includes three electrical welding lines to independently supply power to the three associated welding torches in indoor welding system 5004. In one embodiment, the number of weld power lines in the umbilical 5034 may vary and depends on the number of welding torches in the 5004 indoor welding system.

[0356] In one embodiment, the umbilical 5034 may include communication lines configured to communicate with the inspection detector 5056, the inspection chamber 5112 and/or other electronic modules (e.g., to start or stop welding) of the system of internal welding system 5004. In one embodiment, communications to the internal welding system 5004, including inspection detector 5056, inspection chamber 5112 and/or other electronic modules of the internal welding system 5004, can be carried out from wireless way. It should be appreciated that when a plurality of welding torches are provided, a plurality of inspection/laser detectors 5056 may also be provided.

[0357] In one embodiment, the umbilical 5034 may include a fluid communication line configured to supply compressed air to the internal welding system 5004. In one embodiment, the umbilical 5034 may include another (separate) power line configured to supply power to 5116 batteries to recharge them. In one embodiment, the separate power line for recharging 5116 batteries is optional. In one embodiment, the umbilical 5034 may include a separate power line configured to supply power to one or more electronic modules and/or motors of internal welding system 5004. In another embodiment, this separate power line is optional.

[0358] In one embodiment, the 5004 inner welding system is used for pipe having an inside diameter of 26 to 28 inches with a pipe wall thickness of 0 to 1 inch. Therefore, the 5004 internal welding system is configured to fit holes between 24 and 28 inches. In one embodiment, the 5004 inner welding system is used for pipe having an inner diameter of 24 inches or less with a pipe wall thickness of 0 to 1 inch. In one embodiment, the 5004 inner welding system is used for pipe with an outer diameter of 24 inches or less. In one embodiment, the 5004 inner welding system is used for tubes with an outer diameter of 26 to 28 inches.

[0359] FIG. 10A shows the 5004 internal welding system being constructed, dimensioned and positioned on tubes having an inside diameter of 26 inches with a tube wall thickness of 1 inch. For example, in one embodiment, the outside diameter of the 5004 inner welding system frame structure is 23.32 inches relative to the 26 inch inside diameter (with 1 inch tube wall thickness) of the tubes. For example, for 26-inch inside diameter pipe (with 1-inch pipe wall thickness), the outside diameter of the frame structure (not including wheels) of the 5004 inner welding system is 23.32 inches.

[0360] FIG. 10B shows the 5004 internal welding system being constructed, dimensioned and positioned on tubes having a 24 inch inside diameter with 1 inch tube wall thickness. For example, in one embodiment, the outside diameter of the frame structure of the 5004 inner welding system is 21.32 inches relative to the 24 inch inside diameter (with 1 inch tube wall thickness) of the tubes. For example, for 24-inch inside diameter tube, the outside diameter of the frame structure (not including wheels) of the 5004 inner welding system is 21.32 inches.

[0361] In one embodiment, the frame diameter of the 5004 inner welding system can be a function of the inner welding system's ability to fit through the bends of the tube. In one embodiment, the standard minimum bend radius of the tube is 30 times D, where D is the outside or outside diameter of the tube. That is, the radius of the centerline of the tube is 30 times the outer or outer diameter of the tube. For example, for 26" outer or outer diameter pipe, the minimum bend radius that the 5004 inner welding system must travel is 780 inches (ie (26 inches) x 30). For example, for one 24" outside or outside diameter tube, the minimum bend radius that the 5004 internal welding system must travel is 720 inches (ie (24 inches) x 30). In one embodiment, the longer the structure of the 5004 internal welding system is constructed, the narrower it must be.

[0362] In one embodiment, as shown in FIGS. 10C and 10D, field system 5000 may include a support 5330 for transporting and moving first tube 1022a and second tube 1022b. In one embodiment, the bracket 5330 is configured to supply the second tube 1022a at the second end 1038b of the first tube 1022b after the frame assembly of the inner welding system 5004 is positioned on the second end of the first tube 1022b. In one embodiment, the 5330 cradle may be referred to as a Line Up Module (LUM).

[0363] In one embodiment, there may be as many supports as needed to hold the tube 1022a, 1022b. For example, if tube 1022a or 1022b is small and flexible, there may be up to four brackets spaced along the length of tube 1022a or 1022b. If tube 1022a or 1022b is large and rigid, there may only be two supports along the length of tube 1022a or 1022b.

[0364] In one embodiment, two supports can be used to transport and move the tube so that each support is positioned at one end of the tube. In one embodiment, three supports can be used to transport and move the tube so that two supports are positioned at the ends of the tube and one support is positioned at the center section of the tube. In one modality, the centered support is configured to simply provide support and is not configured to be articulated. In one embodiment, the brackets 5330 used for the inlet tube 1022a can all be configured to be upgraded to transport, move and supply the inlet tube 1022a at the second end of the first tube 1022b (after the internal welding system frame assembly 5004 is positioned at the second end of the first tube 1022b) and re-aligns the inlet tube 1022a in case the pre-weld profile data determines the fit is necessary.

[0365] In one embodiment, bracket 5330 may include a set of driven rollers 5332 external to tubes 1022a, 1022b. In one embodiment, the rollers 5332 of the support 5330 may be referred to as the outer rotatable members. In one embodiment, an outer surface 5346 and/or 5348 (as shown in Figure 2G) of the first tube 1022a and/or the second tube 1022b is movably engaged by the outer rotatable member(s) ) 5332 to facilitate adjustment of the relative placement of tubes 1022a, 1022b based on instructions from one or more 5140 processors.

[0366] In one embodiment, the bracket 5330 includes a fixed structure 5334 that is configured to be fixedly attached to a surface (eg, land), a first movable structure 5336 that is configured to be movable to position the tube horizontally and a second movable frame 5338 that is configured to be movable to position the tube vertically.

[0367] In one embodiment, the 5330 bracket can be hydraulically operated. For example, hydraulic cylinders 5340 positioned on the sides of bracket 5330 can be configured to move second movable frame 5338. In one embodiment, hydraulic cylinder(s) 5342 positioned under bracket 5330 can be configured to move the first movable frame 5336. In one embodiment, the movement of the supports 5330 (positioned at both ends of the tubes) can be coordinated to adjust the linear movement of tube 1022a or 1022b in three directions (top to bottom, left to right , front to back) and adjust the angular movement of the 1022a or 1022 tube in two directions (tilt and yaw).

[0368] In one embodiment, cradle 5330 is operatively associated with one or more 5140 processors. In one embodiment, cradle 5330 is connected wirelessly or using a wired connection to the 5140 processor(s) such that, in the If the pre-weld profile data determines the fit, hydraulic cylinders 5340 and 5342 are adjusted to move and realign inlet tube 1022a based on the pre-weld profile data. In one embodiment, the externally positioned rollers 5332 may be operatively linked and controlled by one or more processors 5140 via first movable frame 5336 and/or second movable frame 5338.

[0369] In one modality, the 5300 bracket can be electrically operated. For example, FIG. 73 shows the electrically operated brackets 6010A and 6010B. In one embodiment, cradle rollers 6010A and 6010B can be driven by motors to move tube 1022a or 1022b linearly and/or angularly. In one embodiment, brackets 6010A and 6010B may include motors operatively linked to lead screw arrangements that allow movement of the first movable frame and/or the second movable frame.

[0370] In general, when aligning tubes for the welding process, there may be two tube alignment errors, for example an angular tube alignment error and a placement pipe alignment error. As shown in FIG. 10E, the angular alignment error causes an opening 5344 in one side of the tube. As shown in FIG. 10F, positional alignment error causes opposite Hi-Lo, that is, on one side (eg 1022b), low on the other side (eg 1022a).

[0371] In one embodiment, the 5330 brackets or the 6010A and 6010B brackets can be used in offshore pipeline alignment and welding procedures. In offshore piping applications, angular and positional tube alignment errors can be corrected by sending control signals from one or more 5140 processors to brackets 5330 or brackets 6010A and 6010B (to control associated rollers 5332). Thus, one or more processors 5140 are configured to adjust the relative positioning between the tubes (to correct for alignment errors) by controlling brackets 5330 or brackets 6010A and 6010B. In one embodiment, one or more processors 5140 are configured to operate bracket 5330 to allow relative movement between first tube 1022a and second tube 1002b based on pre-weld profile data to change an interface region 5136 between the tubes 1022a, 1022b before the welding operation based on instructions from one or more 5140 processors.

[0372] In one embodiment, the tubes 1022a, 1002b can be aligned by a crane and the clamp (internal or external). In one embodiment, the clamp can be constructed and arranged to align the two tubes 1022a, 1002b either horizontally or vertically. In one modality, the crane is configured to control the axial position and both angles (tilt and yaw).

[0373] In one embodiment, referring to FIG. 11, the 5004 internal welding system includes a 5006 section, a 5008 center section and a 5010 steering section.

[0374] In one embodiment, the frame members of the upper section 5006, the center section 5008, and the drive section 5010 may be jointly referred to as a frame assembly or as the structure of the internal welding system 5004. In one modality, the frame assembly or internal welding system structure 5004 can be configured to support all components of each of the most remote sections 5006, the center section 5008, and the drive section 5010. In one mode, the frame assembly or internal welding system frame 5004 may include forward 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 assembly or internal welding system structure 5004 is configured to be placed within tubes 1022a, 1022b.

[0375] In one embodiment, the 5006 facing forward section is the section where the external cables, wiring, and system/external structure hoses (external to the tubes to be welded) connect. In one embodiment, section 5006 forward is configured to house all solder support components as described in detail below. In one embodiment, center section 5008 is configured to align tube segments 1022a, 1022b and perform welding procedures. In one embodiment, drive section 5010 is configured to move internal welding system 5004 from one pipe joint to the next pipe joint. In one embodiment, the 5010 drive section is also configured to house batteries, compressed air, and shielding gas that the rest of the 5004 internal welding system needs to operate.

[0376] In one embodiment, some components of internal welding system 5004 are positioned such that half of the component is positioned in the frontmost section 5006 and the remaining half of the component is positioned in the center section 5008. In one embodiment, some components of internal welding system 5004 are positioned in one of the three sections of internal welding system 5004, but are bonded to another of the three sections of internal welding system 5004. For example, a component of internal welding system 5004 is placed in the front section 5006 of the internal welding system 5004 and is connected to only the center section 5008 of the internal welding system 5004.

[0377] FIG. 12 shows a detailed view of the forward section 5006 of the inner welding system 5004. In one embodiment, the upper section 5006 of the inner welding system 5004 includes a trailer hitch 5012, a front electronics module 5014, a front slip ring 5016, a 5018 front clamp control valve, a 5020 wire feed assembly, a 5022 front position sensor, 5024 adjustable ramps, a 5026 front section frame, 5028 guide wheels, a 5030 front rotation motor, and a front swivel joint 5032. In one embodiment, the front electronics module 5014 can include one or more processors 5014. In one embodiment, the front clamp control valve 5018, the front position sensor 5022, and the front slew motor 5030 can be operatively connected to one or more 5140 processors.

[0378] FIGs. 13-22 show views of various components of the front section 5006 of internal welding system 5004. For example, FIG. 13 shows trailer hitch 5012, FIG. 14 shows the front swivel joint 5032, FIG. 15 shows front slip ring 5016, FIG. 16 shows front section frame 5026, FIG. 17 shows the adjustable ramps 5024, FIG. 18 shows guide wheels 5028, FIG. 19 shows the front rotation motor 5030, FIG. 20 shows the front clamp control valve 5018, FIG. 21 shows front position sensor 5022, and FIG. 22 shows the wired power pack 5020, respectively.

[0379] FIG. 11A shows a view of umbilical 5034 in which inner welding system 5004 is configured to mate with a first end 5035 of umbilical 5034 and an operator control system 5039 is configured to attach to a second end 5037 of umbilical 5034. In one embodiment, first end 5035 of umbilical 5034 is connected to trailer hitch 5012 of front section 5006 of internal welding system 5004. In one embodiment, communications (from internal welding system 5004) with the Ulog system are configured to occur through one or more processors or modules in operator control system 5039. In one embodiment, operator control system 5039 is positioned external to tubes 1022a, 1022b being welded together.

[0380] In one embodiment, front section frame 5026 is constructed and arranged to house/support all components of front section 5006 of internal welding system 5004. In one embodiment, front section frame 5026 is constructed and arranged to provide mounting points for all components in front of the 5004 internal welding system and protect these components from damage. In one embodiment, the front section frame 5026 is constructed and arranged to guide new tube segments in alignment with the old/existing tube segments. In one embodiment, the front section frame 5026 can be made of steel or any other material as would be appreciated by one of skill in the art.

[0381] In one embodiment, the front frame 5026 is constructed and arranged to have a tapered tip configuration to allow the internal welding system 5004 to easily move to the new pipe segment when joining/welding the new pipe segment. tube with the old/existing tube segment. In one embodiment, the tapered tip configuration of front frame 5026 can function as an alignment structure that is configured to facilitate alignment of second tube 1022b with first tube 1022a. In one embodiment, the tapered tip-shaped alignment structure is configured to project outwardly from the second end of first tube 1022a to facilitate alignment of second tube 1022b with first tube 1022a.

[0382] In one embodiment, referring to FIG. 12, the front section frame 5026 includes a sensor 5352 configured to detect a tube end when the internal welding system structure 5004 returns to the tube opening after welding a previous tube. In one embodiment, sensor 5352 may be configured to be movable with the structure of internal welding system 5004. In one embodiment, sensor 5352 is operatively linked or associated with one or more 5140 processors.

[0383] In one embodiment, sensor 5352 may be a rotary switch. For example, the rotary switch may have a prosthesis or wire projecting downwardly slanted to the inner surface of the tube and configured to slidingly engage the inner surface of the tube until it hits the tube and extends downward after reaching the end of the tube. tube to actuate the rotary switch, thus detecting the end of the tube. For example, when the front section frame 5026 reaches the end of the tube, a portion of which will protrude out of the tube to receive the end of the next tube to be welded, the wire is configured to extend out of its normal position to detect the end of the tube. In another embodiment, sensor 5352 may be a linear encoder that is configured to be operatively linked to the wheels/rollers of the inner welding system 5004 to determine the distance traveled by the inner welding system 5004 and using that information to capture/detect the end of the known length of the tube.

[0384] In one embodiment, the sensor 5352 is configured to detect the 5136 interface region between tubes 1022a, 1022b. In one embodiment, one or more 5140 processors are configured to operate 5124 drive motors to move the structure of internal welding system 5004 through at least one of tubes 1022a, 1022b until sensor 5352 detects the 5136 interface region. In this embodiment, sensor 5352 is configured to detect when the structure of inner welding system 5004 is positioned in the region of interface between tubes 1002a, 1022b. In one embodiment, sensor 5352 can be inspection sensor 5056. In one embodiment, sensor 5352 can be a laser. In one embodiment, sensor 5352 may be inspection camera 5112. In one embodiment, inspection detector 5056 and/or inspection camera 5112 are configured to also perform the detection function of sensor 5352.

[0385] In one embodiment, referring to FIG. 12, an end portion 5208 of front section frame 5026 is configured to be connected to a flange portion 5210 (as shown in FIG. 23) of a front bracket 5142 of center section 5008. In one embodiment, the flange portion 5210 (as shown in FIG. 23) end 5208 of front section frame 5026 is configured to be attached to flange portion 5210 of front clamp 5142 of center section 5008 using clamping members, eg screws 5212 (as shown in FIG. 23).

[0386] The front swivel joint 5032 on the front section 5006 is shown in FIGS. 12 and 14. A swivel joint is generally a joint or coupling that is constructed and arranged to allow the rotation of two matched/joined members. The swivel joint is constructed and arranged to provide a seal between a stationary feed passage (tube or tubing) and a rotating member (drum, cylinder or spindle) to allow a fluid to flow into and/or out of the rotating member. . Fluids commonly used with swivel unions include compressed air and purge gas. A swivel joint generally includes a housing, a shaft, a seal, and a bearing. Bearings and seal are mounted around the shaft. Bearings are used to allow a swivel joint member, either the shaft or the housing, to rotate. The seal is constructed and arranged to prevent fluid medium (eg compressed air or purge gas) from escaping outside the swivel joint while in operation. A swivel joint locks an inlet valve while rotating to find an outlet valve. During this time, fluid flows into the swivel from its source and is held within the swivel during movement. This fluid exits the swivel joint when the valve openings meet during rotation and more fluid flows into the swivel again for the next rotation.

[0387] In one embodiment, the front swivel joint 5032 is configured to allow compressed air to flow therethrough. In one embodiment, the front swivel joint 5032 (for example, described in connection with FIG. 25, for example) is constructed and arranged to receive compressed air from a rear swivel joint 5072 (via, for example, a ring rear slider 5080, rotating hub 5078 and front slider ring 5016). The rear swivel has essentially the same components and operates in essentially the same manner as the front swivel 5032 and is therefore not illustrated in the same detail as the front swivel 5032.

[0388] In one embodiment, the front swivel joint 5032 is constructed and arranged to send a portion of the compressed air received to the front clamp control valve 5018 (to actuate and operate the front clamp 5142) through valve 5204. In a In this embodiment, the front swivel joint 5032 is constructed and arranged to send the remaining portion of the compressed air received to a compressor or an external air supply tank 5029 (as shown in FIG. 70) to recharge the system (e.g., fill the compressed air tank) through 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 swivel joint 5032.

[0389] 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 recharge procedure, compressed air from the external air supply tank 5029 travels through valves 5115, 5117 and 5204 to the front swivel joint 5032, from the front swivel joint 5032 to the rear swivel joint 5072 and then through valves 5198 , 5196, 5194 and 5113 to compressed air tank 5128 to refill compressed air tank 5128 with compressed air. In one embodiment, the entire fluid communication path (or supply fluid communication line) between the external air supply tank 5029 and the compressed air tank 5128 is maintained at tank pressure during the refill procedure.

[0390] In one embodiment, the front swivel joint 5032 on the front section 5006 is also configured to allow compressed air from the umbilical 5034 to be connected to the wire feed assembly 5020 which is rotatably mounted on a rotating hub 5078 of the center section 5008 .

[0391] The front slip ring 5016 on the front 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 continuous unrestricted rotation when transmitting energy and/or data signals. The slip ring includes a stationary frame (brush) that rubs against the outside diameter of a rotating frame. As the rotating structure rotates, electrical current or signal is conducted through the stationary structure to the rotating structure that makes the connection. The stationary frame can be a graphite or metal contact (brush) and the rotating frame can be a metal ring. Additional ring/brush assemblies are stacked along the rotary axis if more than one electrical circuit is required. Either the brushes or rings are parked while the other component rotates.

[0392] In one embodiment, the front slip ring 5016 is configured to allow transmission of communication signals from the front electronics module 5014 to a wired feed electronics module 5046 of the wired feed assembly 5020. In one embodiment, the front slip ring 5016 is also configured to allow the transmission of power (welding) and the transmission of communication signals from umbilical 5034 to the internal welding system 5004.

[0393] In one embodiment, as shown in FIGS. 12 and 17, adjustable ramps 5024 are constructed and arranged to improve the alignment of tube segments 1022a, 1022b. In one embodiment, adjustable ramps 5024 are constructed and arranged to be adjustable to accommodate different pipe sizes. In one embodiment, adjustable ramps 5024 are constructed and arranged to also protect center section 5008 from being hit by the incoming tube segment 1022b. In one embodiment, the adjustable ramps 5024 of the internal welding system 5004 are constructed and arranged to be adjustable to extend slightly more than the retracted clamp shoes (i.e., the clamp shoes 5157 in their retracted positions), but extend less than the extended clamp shoes (that is, the 5157 clamp shoes in their extended positions).

[0394] In one embodiment, as shown in FIGS. 12 and 18, guide wheels 5028 are constructed and arranged to prevent inlet tube segment 1022b from scraping the sides of taller front section 5006. In one embodiment, guide wheels 5028 are constructed and arranged to be adjustable. to accommodate different pipe sizes. In one embodiment, guide wheels 5028 are passive members.

[0395] In one embodiment, as shown in FIGS. 12, the more advanced electronics module 5014 includes communication connections to umbilical 1034 and to front slip ring 5016. For example, in one embodiment, front electronics module 5014 is configured to communicate power and communication signals to and from umbilical 5034 and is configured to communicate power and communication signals to and from the front slip ring 5016.

[0396] In one modality, the front 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 modality, the front electronics module 5014 is further configured to receive signals from the front position sensor 5022.

[0397] The front rotation motor 5030 in the front 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 rotating hub 5078 of the center section 5008 while maintaining the front and rear brackets 5142 and stationary 5144.

[0398] In one embodiment, the front rotation motor 5030 may include a displacement gear drive (due to packaging restrictions). For example, in one embodiment, the front rotating motor 5030 has an electric motor with 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 outer gear 5021a can engage a displacement gear 5021b, also having outer teeth. An opposite end of displacement gear 5021b also has outer teeth 5021c. Outer teeth 5021c of the outer/driver gear are constructed and arranged to mate with inner teeth 5023 (as shown in FIG. 19) formed on an inner circumferential surface on a driven (annular) gear member 5021 of the wire feed assembly 5020 to transmit torque from the front rotating motor 5030 to the wire feed assembly 5020. In one embodiment, the outer gear/driver outer teeth 5021c are constructed and arranged to mate with the inner teeth 5023 formed in the driven gear member ( annular) 5021 of the 5020 wire feed assembly using a gear train arrangement (see FIG. 19) to transmit torque from the 5030 front rotating motor to the 5020 wire feed assembly.

[0399] In one embodiment, as shown in FIGS. 12 and 20, the front clamp control valve 5018 is configured to receive compressed air from the stationary side of the front swivel joint 5032.

[0400] In one embodiment, the front clamp control valve 5018 is operatively turned on to receive control signals from the front electronics module 5014. In one embodiment, the front clamp control valve 5018 is configured to supply air compressed to actuate and operate front clamp 5142 when receiving signals from front electronics module 5014.

[0401] In one embodiment, as shown in FIGS. 12 and 21, the front position sensor 5022 may be a proximity sensor and a specially shaped encoder wheel. In one embodiment, the encoder wheel is constructed and arranged to be rotatably mounted to the wire feed assembly 5020 so as to be rotated with the rotating hub 5078.

[0402] In one embodiment, the front position sensor 5022 is operably linked to send control signals to the front electronics module 5014. In one embodiment, the front position sensor proximity sensor 5022 can be configured to send signals control for the 5014 front electronics module when the sensor is at a high point on the encoder wheel. In one embodiment, front electronics module 5014 is configured to use signals received from front position sensor 5022 to determine the orientation of front section 5006 to the rest of internal welding system 5004 (eg, rotating hub 5078).

[0403] In one embodiment, as shown in FIGS. 12, 22, 22A and 22B, the 5020 wire feed assembly includes a 5036 wire spool holder, a 5038 wire straightener, a 5040 welding wire guide tube, a 5042 shielding gas control valve, a wire feed system 5044, wire feed electronics module 5046, and a wire feed assembly frame 5048. In one embodiment, an exemplary spool of solder wire 5272 is shown in FIG. 22A. In one embodiment, wire straightener 5038, shielding gas control valve 5042, and 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 5140 processors.

[0404] In one embodiment, the wire feed assembly 5020 is constructed and arranged to house the 5272 wire spools, wire spool holders, wire straighteners, wire feed system, and wire feed control valves. shielding gas for each of the three illustrated welding torches 5502 in center section 5008 of indoor welding system 5004. In the illustrated embodiment, wire feed assembly 5020 includes three wire spool holders 5036, three wire straighteners 5038, three 5040 welding arc tubes, three 5042 shielding gas control valves, and three 5044 wire feed systems associated with three illustrated welding torches 5502 in center section 5008 of internal welding system 5004. In one embodiment, the number from wire spool holders, wire straighteners, arc welding (guide) tubes, shielding gas control valves, welding wire spools, and wire feed systems to the inland welding system. 5004 suit may vary and depend on the number of welding torches.

[0405] In one embodiment, the 5272 spool of solder wire has a size of 7 (7/8) inches and a weight of 10 pounds. In one modality, the size of the electrode or solder wire is 0.03 inches. In one embodiment, the electrode or welding wire is made of a carbon steel material. In one embodiment, the electrode or welding wire is an ER70S-6 carbon steel MIG welding wire manufactured, for example, by Chicago Electric Welding Systems. In one embodiment, the electrode or welding wire is designed for use with various shielding gas mixtures such as 100% carbon dioxide (CO ), a mixture of 75% Argon and 25% CO , or a mixture of 98% Argon and 2% O2.

[0406] In one embodiment, the wire feed assembly 5020 is constructed and arranged to be connected to the rotating hub 5078 of the center section 5008 such that the rotation of the wire feed module 5020 through the front rotation motor is translated directly to the rotating hub 5078. In one embodiment, the wire feed assembly 5020 is constructed and arranged to be secured (e.g., using clamping members) to the rotating hub 5078 of the center section 5008. In one embodiment, the assembly of 5020 Wired Power is also constructed and arranged to house electronics to operate all motors in the 5020 Wired Power Assembly and the 5078 Rotating Hub.

[0407] In one embodiment, the wired power assembly structure 5048 is constructed and arranged to be hollow so as to allow power, communication signals, shielding gas, welding wire/electrode, motor control signals and air compressed to enter, exit and cross.

[0408] In an embodiment as shown in FIG. 22, wire spool holder 5036 is constructed and arranged to receive and hold electrode/solder coils (not shown) for use by inner welding system 5004. In one embodiment, wire spool holder 5036 may include a member 5220 retaining wire configured to retain the solder wire/electrode coil in it.

[0409] In one embodiment, retaining member 5220 may be removed positioned on an axis 5226 of wire spool holder 5036 using a locking member 5222 attached to retaining member 5220. Locking member 5222 may include a region of smaller diameter and a region of larger diameter. In one embodiment, a locking member receiving opening may be formed in axle 5226 as having a generally closed circle cross-sectional shape, with a side opening 5224 extending outwardly from axle 5226. , the locking member 5222 is slidably slidable such that the larger diameter region or the smaller diameter region is within the generally closed circular sectional shape of the locking member receiving opening. When the largest diameter region is positioned in the locking member receiving opening, the shaft 5226 surrounds the largest diameter region, which is unable to pass through the side opening 5224, locking the retaining member 5220 to the shaft 5226 due to engagement. between the locking member 5222 and the locking member receiving opening. Alternatively, where locking member 5222 is positioned such that the smaller diameter region is generally surrounded by the locking member receiving opening, retaining member 5220 may be freely withdrawn from shaft 5226, as the region of smaller diameter may pass through side opening 5224. In another embodiment, retaining member 5220 may be detachably attached to shaft 5226 of wire spool support 5036 using a retaining screw.

[0410] The welding wire or electrode coming out of the welding wire/electrode coil may have a permanent bend to it. In one embodiment, wire straightener 5038 is configured to remove permanent curl and straighten the welding wire (e.g., bending the welding wire in the other direction). Direct welding wire configuration helps the welding wire to pass through the 5040 arc weld tube (guide tube) more easily. In addition, supplying direct weld wire to the 5502 welding torch results in more consistent welds. In one embodiment, wire straightener 5038 is optional.

[0411] In one embodiment, the welding arc tube (guide) 5040 is constructed and arranged to guide the welding wire/electrode from the wire feed system 5044 to the welding torch 5502. In one embodiment, the welding tube welding arc (guide) 5040 connected at both ends. In one embodiment, the welding wire is sheathed by welding arc tube (guide) 5040.

[0412] In one embodiment, the wire feed system 5044 is constructed and arranged to pull the welding wire through the wire straightener 5038 from the coil of welding wire 5272 and push the welding wire through the welding arc tube. (guide) 5040 for the 5502 welding torch.

[0413] In one embodiment, the 5044 wire feed system is configured to be automatically controlled to supply the appropriate amount of wire to the 5502 welding torch. In one embodiment, the 5044 wire feed system may include the motor and two knurled wheels that are configured to pull the welding wire through the wire straightener 5038 of the coil of welding wire 5272 and push the welding wire through the welding arc tube 5040 to the welding torch 5502. In one embodiment, the motor(s) of the wired supply system (5004) may include an encoder that is configured to measure the motor rotations. In one embodiment, the motor(s) of the 5004 wire feed system are operatively connected to one or more 5140 processors. This information can be used by the one or more 5140 processors to determine the amount of wire that is fed. into welding torch 5502 and to regulate the amount of welding wire to be fed into welding torch 5502. In one embodiment, when rotating hub 5078 is rotated, welding wire/electrode is fed to torch 5502 by the assembly of 5020 wired power supply.

[0414] In one embodiment, the 5042 shielding gas control valve is configured to control the flow of shielding gas to the welding torch through a shielding gas line. In one embodiment, each 5502 welding torch has a corresponding 5042 shielding gas control valve connected to it.

[0415] In one embodiment, the shielding gas is stored in the excitation section 5010 and is brought to the wired feed assembly 5020 by a hose/shield gas line for distribution to one or more 5502 welding torches. In one embodiment, shielding gas control valve 5042 is configured to receive shielding gas from rear swivel 5072 (e.g., through rear slip ring 5080 and rotating hub 5078).

[0416] In one embodiment, shielding gas control valve 5042 is operatively connected to receive control signals from wired power electronics module 5046. In one embodiment, shielding gas control valve 5042 is configured to supply the shielding gas to the corresponding welding torch when receiving signals from the 5046 wired power electronics module.

[0417] In one embodiment, wire feed electronics module 5046 is configured to send and receive power and upstream communication signals through front slip ring 5016 to front electronics module 5014. In one embodiment, the module Wired power electronics module 5046 is configured to send and receive power and downstream communication signals through rear slide ring 5080 to a center section electronics module 5064.

[0418] In one embodiment, wired feed electronics module 5046 is configured to control all motors and valves attached to rotating hub 5078 of center section 5008. For example, wired feed electronics module 5046 is configured to control the wire feed system, axial movement of the 5502 welding torch, the radial movement of the 5502 welding torch, the tilting movement of the 5502 welding torch and/or the flow and distribution of shielding gas. That is, the wired power electronics module 5046 is operatively connected to the shielding gas control valve(s) (5042) to control the flow and distribution of shielding gas to the torch(es). s) 5502 of solder.

[0419] In one embodiment, the wired feed electronics module 5046 is operatively connected to the 5550 axial welding torch motor to control axial movement of the 5502 welding torch. In one embodiment, the wired power electronics module 5046 is operatively connected to radial welding torque motor 5512 to control radial movement of welding torch 5502. In one embodiment, wire feed electronics module 5046 is operatively connected to tilt welding torch motor 5588 to control the tilt movement of the 5502 welding torch. In one modality, the 5550 axial welding torch motor, radial welding torch motor, and 5588 tilting torsional motor can be designated individually or together as "motor (s) of welding torch".

[0420] In one embodiment, the wire feed electronics module 5046 is configured to communicate with and control a 5056 inspection detector and a 5112 inspection camera both rotatably mounted on the 5078 rotating hub. 5056 is transported by the 5004 inner welding system frameset. In one embodiment, the inspection chamber 5112 is transported by the 5004 inner welding system frameset.

[0421] In one embodiment, the inspection detector 5056 may include an inspection laser, a three-dimensional inspection camera, an inspection ultrasound sensor system, an electrical capacitive inspection probe, and any other inspection detectors as would be appreciated by one versed in the technique.

[0422] FIGs. 23 and 24 show a front view and a cross-sectional view of the center section 5008 of the inner welding system 5004. In one embodiment, as discussed above, the front frame 5026 of the front section 5006 is connected to the front bracket 5142 of the center section 5008. and wire feed assembly 5020 is rotatably connected to rotating hub 5078.

[0423] In one embodiment, the center section 5008 of the internal welding system 5004 includes the front clamp 5142 (or the first pipe coupling structure 5052), the inspection detector 5056, a weld head assembly or torch module 5500, a rear clamp 5144 (and a second tube coupling frame 5054), a rear clamp control valve 5062, the center section electronic module 5064, the toe-in wheels 5066, a center section frame 5068, adjustable ramps 5070 , rear swivel coupling 5072, rear rotation motor 5074, rear position sensor 5076, rotation module 5078, and rear slip ring 5080.

[0424] In one embodiment, the front clamp 5142 (or the first pipe coupling structure 5052), the inspection detector 5056, the weld head assembly or the torch assembly 5500, the rear clamp 5144 (and the second pipe coupling structure 5054), rear clamp control valve 5062, rear rotation motor 5074, rear position sensor 5076 are operatively connected to one or more processors 5140. In one embodiment, inspection chamber 5112 is operatively linked to one or more 5140 processors. In one embodiment, center section electronics module 5064 may include one or more 5140 processors. a clamp to securely fasten to a pipe surface, or an interior seal that is configured to create a gas seal against the pipe interior surface, or a combination of both clamps and above mentioned seal. mentioned. For example, in one embodiment, first tube engaging structure 5052 may be first clamp 5142, first seal 5146, or a combination thereof. In one embodiment, the second tube engaging structure 5054 may be the second clamp 5144, the second seal 5148, or a combination thereof. In one embodiment, the first and second tube engaging structures 5052 and 5054 are carried by the inner welding system frame assembly 5004.

[0425] FIGs. 25-31 show views of various components of the center section 5008 of internal welding system 5004. For example, FIG. 25 shows the rear swivel joint 5072, FIG. 26 shows rear slip ring 5080, FIG. 27 shows center section frame 5068 and adjustable ramps 5070, FIG. 28 shows wheels 5066, FIG. 29 shows the rear clamp control valve 5062, FIG. 30 shows front clamp 5142, and FIG. 31 shows the rotation module 5078, respectively.

[0426] The rear swivel joint 5072 in the center section 5008 is shown in FIGs. 23, 24, and 25. In one embodiment, the structure and operation of the rear swivel joint 5072 is similar to the front swivel joint 5032 and therefore the structure and operation of the rear swivel joint 5072 will not be described in detail in this document, except for differences noted below.

[0427] In one embodiment, the rear swivel joint 5072 is configured to allow both the flow of compressed air and the flow of shielding gas (or purge gas) therethrough. In one embodiment, the rear swivel joint 5072 in the center section 5008 is configured to allow compressed air from a compressed air tank 5128 (as shown in Figures 32A and B) of the drive section 5010 to be connected through the rotating hub 5078 of the center section 5008 to front swivel joint 5032. In one embodiment, rear swivel joint 5072 in center section 5008 is also configured to connect shield gas tanks 5114 (as shown in FIGS. 32A and 32B) in drive section 5010 to the 5042 Shield Gas Control Valves on the 5020 Wired Power Assembly of the Front Section 5006.

[0428] In one embodiment, the rear swivel joint 5072 is constructed and arranged to send a portion of the compressed air received to the rear clamp control valve 5062 (to operate the rear clamp 5144). In one embodiment, the rear swivel joint 5072 is constructed and arranged to send the remaining portion of the compressed air received to the front swivel 5032 (e.g., through the rear swivel ring 5080, the swivel hub 5078, and the front swivel ring 5016) . In one embodiment, the remaining portion of the received compressed air sent to the front swivel 5032 passes through the rear swivel 5072.

[0429] In one embodiment, the front and rear swivel unions 5032 and 5072 of this application may be the type that is commercially available under the name Series 012 2 Pass Threaded Shaft Unions, manufactured by Rotary Systems, Inc. In another embodiment, the front and rear swivel joints of the present application can be any swivel joint that would be appreciated by one of ordinary skill in the art.

[0430] In one embodiment, the structure and operation of the rear slip ring 5080 is similar to the front slip ring 5016 and therefore the structure and operation of the rear slip ring 5080 will not be described in detail in this document, except for differences noted below.

[0431] In one embodiment, as shown in FIGS. 23, 24 and 26, rear slip ring 5080 in center section 5008 is configured to allow transmission of communication signals between wire electronics feed module 5046 and center section electronics module 5064.

[0432] In one embodiment, the front and rear slip rings 5016 and 5080 of the present application may be of the type that is commercially available under the name AC6275, manufactured by Moog, Inc. In one embodiment, the front and rear slip rings 5016 and 5080 of the present application can be classified as 50 amps. In another embodiment, the front and rear slip rings of the present application can be any swivel joint that would be appreciated by one of ordinary skill in the art.

[0433] In one embodiment, as shown in FIGS. 23 and 24, center section electronics module 5064 in center section 5008 includes communication cables for wired power assembly 5020 through rear slip ring 5080 and communication cables for drive section 5010. In one embodiment, center section electronics module 5064 in center section 5008 is configured to control rear rotation motor 5074 and receive signals from rear position sensor 5076. In one embodiment, center section electronics module 5064 in center section 5008 is also configured configured to control the 5062 rear clamp control valve.

[0434] In one embodiment, as shown in FIGS. 23, 24 and 27, center section frame 5068 is constructed and arranged to house/support all components of center section 5008 of internal welding system 5004. In one embodiment, center section frame 5068 is constructed and arranged to provide mounting points for all components located in the center section 5008 and protect those components from damage. In one embodiment, center section frame 5068 is also constructed and arranged to connect to drive section 5010 via a U-shaped hinge that allows internal welding system 5004 to bend into curved tubes. In one embodiment, the center section frame 5068 can be made of steel or any other material as would be appreciated by one of ordinary skill in the art.

[0435] 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 bracket 5144. In one embodiment, the end portion 5214 of the center section frame 5068 is configured to be attached to the 5216 flange portion of the 5144 rear clamp using clamping members, eg 5218 screws.

[0436] In one embodiment, as shown in FIGS. 23, 24, and 27, the 5070 Adjustable Chutes are constructed and arranged to help center the 5004 Inner Welding System when the 5004 Inner Welding System is being placed on a tube. In one embodiment, 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 5070 adjustable ramps are constructed and arranged to be adjustable to accommodate different pipe sizes.

[0437] In one embodiment, as shown in FIGS. 23, 24, and 28, toe-in wheels 5066 are constructed and arranged to support the weight of center section 5008. In one embodiment, toe-wheels 5066 are constructed and arranged to be flexible to protect internal welding system 5004 from knocks. impactful when the 5004 internal welding system crosses a weld ball. In one embodiment, toe-wheels 5066 are constructed and arranged to have an adjustable toe-in angle to assist internal welding system 5004 to run directly on the tube. In one embodiment, convergence wheels 5066 are constructed and arranged to be height adjustable for different tube sizes. In one embodiment, convergence wheels 5066 are passive members.

[0438] In one embodiment, as shown in FIGS. 23, 24 and 29, the rear clamp control valve 5062 is constructed and arranged to receive compressed air from the stationary side of the rear swivel joint 5072.

[0439] In one embodiment, rear clamp control valve 5062 is operatively connected to receive control signals from center section electronics module 5064. In one embodiment, rear clamp control valve 5062 is configured to supply air compressed to actuate and operate rear clamp 5144 when receiving signals from center section electronics module 5064.

[0440] In an embodiment as shown in FIG. 24, the rear position sensor 5076 may be a proximity sensor and a specially shaped encoder wheel. In one embodiment, the encoder wheel is constructed and arranged to be rotatably mounted to the rotating hub 5078.

[0441] In one embodiment, rear position sensor 5076 is operatively linked to send control signals to center section electronics module 5064. For example, in one embodiment, rear position sensor proximity sensor 5076 can be configured to send control signals to the 5064 center section electronics module when the sensor is at a high point on the encoder wheel. In one embodiment, center section electronics module 5064 is configured to use signals received from rear position sensor 5076 to determine the orientation of center section 5008 relative to the rest of internal welding system 5004 (e.g., rotating hub 5078).

[0442] The 5074 rear rotation motor 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 rotating hub 5078 of the center section 5008 while maintaining the clamps front and rear 5142, 5144 stationary. In one embodiment, rotation motors 5030 and 5074 are configured to circumferentially rotate welding torch 5502 (360° rotation) along an interface region 5136. In one embodiment, rotation motors 5030 and 5074, configured to directing the radiation inspection beam, are also configured to drive the 5502 welding torch at least 360° with respect to the axis of the AA tube so as to complete a rotationally continuous, rotational pass weld.

[0443] In one embodiment, the front rotation motor 5030 and the rear rotation motor 5074 may be referred to as the steer motors. In one embodiment, the front rotation motor 5030 and the rear rotation motor 5074 are operatively associated with one or more processors 5140.

[0444] In one embodiment, the 5074 rear rotation motor has an electric motor with a rotor, a rotary shaft rotated by the rotor, and an exciter gear supported by the rotating shaft and having teeth thereon. Actuator gear teeth are constructed and arranged to engage with teeth formed in a driven gear member 5079 of rotating hub 5078 to transmit torque from the rear rotation motor 5074 to the rotating hub 5078.

[0445] In one embodiment, rotating hub 5078 is constructed and arranged to rotate during weld, pre-weld sweep, and post-weld sweep procedures. In one embodiment, the rotating hub 5078 is positioned between the first and second brackets 5142 and 5144. Since the first and second brackets 5142 and 5144 are not physically connected to one another, the front rotation motor 5030 and the rotation motor The rear end 5074 at each end of the rotating hub 5078 are timed to prevent the two tubes 1022a, 1022b from moving relative to one another. In one embodiment, the two tube engaging structures 5142, 5144 may be rotated relative to one another by rotating the front rotation motor 5030 and the rear rotation motor 5074, for example, at different speeds and/or in different directions. In one embodiment, only when the front rotation motor 5030 and the rear rotation motor 5074 are rotating at the same speed and in the same direction, do the welding torch 5502 and inspection detector 5056 rotate along the interface region 5136 between tubes 1022a, 1022b (e.g. without moving tube engaging structures 5142, 5144).

[0446] In one embodiment, a central portion 5077 of rotating hub 5078 includes slits/openings through which shielding gas hoses, bow tubes, welding power cables, motor cables, detector cables inspection and camera cables are configured to pass.

[0447] In one embodiment, as shown in FIGS. 23, 24 and 30, front clamp 5142 has a hollow configuration. In one embodiment, an opening 5082 through the center of front clamp 5142 is constructed and arranged to be large enough to allow all necessary cables and hoses to pass through. In one embodiment, opening 5082 of front clamp 5142 is also constructed and arranged to allow for a structural member that is necessary to support the weight of the front half of the internal welding system 5004, as well as to maintain the alignment of the two halves/segments. tube 1022a, 1022b of the solder joint. In one embodiment, the front and rear brackets 5142, 5144 are constructed and arranged to be mounted to the rotating hub 5078, for example, by angular contact ball bearings 5108, 5098 which are preloaded to provide rigidity.

[0448] In one embodiment, the inner surface 5130, 5132 of the first tube 1022a and/or the second tube 1022b is engaged and manipulated by the first clamp 5142 and the second clamp 5144, respectively to adjust the relative positioning of the tubes based on the instructions of one or more processors 5140. In one embodiment, adjustment of the relative positioning of tubes 1022a, 1022b is achieved without disengaging the first tube engaging structure 5144 from the interior surface 5132 of the first tube 1022b and without disengaging the second tube engaging structure from tube 5142 of the inner surface 5130 of the second tube 1022a. This can be done because rotation motors 5030 and 5074 are configured to rotate tubes 1022a, 1022b without disengaging tube engaging structures 5144, 5142 as described in this application.

[0449] In one embodiment, as shown in FIGS. 23, 24 and 30, front bracket 5142 generally includes a piston 5084, a cylinder 5086, a bushing 5088, clamping shoe pin members 5090, connecting members 5092, a shaft 5094, a hub 5096, a front bearing 5098 , a spider member 5100, a bell-shaped housing 5102, a front plate 5104, a back 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 supporting the rotating 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 therefore the structure, configuration and operation of the rear clamp 5144 will not be described in detail in this document.

[0450] In one embodiment, the front clamp 5142 is configured to secure one of the tubes 1022a, 1022b and the second clamp 5144 is configured to secure the other of the tubes 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 inner welding system 5004 may, individually or together, be referred to as the inner welding system 5004 brake system which secures the structure of the inner welding system 5004 at a desired location within of tubes 1022a, 1022b. In one embodiment, the front and rear clamps 5142, 5144 are radially extending clamps that fit the inner surface 5130, 5132 of tubes 1022a, 1022b, respectively, to protect the frame of the inner welding system 5004 from movement. The operation of the front and rear clamps 5142 and 5144 will be discussed in detail below.

[0451] In one embodiment, internal welding system 5004 includes first tube engaging structure 5052, second tube engaging structure 5054, inspection detector 5056, one or more processors 5140; and welding torch 5502. In one embodiment, inspection detector 5056, inspection chamber 5112, welding torch 5502, and welding head assembly 5500 are rotatably mounted on rotating hub 5078. Structure, configuration and operation of each of the first tube engaging structure 5052, the second tube engaging structure 5054, the inspection detector 5056, the inspection camera 5112, the welding torch 5502, and the welding head assembly 5500 are described in detail. with respect to FIGS. 30 and 33-59 and their related descriptions.

[0452] FIGS. 32A and 32B show detailed side and top views of the 5010 drive section of the internal welding system 5004. In one embodiment, the drive section 5010 of the internal welding system 5004 includes the 5114 shielding gas tanks, the 5116 batteries, the 5118 drive section electronics module, 5120 pneumatic valves, 5122 drive wheels or rollers, 5124 drive motors, 5126 brakes, and 5128 compressed air tank. In one embodiment, 5120 pneumatic valves include a 5190 brake valve and a 5192 drive wheel valve (both shown in FIG. 70). In one embodiment, drive section 5010 of internal welding system 5004 includes a drive section frame 5278. In one embodiment, drive section frame 5278 may be made of steel or any other material as would be appreciated by a skilled person. in technique.

[0453] In one embodiment, the 5118 drive section electronics module may include one or more 5140 processors. In one embodiment, the 5120 pneumatic valves (the 5190 brake valve and the 5192 drive wheel valve) and the motors 5124 drives may be operatively connected to one or more 5140 processors.

[0454] In one embodiment, the drive section 5010 can be connected to the center section 5008 through a universal joint 5123 and spring members 5125.

[0455] In one embodiment, the 5114 shielding gas tanks are constructed and arranged to hold the shielding gas needed for the 5502 welding torches. In one embodiment, the hoses are constructed and arranged to connect the shielding gas tanks 5114 to the rear swivel joint 5072 in the center section 5008.

[0456] In one embodiment, 5116 batteries are lithium ion batteries. In one embodiment, the 5116 batteries are configured to power all of the electronic components as well as the electric motors 5124 driving the internal welding system 5004. For example, in one embodiment, the 5116 batteries are configured to power the electronics module center section 5064, front section electronics module 5014, drive section electronics module 5118, and wire feed electronics module 5046. In one embodiment, batteries 5116 may be operatively linked to one or more processors 5114 .

[0457] In one embodiment, the 5116 batteries are also configured to power the 5512 Radial Welding Torch Motor, 5588 Tilt Welding Torch Motor, 5550 Axial Welding Torch Motor, Power Systems Motors with wire 5044, front and rear rotation motors 5030 and 5074, and drive motors 5124. In one modality, the 5116 batteries are not configured to provide welding power. In one embodiment, the 5116 batteries are configured to supply power only to the 5118 drive section electronics module and the 5124 drive motors, while power to the rest of the motors and the 5004 internal welding system electronics modules, including Radial Welding 5512 Torch Motor, 5588 Tilt Welding Torch Motor, 5550 Axial Welding Torch Motor, 5044 Wire Feed Systems Motors, 5030 and 5074 Front and Rear Rotate Motors, center section electronics module 5064, front section electronics module 5014, and wired power electronics module 5046 are supplied from an external power source via the range/umbilical rod 5034.

[0458] In one embodiment, drive motors 5124 are configured to drive rollers or wheels 5122 to move the frame assembly (including first tube engaging structure 5052, second tube engaging structure 5054, to (s) ) welding torch(es) 5502 and inspection detector 5056) of internal welding system 5004, from the first end of tube 1022a, 1022b to the second end of tube 1022a, 1022b along an interior 5130, 5132 of the tube 1022a, 1022b. In one embodiment, the 5124 drive motors of the 5010 drive section are configured to move the frame of the inner welding system 5004 under the 1004 piping after each weld is complete. In one embodiment, the 5124 drive motors of the 5010 drive section are configured to accelerate and decelerate internal welding system 5004 in pipeline 1004.

[0459] In one mode, the power source is carried by the 5004 internal welding system frame assembly and is configured to power the 5124 drive motors. In one mode, the 5124 drive motors of the 5010 drive section are powered electrically. In one embodiment, the 5124 drive motors of the 5010 drive section are powered by the 5116 batteries.

[0460] In one embodiment, drive rollers 5122 are configured to engage inner surfaces 5130, 5132 of one or more of tubes 1022a, 1022b. In one embodiment, drive rollers 5122 are operatively connected to drive motors 5124 of drive section 5010. In one embodiment, drive rollers 5122 are configured to be driven by a pneumatic cylinder 5137 that is operatively associated with pneumatic valves 5120. to receive compressed air from compressed air tank 5128. In one embodiment, drive rollers 5122 are made of an elastomeric material or a rubber material.

[0461] In one embodiment, drive rollers 5122 are configured to allow movement of internal welding system 5004 under pipe 1004 after each weld is complete. In one embodiment, inner welding system 5004 may include a plurality of drive rollers 5122 that are configured to rotatably support the frame assembly or structure of inner welding system 5004. For example, in one embodiment, inner welding system 5004 includes four active drive wheels. That is, two drive wheels on each side that are 180° apart. In one modality, the number of drive wheels can vary. In one embodiment, drive rollers 5122 may include bearing strips thereon to increase their traction when internal welding system 5004 is driving through the pipeline.

[0462] In one embodiment, two of the four 5122 drive rollers can be directly connected and driven by their respective 5124 drive motors. In one embodiment, the other two 5122 drive rollers can be connected to the drive wheels by the motor by chains 5111 and are driven by the engine-driven drive wheels.

[0463] In one embodiment, drive rollers 5122 are constructed and arranged to drive welding system 5004 within tubes 1022a, 1022b until welding system 5004 is in the desired location. In one embodiment, drive rollers 5122 are constructed and arranged to be pressed against the interior of the tube by a pneumatic cylinder.

[0464] In one embodiment, brake 5126 is configured to be actuated by a pneumatic cylinder 5133 that is operatively associated with pneumatic valves 5120 to receive compressed air from compressed air tank 5128. In one embodiment, brake 5126 of the system 5004 internal solder is for emergency use. For example, the 5126 brake can be used in case the 5124 drive motors of the 5010 drive section do not decelerate the 5004 internal welding system for some reason. For example, the 5126 brake can be applied to flanks to keep the 5004 internal welding system from rolling deep in the 1004 pipe or falling off the pipe according to the direction of slope. In one mode, the 5126 brake is configured to be controlled manually or automatically.

[0465] In one embodiment, the 5126 brake can also be used to secure the 5004 internal welding system frame in place within the tubes during the welding procedure, the pre-weld sweep procedure and/or the sweep procedure of post-welding. For example, the 5126 brake can be configured to protect the 5004 internal welding system frame from movement at the desired location within the tubes during the welding procedure, the pre-weld sweep procedure and/or the powder sweep procedure. - solder.

[0466] In one embodiment, the compressed air tank 5128 is constructed and arranged to hold air to operate the brake 5126, the drive rollers 5122, and the front and rear clamps 5142, 5144. In one embodiment, the air tank compressed air 5128 is constructed and arranged to be connected to umbilical 5034 through front and rear swivel joints 5032, 5072 so that compressed air tank 5128 can be refilled as needed.

[0467] In one embodiment, pneumatic valves 5120 are constructed and arranged to control air to the two pneumatic cylinders that are configured to engage and operate brake 5126 and drive rollers 5122, respectively.

[0468] In one embodiment, the 5118 drive section electronics module is configured to allow the transmission of upstream communication signals to the center section electronics module 5064. In one embodiment, the drive section electronics module 5118 is also configured to control the 5124 drive motors and the two 5120 pneumatic valves.

[0469] In one embodiment, one or more 5140 processors are configured to operate the 5124 drive motors to move the structure of the internal welding system 5004 through at least one of the tubes 1022a, 1022b until sensor 5352 detects the interface region 5136 between tubes 1022a, 1022b. In one embodiment, one or more processors 5140 are configured to operate the brake system of inner welding system 5004 to protect the structure of inner welding system 5004 from movement at a location within tubes 1022a, 1022b that positions the inspection detector 5056 with respect to interface region 5136 to allow inspection detector 5056 to detect the profile of interface region 5136 between tubes 1022a, 1022b.

[0470] FIG. 33 shows a view of the center section 5008 of the inner welding system 5004 being positioned within the tube segments 1022a, 1022b, where some components of the center section 5008 are not shown for the sake of clarity. For example, front and rear clamps 5142, 5144, rotating hub 5078, weld head assembly 5500, inspection detector 5056, and inspection camera 5112 are shown in FIG. 33.

[0471] In one embodiment, the 5000 field system for welding two pipes includes a 5138 computer system to facilitate pipe welding. In one embodiment, computer system 5138 includes one or more processors 5140 that are communicatively connected to soldering system 5004. In one embodiment, computer system 5138 and one or more processors 5140 may be communicatively connected to soldering system 5004 ( and one or more of its components) via one or more wired or wireless communication links. As an example, wired communication links can include one or more Ethernet links, coaxial communication links, fiber optic communication links, or other wired communication links. As another example, wireless communication links may include one or more Wi-Fi communication links, Bluetooth communication links, near-field communication (NFC) links, cellular communication links, or other wireless communication links . In one embodiment, one or more components of welding 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 use one or more wireless communication links to allow one or more processors 5140 or one or more components of soldering system 5004 to communicate with one another to reduce the number of communication cables in the system. 5004 Welding System to reduce the potential entanglement of cables that can delay operations or damage other components of the 5004 Welding System. For example, reducing the number of communication cables in the 5004 Welding System in some embodiments can reduce potential cable entanglement during rotation of an inspection device (eg, inspection laser, inspection camera, or other inspection device), a welding torch, or other component of the 5004 welding system.

[0472] In one embodiment, the 5138 computer system and its one or more 5140 processors may be positioned on the 5000 field system. In another embodiment, the 5138 computer system and its one or more 5140 processors may be positioned remotely to from the 5000 field system. In one embodiment, one or more 5140 processors 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 others mechanisms for electronic information processing.

[0473] It should be appreciated that the "one or more processors", as disclosed herein, may constitute a single processor that is located onboard and location for the specific system or component being discussed, offboard and location for the specific system or component under discussion, or remotely located for the specific system or component being discussed. Also, the connection to one or more processors can be wired or wireless. In addition, the "one or more processors" may also refer to a plurality of processors that are onboard and local, a plurality of processors that are not onboard and local, a plurality of processors that are remote, or any combination of a onboard (and local), not onboard (and local) and remote processors. When referring to onboard processors, such processors refer to processors that are physically transported (ie physically connected and moved with) by the specific system or component. When referring to non-board processors, these refer to processors that are local to a workplace and communicate wirelessly with on-board electronics. Non-board processors can also refer to electronics that are connected to the on-board system (eg, via a reach rod) and are local to the job site. Viewed in another light, if the processor moves with the reach rod, it can also be considered an "on-board" processor.

[0474] In one embodiment, first pipe engaging structure 5052 is configured to engage an interior surface 5130 of first tube 1022a to allow first pipe engaging structure 5052 to be secured relative to first pipe 1022a. In one embodiment, second tube engaging structure 5054 is configured to engage an interior surface 5132 of second tube 1022b to allow second tube engaging structure 5054 to be secured relative to second tube 1022b.

[0475] In one embodiment, inspection detector 5056 is positioned between first tube engagement structure 5052 and second tube engagement structure 5054 and is configured to emit a radiation inspection beam. In one embodiment, an inspection detection motor is operatively associated with inspection detector 5056 to direct the radiation inspection beam along the interface region 5136 between tubes 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, front and rear rotation motors 5030 and 5074 are configured to rotationally move inspection detector 5056 along interface region 5136. In one embodiment, inspection detector 5056 is configured to generate based signals in a profile of the 5136 interface region between the tubes 1022a, 1022b. In one embodiment, the 5136 interface region is an annular interface region. In one embodiment, the interface region 5136 is within tubes 1022a, 1022b at regions of tubes 1022a, 1022b adjacent to where the solder would go.

[0476] The term "interface region", as used in this document, refers to the interior surfaces of the tubes 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 entire inner bevel of the two tubes 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.

[0477] In one embodiment, wheels 5028 on the front section 5006 of the inner welding system are constructed and arranged to prevent clamps from dragging the inner surfaces of the tube. The less the 5028 wheels extend, the easier the internal welding system will fit around the curves of the tubes. In one mode, wheels 5028 may be adjustable. In one mode, wheels 5028 may not be adjustable. In one embodiment, the wheels 5066 (as shown in Figure 23) on the rear bracket 5144 and the adjustable wheels 5276 (as shown in Figure 32A) at the rear of the drive section 5008 are constructed and arranged so that the centerline of the clamp is about 0.25 inches below centerline of pipe. With this configuration, when the clamps expand against the inner surfaces of the tube, the expander picks the clamp away from the wheels instead of pressing the wheels into the inner walls of the tube.

[0478] In some embodiments, the "pipe engagement structure" comprises a clamp that securely engages a pipe surface. The clamp, for example, may include one or more shoes or other support structure configured to securely engage with a pipe surface to prevent movement of the same. In another embodiment, the "tube fitting structure" comprises a seal that sealingly engages the interior surface of a tube so as to inhibit gas from passing therethrough. Such a seal may comprise, for example, an inflatable bladder, resilient structure or other engineering structure that engages the surface of the inner tube to inhibit gas from passing therethrough. This seal can be used in a purge operator to remove oxygen from a region in the pipe to be welded to prevent or reduce oxidation as a result of the welding process. In yet another embodiment, the pipe engaging structure comprises a combination of a clamp and a seal, or one or more clamps and/or one or more seals.

[0479] In one embodiment, the first tube engaging structure 5052 includes the first clamp 5142 and the second tube engaging structure 5054 includes the second clamp 5144.

[0480] In one embodiment, the first pipe engaging structure 5052 includes a first seal 5146 and the second pipe engaging structure 5054 includes a second seal 5148.

[0481] In one embodiment, the second seal 5148 and the second clamp 5144 may be referred to as the tail seal 5148 and the tail clamp 5144, respectively. In one embodiment, first seal 5146 and first bracket 5142 may be referred to as front seal 5146 and front bracket 5142, respectively.

[0482] In one embodiment, first tube engaging structure 5052 includes clamp 5142 and second tube engaging structure 5054 includes seal 5148. In one embodiment, first tube engaging structure 5052 includes seal 5146 and second tube engaging structure 5054 includes clamp 5144.

[0483] In one embodiment, the first tube engagement structure 5052 includes the clamp 5142 and the seal 5146, the second tube engagement structure 5054 includes the clamp 5144 and the seal 5148. In one embodiment, the first tube engagement structure 5052 includes clamp 5142 and seal 5146 and second tube engaging structure 5054 includes clamp 5144. In one embodiment, first tube engaging structure 5052 includes clamp 5142 and seal 5146 second pipe engaging structure 5054 includes seal 5148. In one embodiment, first tube engaging structure 5052 includes clamp 5142 and second tube engaging structure 5054 includes clamp 5144 and seal 5148. In one embodiment, first tube engaging structure 5052 includes seal 5146 and second tube engaging structure 5054 includes clamp 5144 and seal 5148.

[0484] In the configuration where there is a seal on one side of the 5056 inspection detector and the 5112 inspection chamber and a clamp on the other (opposite) side of the 5056 inspection detector and the 5112 inspection chamber, a high purge gas pressure is sent to a region between the clamp and the seal. The purge gas from the region between the clamp and the seal can flow through the small space between the tubes that are about to weld and can also be exhausted from the tubes on the side of inspection detector 5056 and inspection chamber 5112 where there is no seal and has only the clamp. This optional configuration prevents overpressure in the region between the clamp and the seal (eg compared to arrangements with two seals, one on each side of the 5056 inspection detector and the 5112 camera), without the provision of a regulator to regulate pressure with the purge gas region and/or a separate overpressure relief valve for the region between the clamp and the seal. The continuous supply of high pressure purge gas in the region between the clamp and the seal is configured to reduce oxygen in a region in close proximity to the welding torch during a welding operation.

[0485] In another embodiment, the first and second seals may optionally have openings therethrough to prevent overpressure of the purge gas chamber formed between the first and second seals. In another embodiment, one or both seals, in which an inflatable seal chamber is provided for the seal, may be partially inflated to provide a predefined or calculated space around it to allow flow out of the purge area at a rate desired.

[0486] When two purge seals 5146, 5148 are provided, inert gas is introduced into the purge chamber between them. It should be understood, however, that bleed seals 5146, 5148 need not (and typically do not) create a perfect seal. Inert gas is leaked, for example, through the space between the two tubes 1022a, 1022b being welded together. Inert purge gas can also flow around seals 5146, 5148, which need not be perfect. Of course, during the welding operation, the space between tubes 1022a, 1022b is slowly closed and sealed. As a result, the pressure within the purge chamber between tubes 1022a, 1022b can increase as the weld between tubes 1022a, 1022b is created. As such, the pressure sensor provided within the purge chamber senses the pressure within the purge chamber and generates signals to one or more 5140 processors, which in turn communicate with one or more valves and/or one or more regulators, in order to control or regulate the pressure of the purge gas inside the purge chamber to avoid overpressure. The overpressure within the purge chamber would apply an outwardly directed gas force greater than desired through the space between the tubes to be welded and potentially alter the desired weld result. In a different embodiment, only a single seal 5146, 5148 is provided to create a purge chamber that is sealed on one side only. This arrangement still provides a reasonable purge chamber, which is largely devoid of oxygen, and also avoids any possibility of overpressure. In such an embodiment, the inert purge gas will leak not only from the space between the tubes, but also through an end of the tube that is unsealed and therefore may consume more gas compared to the double sealing realization.

[0487] In one embodiment, the inspection detector 5056 and the inspection chamber 5112 are configured to be positioned axially (relative to the tube axis) between the first clamp 5142 and the second seal 5148. That is, the first clamp 5142 and second seal 5148 are each positioned on axially opposite sides of inspection detector 5056 and inspection camera 5112.

[0488] In one embodiment, the inspection detector 5056 and the inspection chamber 5112 are configured to be positioned axially (relative to the tube axis) between the first seal 5146 and the second clamp 5144. That is, the first seal 5146 and second bracket 5144 are each positioned on axially opposite sides of inspection detector 5056 and inspection camera 5112.

[0489] In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the tube axis) between the first clamp 5142 and the second clamp 5144. That is, the first clamp 5142 and second bracket 5144 are each positioned on axially opposite sides of inspection detector 5056 and inspection camera 5112.

[0490] In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the tube axis) between the first seal 5146 and the second seal 5148. That is, the first seal 5146 and second seal 5148 are each positioned on axially opposite sides of inspection detector 5056 and inspection camera 5112.

[0491] In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the tube 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 axially positioned on one side of the inspection detector 5056 and the inspection chamber 5112 and the second clamp 5144 and the second seal 5148 are axially positioned on the other side of the detector inspection camera 5056 and inspection camera 5112.

[0492] In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the tube axis) between the first seal 5146, the clamp 5142, and the second seal 5148. That is, first seal 5146 and first clamp 5142 are axially positioned on one side of inspection detector 5056 and inspection chamber 5112 and second seal 5148 are axially positioned on the other (opposite) side of inspection detector 5056 and inspection camera 5112 .

[0493] In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the tube axis) between the first seal 5146, the second seal 5148 and the second clamp 5144. , second seal 5148 and second clamp 5144 are axially positioned on one side of inspection detector 5056 and inspection camera 5112 and first seal 5146 are axially positioned on the other (opposite) side of inspection detector 5056 and inspection camera. inspection 5112.

[0494] In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the tube axis) between the first seal 5146, the clamp 5142, and the second clamp 5144. That is, first seal 5146 and first clamp 5142 are axially positioned on one side of inspection detector 5056 and inspection camera 5112 and second clamp 5144 are axially positioned on the other (opposite) side of inspection detector 5056 and inspection camera 5112 .

[0495] In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the tube axis) between the first clamp 5142, the second seal 5148 and the second clamp 5144. , second seal 5148 and second clamp 5144 are axially positioned on one side of inspection detector 5056 and inspection camera 5112 and first clamp 5142 are axially positioned on the other (opposite) side of inspection detector 5056 and inspection camera. inspection 5112.

[0496] In one or more embodiments, because the inspection detector 5056 is positioned between the clamps 5142, 5144, it is able to extract profile data between the clamps 5142, 5144 after the clamps 5142, 5144 have been secured in place. As such, inspection detector 5056 can continue to scan and detect the profile of interface region 5136 during a weld operation. This is beneficial for some applications as the 5136 interface region may change slightly as the two tubes 1022a, 1022b are being welded, as the soldered connection itself may change the 5136 interface region in other areas that still were not soldered. Therefore, inspection detector 5056 allows the detection and determination of any change in one or more characteristics of interface region 5136 instantly, or in "real time" in regions of interface region 5136 about to be welded. In addition, since inspection detector 5056 is positioned between clamps 5142, 5144, it is capable of extracting pre-weld profile data from the 5136 interface region after clamping force is applied by clamps 5142, 5144. clamping force of clamps 5142, 5144 themselves may change the 5136 interface region. For example, clamping force may slightly change the distance between the tube ends and/a relative height displacement between the tube ends in certain regions (or all) of the 5136 interface region. In addition, the clamping force applied by clamps 5142, 5144 may change the roundness of one or both tubes (for example, the first clamp may change the circumference of the first tube to be welded and/or the second clamp may change the circumference of the second tube to be welded. In one embodiment, for example, the clamp shoes for any of the clamps 5142, 5144 are provided symmetrically. and spaced evenly circumferentially around the interior of the tube being engaged. In addition, the outermost surface of each clamp shoe may be equally spaced from the center axis of the clamp. The spacing of each clamp shoe can be adjusted to be slightly larger than the inside diameter of the tube. In this way, if each clamp shoe is extended to its maximum position, the clamping force of clamp 5142, 5144 can be used to change the shape of a tube slightly out of circumference to one that is more rounded. Until the full clamping force is applied by both clamps 5142, 5144, the profile of the interface region 5136 is still not completely determined because of the possibility of shape change. The inspection detector 5136 described in this document can be used to determine the profile after the fixture has been applied.

[0497] In one or more embodiments, because the inspection detector 5056 and/or the camera 5112 is positioned between the two seals, the inspection detector 5056 and/or the camera 5112 are able to extract profile data between the seals 5146 , 5148 after seals 5146, 5148 have been coupled with inner surfaces 5130, 5132 of tubes 1022a, 1022b to be welded. As such, inspection detector 5056 can continue to scan and detect the profile of interface region 5136 before, during and/or after a welding operation in which regions between seals 5146, 5148 have been supplied or filled with a gas. purge. This is beneficial for some applications as the 5136 interface region can 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, inspection detector 5056 and/or camera 5112 (along with one or more processors 5140) determines that a slight modification of the weld or an additional welding operation is desirable, such modification or additional welding operation can be performed without the need to reset the purge chamber (for example, compared to a contemplated arrangement in which a post-weld inspection detector and/or a camera are located outside the purge chamber and the introduction of inspection detector 5056 and/or of the 5112 camera to inspect the 5136 welded interface region only after the purge chamber has been broken). Thus, inspection detector 5056 can be used to scan interface region 5136 between tubes 1022a, 1022b to profile the interface region 5136 between tubes 1022a, 1022b subsequent to a welding operation and generate profile data. scan-based post-weld and this post-weld profile data can be obtained and optionally a corrective weld or other additional weld can be achieved based on the post-weld profile data without releasing clamps 5142, 5144 and /or seals 5146, 5148.

[0498] In one embodiment, clamps 5142, 5144 are configured to rotate. In one embodiment, the clamps 5142, 5144 are configured to rotate in opposite directions to each other.

[0499] Furthermore, as described in this document, the present system allows the relative rotation between the first clamp and the second clamp 5142, 5144, after they have been fixed on the first and second interiors of tubes 5130, 5132, respectively. This can be accomplished by one or more orient motors 5030, 5074 operating one or both clamps 5142, 5144 as described in this document. Such relative rotation of tubes 1022a, 1022b can be conducted in response to pre-weld profile data determining that a better combination of rotation between the tube ends is available and can be accomplished by relative rotation of one or both clamps 5142, 5144. This relative rotation is performed without the need to unlock the first and second clamps 5142, 5144, and while the inspection detector 5056 remains axially positioned between the clamps 5142, 5144. After the first and/or second tube 1022a, 1022b is rotated, there is a new profile of the 5136 interface region and the inspection detector 5056 can again be used to scan the 5136 interface region to obtain new pre-weld profile data. It should be appreciated that because clamp 5142, 5144 does not even need to be released to get the new pre-weld profile data, unnecessary downtime can be avoided. During the relative rotation of tubes 1022a, 1022b, it should be appreciated that, in one embodiment, rollers 5332 of outer support 5330 (6010A, 6010B) may be used (per instructions from one or more processors 5140) to co-operate with a or more clamps 5142, 5144 to effect such relative rotation.

[0500] In one embodiment, clamps 5142, 5144 and seals 5146, 5148 are positioned within tubes 1022a, 1022b to form an inner sealed region/area. In one embodiment, clamps 5142, 5144 and seals 5146, 5148 are configured to seal opposite sides of a seam to be welded.

[0501] In one embodiment, clamp 5142 and seal 5146 are activated together and clamp 5144 and seal 5148 are activated together. In one embodiment, clamps 5142, 5144 and seals 5146, 5148 are controlled by the same valve.

[0502] In one embodiment, seals 5146, 5148 are activated with clamp 5142. In one embodiment, seals 5146, 5148 are activated with clamp 5144. In one embodiment, clamp 5142 and seal 5146 are independently activated and clamp 5144 and seal 5148 are independently activated. In one embodiment, a separate seal control system can be configured to operate both seals 5146, 5148 that are independent of (and separate from) a clamp control system that is configured to operate both clamps 5142, 5144.

[0503] In one embodiment, the clamp 5144 is positioned relative to the end of the tube 1022b. In one embodiment, clamp 5142 and seal 5146 are then activated together. In one embodiment, when tube 1022a is positioned relative to tube 1022b, clamp 5144 and seal 5148 are activated together.

[0504] 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 tubes 1022a, 1022b and an extended position (as shown in FIGS. 35A) where clamps 5142, 5144 are configured to apply clamping forces to the inner surfaces 5130, 5132 of tubes 1022a, 1022b. In one embodiment, clamps 5142, 5144 are constructed and arranged to engage (make contact) with tubes 1022a, 1022b and impart forces that grip and shape tubes 1022a, 1022b.

[0505] In one embodiment, the structure, configuration and operation of clamps 5142, 5144 are shown and explained in relation to FIGS. 30 and 33-42. For example, FIG. 33 and 34 show a perspective and cross-section of the center section 5008 of inner welding system 5004 being positioned within tube segments 1022a, 1022b, where both clamps 5142, 5144 and seals 5146, 5148 are encircling inner surfaces 5130 and 5132 of tube segments 1022a, 1022b and in which some components of center section 5008 are not shown for clarity; FIG. 35 shows a view of the center section 5008 of inner welding system 5004 which is positioned within tube segments 1022a, 1022b, with only clamps 5142, 5144 (without seals) engaging the inner surfaces 5130 and 5132 of the tube segments. tubes 1022a, 1022b and where some components of the center section are not shown for clarity; FIG. 36 shows a perspective view of the clamp shoe 5157 attached to the clamp shoe pin member 5090 positioned on the spider member 5100; FIG. 37 shows a perspective view of 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 hub 5096 of clamps 5142 or 5144 with clamp shoe pin members 5090 and connecting members 5092 connected thereto.

[0506] In an embodiment as shown in FIG. 35C, clamps 5142, 5144 are shown in the stowed position to show how ramps 5026, 5070 extend a little higher. In FIG. 35C, 5502 welding torches are shown in their extended positions. Typically, welding torches 5502 would only extend after extensions 5142, 5144 were extended.

[0507] In one embodiment, referring to FIG. 36, welding system 5004 may include a plurality of first clamp shoes 5157 circumferentially, equally spaced from one another in their respective spider member 5100 and a plurality of second clamp shoes 5157 circumferentially, equally spaced from one another in their respective Spider limb 5100.

[0508] In one embodiment, the 5157 clamp shoes can have different heights for different sized pipes and can be improved, for example, with shims or any other adjusting members. In one embodiment, the clamp shoes 5157 may be self-centering members. In one embodiment, the clamp shoes 5157 of the inner welding system 5004 are constructed and arranged to have a radial clearance of about 1 inch to the inner surfaces of the tube.

[0509] In one embodiment, each clamp shoe 5157 includes tube surface contact members (or surfaces) 5156. In one embodiment, tube surface contact members 5156 are constructed and arranged to frictionally engage when the clamps 5152, 5154 are extended, the inner surfaces 5130, 5132 of tubes 1022a, 1022b on either side of the interface region 5136.

[0510] In one embodiment, referring to FIGS. 30 and 36-38, each clamp shoe 5157 is constructed and arranged to be connected and positioned to 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 aperture 5158 in spider member 5100. In one embodiment, apertures 5158 in spider member 5100 are constructed and arranged to extend generally radially in spider member 5100 to allow for radial movement (e.g. , radially upward and downward 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 can 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 to the inner surfaces 5130, 5132 of the tubes 1022a, 1022b.

[0511] In one embodiment, referring to FIG. 38, one end 5164 of the clamp shoe pin member 5090 is connected to the clamp shoe 5157 and the other end 5166 of the clamp shoe pin member 5090 is connected to the connecting 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 connecting member 5092 therein. In one embodiment, end 5166 of clamp shoe pin member 5090 also includes apertures 5170 that are constructed and arranged to receive clamp members 5172 for connecting connecting member 5092 to end 5166 of clamp shoe pin member 5090.

[0512] In one embodiment, referring to FIG. 37 , spider member 5100 may include openings 5162 that are constructed and arranged to allow connection between clamp shoe pin members 5090 and connection members 5092. In one embodiment, openings 5162 of spider member 5100 are also constructed and arranged to allow movement of link member 5092 when brackets 5142, 5144 are moved between their retracted and extended positions. In one embodiment, spider member 5100 is attached to respective brackets 5142 or 5144.

[0513] In one embodiment, the connecting member 5092 is an elongated member with openings formed in its end portions. In one embodiment, the end portions of the link member have generally rounded configurations to allow movement of the link member 5092 when the brackets 5142, 5144 are moved between their retracted and extended positions.

[0514] In one embodiment, referring to FIGS. 30, 39 and 40, one end of connecting member 5092 is connected to clamp shoe pin member 5090 and the other end of connecting member 5092 is connected to hub 5096. In one embodiment, each clamp shoe is thus connected to hub 5096 via its associated clamp shoe pin member 5090 and connecting member 5092.

[0515] In one embodiment, hub 5096 may include notches 5174 (as shown in FIG. 40) that are constructed and arranged to allow connections between connecting members 5092 and hub 5096. In one embodiment, notches 5174 of the hub 5096 are also constructed and arranged to allow movement of link members 5092 in notches 5174 when the clamps are moved between their retracted and extended positions.

[0516] In one embodiment, referring to FIG. 30, clamp 5152 or 5154 includes cylinder 5086, piston 5084, and shaft 5094. In one embodiment, piston 5084 is configured to be axially movable in cylinder 5086, and shaft 5094 is secured to piston 5084. In one embodiment, , shaft 5094 is movable with piston 5084.

[0517] In one embodiment, hub 5096 is constructed and arranged to be connected to shaft 5094 which is moved longitudinally by reciprocating piston axially 5084, e.g. actuated by fluid pressure (hydraulic or pneumatic) within cylinder 5086.

[0518] Clamps 5142, 5144 are moved from the retracted position (as shown in FIGS. 35B) where clamps 5142, 5144 are not in contact with the inner surfaces 5130, 5132 of tubes 1022a, 1022b to the extended position (as shown in Figures 35A) where clamps 5142, 5144 are configured to apply clamping forces to the inner surfaces 5130, 5132 of tubes 1022a, 1022b, activating cylinder 5086 so that piston 5084 is moved axially in cylinder 5086. , compressed air from the front swivel union 5032 through the front clamp control valve 5018 enters an inlet 5031 (as shown in FIG. 30). Compressed air entering inlet 5031 pushes piston 5084 forward to move clamps 5142, 5144 to the extended position.

[0519] That is, the axial movement of piston 5084 causes an axial movement of shaft 5094 connected to piston 5084. In one mode, axial movement of shaft 5094, in turn, causes an axial movement of hub 5096. In one mode , the axial movement of the hub 5096 is translated to a radial movement of the shoe pin members of the clamp 5090 through its connecting members 5092. Thus, the radial clamping forces are generated by the fluid pressure of the compressed air acting on the piston. 5084 which actuates link members 5092 which convert axial movement of piston 5084 (through shaft 5094 and hub 5096) to radial movement of clamp shoes 5157.

[0520] In one embodiment, the cylinder size, applied fluid pressure, and the sizes of various components of the clamps 5142 and 5144 can be changed to control the clamping forces that are applied by the clamps to the inner surfaces 5130, 5132 of the tubes. 1022a, 1022b.

[0521] In one embodiment, seals 5146, 5148 have a generally threaded or annular configuration to allow a portion of the center section (eg, front clamp 5142 or rear clamp 5144) to pass through. In one embodiment, seals 5146, 5148 are constructed and arranged to be radially expandable members. In one embodiment, seals 5146, 5148 are constructed and arranged to be connected to a pneumatic or hydraulic line that conveys liquid to seals 5146, 5148 to inflate them. As seals 5146, 5148 inflate, they are constructed and arranged to engage the inner surfaces 5130, 5132 of tubes 1022a, 1022b, respectively forming a chamber 5150 therebetween. In one embodiment, seal 5146, when inflated, engages interior surface 5130 of tube 1022a and seal 5148, when inflates, engages interior surface 5132 of tube 1022b. In one embodiment, seals 5146, 5148, when inflated, engage opposite sides of interface region 5136. In one embodiment, chamber 5150 is a closed volume that may be referred to as a purge gas chamber. In one embodiment, chamber 5150 is constructed and arranged to receive a purge gas therein.

[0522] In one embodiment, the 5004 internal welding system may include a purge gas tank configured to supply purge gas between the first inflated seal 5146 and the second inflated seal 5148 to reduce oxygen between the first and second seals 5146 and 5148 during a welding operation. In one embodiment, the purge tank can be positioned in the drive section 5010 of the internal welding system 5004. In one embodiment, the purge gas is configured to prevent oxidation during a welding process. In one embodiment, the purge gas is an inert gas. In one embodiment, the purge gas can include argon, helium, nitrogen, or a combination thereof. In one embodiment, the purge gas can include a combination of argon and CO2.

[0523] In one embodiment, the purge gas is pumped into the sealed inner region that is formed between the first and second inflated seal 5146, 5148. By keeping the inner region sealed and free of oxygen, the oxidation that can result from Extreme resistance that occurs during the welding process can be prevented.

[0524] In one embodiment, the 5004 internal welding system may include a 5176 oxygen sensor and a 5178 pressure sensor. In one embodiment, the 5176 and 5178 oxygen and pressure sensors are operatively linked to or to one of the 5140 processors. In one embodiment, oxygen and pressure sensors 5176 and 5178 are constructed and arranged to be positioned on rotating hub 5078. In another embodiment, oxygen and pressure sensors 5176 and 5178 are constructed and arranged to be positioned on spider member 5100. (for example, between the clamps).

[0525] In one embodiment, the oxygen sensor 5176 is configured to measure the oxygen content of the gas in the 5150 purge chamber and sends oxygen content data, which is indicative of the oxygen content of the gas in the 5150 purge chamber, to one or more 5140 processors. In one embodiment, one or more 5140 processors are configured to receive the oxygen content data, compare the received oxygen content data to its predetermined oxygen content value, and generate an overflow signal of oxygen gas if the oxygen content data is greater than the predetermined oxygen content value. In one embodiment, based on the excess oxygen gas signal, the 5004 internal welding system can be configured to open a valve structure to allow the purge gas (from the purge gas source/tank) to flow into the chamber. 5150 purge until the measured oxygen content drops below the predetermined oxygen content value. In one modality, based on excess oxygen gas signal, the 5004 internal welding system can be configured to stop the welding process.

[0526] In one embodiment, the pressure sensor 5178 is configured to measure the 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 one or more 5140 processors. In one embodiment, one or more 5140 processors 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 pre-determined pressure value. In one embodiment, based on the overpressure signal, the internal welding system 5004 can be configured to open an exhaust valve structure to release pressure in the purge chamber 5150 until the measured pressure drops below the predetermined pressure value. . In one modality, based on the overpressure signal, the 5004 internal welding system can be configured to stop the welding process.

[0527] 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 chamber of 5150 purge gas are all optional.

[0528] In one embodiment, referring to FIG. 33, internal welding system 5004 includes inspection camera 5112 configured to be positioned between first tube engaging structure 5052 and second tube engaging structure 5054. In one embodiment, inspection camera 5112 is constructed and disposed. to be rotatably mounted and connected to the 5078 swivel hub.

[0529] In one embodiment, inspection camera 5112 is operatively linked to one or more 5140 processors. In one embodiment, inspection camera 5112 is configured to send camera inspection data before, subsequently, or during a weld operation. for one or more 5140 processors.

[0530] In one embodiment, the camera inspection data may generally include image(s), captured by the 5112 inspection camera, of the weld joint. In one embodiment, inspection camera 5112 is configured to capture the image(s) of the weld joint during or subsequent to the welding operation.

[0531] In one embodiment, the camera inspection data may generally include image(s), captured by inspection camera 5112, of the 5136 interface region between tubes 1022a, 1022b. In one embodiment, inspection camera 5112 is configured to capture the image(s) of the interface region 5136 between tubes 1022a, 1022b before or during the welding operation.

[0532] In one embodiment, the 5112 inspection camera can be any device that is configured to capture/view the solder joint or the 5136 interface region between tubes 1022a, 1022b. In one embodiment, camera device 5112 may be a two-dimensional (2D) camera for visual inspection of the solder joint or the 5136 interface region between tubes 1022a, 1022b.

[0533] In one embodiment, the 5112 inspection camera may be a two-dimensional (2D) Charge Device (CCD) color camera. In one embodiment, one or more processors 5140 that are associated with inspection camera 5112 may be configured to analyze the image(s) captured by inspection camera 5112 to detect any defects present in the weld joint. In one modality, a visual signal can be distributed to an external operator view based on the analysis. For example, the 2D camera might be a color camera and a change in color might indicate a weld defect to the operator. In one modality, a noticeable change in profile can also indicate a weld defect.

[0534] In one embodiment, the 5112 inspection camera is configured to obtain a thermal image of (eg, various metal color regions) of the joint/weld region. This thermal image is then analyzed to determine what temperatures the different regions of the weld joint/region have reached.

[0535] In one embodiment, the images provided by the 5112 inspection camera may be color images. In one embodiment, one or more processors 5140 that are associated with inspection camera 5112 can be configured to analyze the color of each pixel in the received image to determine the temperature associated with that pixel.

[0536] In another embodiment, the images provided by the 5112 inspection camera may be grayscale images. In one embodiment, one or more processors 5140 that are associated with inspection camera 5112 can be configured to analyze the intensity or brightness of each pixel in the received image to determine the temperature associated with that pixel. In one embodiment, one or more 5140 processors that are associated with the 5112 inspection camera can be configured to analyze the pixel properties of the received image to determine if the temperature is outside the predetermined temperature threshold or range (and is a relatively large one. too high or relatively low) and or if there is a large temperature difference between adjacent pixels. In one embodiment, abnormal temperature(s) or temperature differences may be an indication of the occurrence of a solder defect.

[0537] For example, in one modality, the image can be analyzed to determine if a region or regions of the weld joint/weld region has reached a relatively high or relatively low temperature. In one embodiment, the image can be analyzed to determine if a region or regions of the weld joint/weld region have temperature differences/changes. In one embodiment, a temperature of each weld joint region/sold region is determined and the determined temperature of each weld joint region/sold region is compared to a predetermined temperature threshold or range to determine whether a region or regions of the solder joint/weld region has reached a relatively high temperature and/or a region or regions of the solder joint/weld region has temperature differences/changes.

[0538] In one embodiment, the 5112 inspection camera is configured to move the 5502 welding torch so that an operator can inspect the weld as soon as the weld is created by the 5502 welding torch.

[0539] In various embodiments, the inspection detector comprises a laser, 3D camera, ultrasound and an electrical capacitive probe. Where a laser is used, the laser type can be a laser displacement sensor. In one embodiment, the laser may be the LK-G5000 high-speed/high-precision laser displacement sensor manufactured by Keyence. In one embodiment, the laser can be an intelligent laser sensor, such as the Smart Laser Sensor SLS-050 manufactured by Meta Vision Systems Inc.

[0540] In one embodiment, the inspection detector may include an emitter to emit the radiation inspection beam and a receiver to receive reflected radiation inspection signals. In one or more embodiments, the detector receiver comprises a sensor that detects reflected radiation and generates signals based on the reflected radiation. Signals are received by one or more processors. In one embodiment, the signals contain data and information corresponding to the three-dimensional profile of the interface region between the tubes to be welded and can be used to detect, for example, the relative heights of the surfaces of adjacent tubes in the regions to be welded, the spacing relative between the tubes, any non-uniformities in the adjacent surfaces to be welded (for example, in the bevels of the same). In addition, as the inspector's detector scans along the entire interface between the tubes, it can determine the specific interface profile in any specific region of the scan. This information can be used by one or more processors to control the operation of the welding torch to provide a custom/adapted weld that is specifically tailored to the structural profile of the tubes to be welded in its interface region.

[0541] In one embodiment, the 5000 system may include enclosures 5852, 5854 (as shown in FIG. 31) that are configured to house and protect the inspection detector 5056 and inspection camera 5112, respectively, from sparks from hot solder (spatter) and/or other debris that may return to the 5056 inspection detector and/or the 5112 inspection camera during a soldering operation.

[0542] In one embodiment, housings 5852, 5854 of inspection detector 5056 and/or inspection camera 5112 may be made of polycarbonate material. In one embodiment, portions of housings 5852, 5854 may be configured to be removable to facilitate cleaning (e.g., removing solder spatter or other solder debris therefrom) or repair. In one embodiment, the housing portions 5852, 5854 may include the camera lens shield or the inspection detector lens shield. In one embodiment, portions of housings 5852, 5854 of inspection detector 5056 and/or inspection camera 5112 can be configured to be disposable so that portions of housings 5852, 5854 can be easily replaced when they are obstructed with the spatter of solder or other solder debris. For example, in one embodiment, the 5112 inspection camera may include a polycarbonate (rectangular) member in front of its lens that can be replaced when clogged/blocked by solder spatter or other solder debris.

[0543] In one modality, pre-weld inspection, flash inspection and post-weld inspection can be performed by inspection detector 5056. In one modality, pre-weld inspection, flash inspection and post-weld inspection can be performed by inspection detector 5056 and inspection camera 5112.

[0544] In one embodiment, the inspection detector 5056 includes an emitter 5180 for emitting the radiation beam and a receiver 5182 for receiving inspection signals of reflected radiation. In one embodiment, inspection detector 5056 transmits radiation to interface region 5136. In one embodiment, 5182 received from inspection detector 5136 is configured to receive radiation reflected from surfaces of interface region 5136 and generate electronic signals. based on it. In one embodiment, the receiver or sensor 5182 of inspection detector 5056 is configured to detect the reflected signal to detect the 3D topography of the weld joint/weld region. The 5056 inspection detector may interchangeably, referred to in this document as the inspection laser.

[0545] In one embodiment, the inspection detector 5136 includes a plurality of inspection detectors that transmit radiation to the 5136 interface region. of the 5136 interface region and generating electronic signals based thereon.

[0546] In one embodiment, inspection detector 5056 may include a laser displacement sensor. In one embodiment, inspection detector 5056 may include a complementary metal-oxide-semiconductor (CMOS) sensor. In one embodiment, inspection detector 5056 may include a high definition Ernostar-type lens. In one embodiment, one or more processors 5140 that are associated with inspection detector 5056 are configured to use triangulation to detect the position of light reflected in the RS-CMOS sensor.

[0547] In one embodiment, inspection detector 5056 may receive its power from wired power electronics module 5046. In one embodiment, wired power electronics module 5046 is configured to receive its power to from the 5116 batteries in the 5010 drive section through the 5080 rear slip ring. Thus, the inspection detector 5056 receives its power from the 5116 batteries in the 5010 drive section through the 5080 rear slip ring and the wired power electronics module 5046. This may be the case when the 5034 range/umbilical rod cables, hoses and/or wires are disconnected from the 5004 system, for example when the 5004 system is traveling from one solder joint to the next solder joint.

[0548] In another embodiment, the inspection detector 5056 can receive its energy directly from the umbilical/reach rod 5034. For example, when the cables, hoses and/or wires to the range/umbilical rod 5034 are connected from the system 5004 , the 5056 inspection detector can receive its energy directly from the 5034 umbilical/reach rod.

[0549] It should be appreciated that, in some embodiments, power and communication of inspection detector 5056 and/or camera 5112 may be desired. Such power and/or communication of inspection detector 5056 and/or camera 5112 may occur with components, such as one or more 5140 processors and/or a power source, that are outside of the pipe engaging structures (eg outside of clamps 5142, 5144 and/or seals 5146, 5148). In some embodiments, where power and/or communication takes place over a wired (as opposed to wireless) physical and/or power connection line, this physical connection line may take into account rotation through the hub. rotary 5078, for example, to reduce or prevent twisting and/or kinking of the physical connecting line. As such, in an example as described in this document, the physical connection line (which can transmit information and/or power) may be provided with (i) a movable portion that moves with the inspection detector 5056 while the inspection detector 5056 directs the inspection beam along the interface region under the rotational force of one or more orientation motors, and (ii) a stationary portion that remains fixed during the movement of the movable portion. The stationary and rotating portions of the interconnected line can be connected through the described slip ring which provides the interface between the movable and fixed portions of the physical connection line to allow signals to pass from the movable portion to the stationary portion. It should be appreciated that a single physical connection line (eg with multiple and discrete wires) or a plurality of physical connection lines (separate lines for power and communication) can be used. Furthermore, if on-board power is supplied to the inspection detector, only one communication line can pass through the slip ring. If wireless communication with the inspection detector is provided, then only an electrical line can pass through the slip ring. If on-board power and wireless communication are provided, a communication via physical connection need not be provided.

[0550] Similar to what has been described in relation to the physical connection communication line, it may also be desirable to supply the inert gas to an axial location between the pipe mating structures (for example, between clamps and/or seals) through a pneumatic line or tube for conveying pressurized inert gas. There may also be a desire to reduce twisting and/or entanglement of the pneumatic line that would otherwise occur during rotation of the rotating hub 5078. As such, the pneumatic line can be provided with the stationary portion connected with the source of inert gas and the movable portion extending into the rotating hub, the movable portion being coupled to the stationary portion via the swivel joint. The swivel joint allows for relative rotation between the stationary and movable pneumatic portions.

[0551] In one embodiment, the inspection detector 5056 can be operatively associated with the inspection motor to direct a beam of radiation along the 5136 interface region between tubes 1022a and 1022b. In one embodiment, the inspection detector 5056 and 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 indistinctly referred to as the inspection motor .

[0552] In one embodiment, inspection detector 5056 is configured to detect a feature of the interface region 5136 between tubes 1022a, 1022b. In one embodiment, the interface region feature 5136 may include a space between tubes 1022a, 1022b. In one embodiment, the feature of the interface region 5136 may include a radial displacement (e.g., high/low) between tubes 1022a, 1022b. In one embodiment, the feature of the 5136 interface region may include geometry at each weld location. In one embodiment, the feature of the interface region 5136 may include chips, meters, or any irregularities in tubes 1022a, 1022b. In one embodiment, the feature of the interface region 5136 may include circumference of tubes 1022a, 1022b. In one embodiment, the feature of the interface region 5136 may include bevel contours of tubes 1022a, 1022b (after tube alignment). In one embodiment, the feature of the interface region 5136 may include various metal color regions of the weld joint/sold region. For example, these color regions are analyzed to determine what temperatures the different regions of the weld joint/weld region have reached.

[0553] In one embodiment, the inspection detector 5056 can be configured to detect the characteristic of the 5136 interface region between the tubes 1022a, 1022b, for example, before the 5502 weld twist has been activated to initiate the clamping/welding of tubes 1022a, 1022b to one another. For example, the feature of the interface region 5136 may include a pipe bevel geometry, a space between the adjacent inner ends of the tubes 1022a, 1022b (after tube alignment), a space between the notches of the tubes 1022a, 1022b ( after tube alignment), etc. In one embodiment, inspection detector 5056 may be configured to detect the characteristic of the interface region 5136 between tubes 1022a, 1022b, e.g., 1022b, during a welding operation, in a region of the interface before the weld material is deposited on it. For example, the feature of the 5136 interface region may include a height difference between the bevel edges of the tubes after their alignment. In one embodiment, the characteristic of the 5136 interface region can include very low differences between adjacent edges of the tubes (e.g., at the inwardly bevelled portions). In one embodiment, inspection detector 5056 may be configured to detect the characteristic of the interface region 5136 between tubes 1022a, 1022b, for example, subsequent to a welding operation. For example, the feature of the interface region 5136 may include a feature of the formed solder spheres, solder shape parameters such as mismatch, sphere concavity, the reentrant angle.

[0554] In one embodiment, one or more processors 5140 are configured to operate inspection detector 5056 and motor 5030, 5074 to scan the 5136 interface region between tubes 1022a, 1022b.

[0555] In one embodiment, one or more 5140 processors are configured to interact with inspection detector 5056 to scan the 5136 interface region between tubes 1022a and 1022b to determine a profile of the 5136 interface region between tubes 1022a and 1022b before a weld procedure and generate pre-welded profile data based on this.

[0556] The term "profile", as used in this document, is a generic term to refer to the physical attributes of the interface region to be welded between the tubes. The term "profile data" refers to data, corresponding to the profile, which can be derived from the region of the interface. For example, this data can be obtained by scanning the interface region with an inspection detector such as a laser. Profile data can contain numerous types of information about the profile, such different types of information are referred to in this document as "characteristics".

[0557] In one embodiment, one or more 5140 processors are configured to interact with inspection detector 5056 to scan the 5136 interface region between tubes 1022a, 1022b to determine the profile of the 5136 interface region between tubes 1022a and 1022b during a welding process, in a region of the 5136 interface before the weld material is deposited on it and generates instantaneous profile data. In one embodiment, one or more processors 5140 are configured to generate weld signals to control the 5502 welding torch based on instantaneous profile data. Instant profile data is described in detail below. The term "snapshot" as used in this document also means or refers to "real time", which means that detection or detection is used by one or more processors during an actual welding operation to control the welder. Of course, because the inspection detector, the welding torch follows the inspection detector/inspection laser, whether a set value, some loading (or slight delay) is required between receiving the profile data and using this type by the or more processors to control the welding torch.

[0558] In one embodiment, one or more 5140 processors are configured to interact with inspection detector 5056 to scan the 5136 interface region between tubes 1022a and 1022b to determine the profile of the 5136 interface region between tubes 1022a and 1022b subsequent to a weld procedure and generate post weld profile data based on this. Post weld profile data is described in detail below.

[0559] In one embodiment, inspection detector 5056 is configured to work in conjunction with welding torch 5502 of welding system 5004 to detect the interface joint profile or/and weld material profile to apply weld material to the edge joint in the proper location and quantity. In one embodiment, inspection detector 5056 is configured to examine the weld and send a signal to one or more 5140 processors of the 5502 pivot weld head to control movement of the 5502 weld head around the entire edge joint. Specifically, the 5502 welding torch is configured to shift the inspection detector as the weld head control system continuously receives weld profile information from the edge joint. The information is then used to continuously adjust the 5502 welding torch to achieve the desired weld structure/profile.

[0560] In one embodiment, indoor welding system 5004 may include a 5502 welding torch inspection detector. In one embodiment, indoor welding system 5004 includes three 5502 welding torches and three associated 5056 inspection detectors. In one embodiment, the 5004 indoor welding system may include two 5502 welding torch inspection detectors. In one embodiment, the number of inspection detectors used in the 5004 indoor welding system may vary.

[0561] In one embodiment, the 5000 field system of the present patent application is an intelligent internal inspection system that places the internal automation, including the 5112 inspection camera, the 5056 inspection detector, and the 5502 welding head or torch. between the spaced clamps 5142, 5144 and the sealed structure 5146, 5148. In one embodiment, the 5000 field system of the present application is an intelligent internal inspection system that places the 5112 inspection camera and the 5056 inspection detector between the spaced clamps 5142, 5144 and the sealed structure 5146, 5148. In one embodiment, the 5000 field system of the present application is an intelligent internal inspection system that places the internal automation, including the 5112 inspection camera, the detector inspection hole 5056 and the welding head or torch 5502 between the spaced clamps 5142, 5144.

[0562] In one embodiment, the soldering system is attached to the back of the in-line clamp, making it an in-line analytical tool that minimizes downtime associated with using a third-party tool. In one embodiment, both inspection chamber 5112 and inspection detector 5056 are used to inspect the weld. In one embodiment, inspection camera 5112 is configured to capture a two-dimensional image of the weld and analyze the color of the weld. Since the weld color is indicative of what temperature the material was raised during the welding process, the information obtained by the 5112 inspection camera helps to determine if the weld was done correctly. In one embodiment, inspection detector 5056 is configured to analyze the weld profile. In one embodiment, the inspection detector 5056 in conjunction with the color chamber 5112 of the two-dimensional (2D) charge-coupled device (CCD) is configured to perform a rotational inspection directly after the rotational welding and hot-pass procedures. In one embodiment, the weld system 5004 is configured to provide the rotational pass weld layer profile and 2D raw color image showing the discoloration and any geometric defects of the rotational pass weld layer. In one embodiment, solder system 5004 is configured to create a permanent recording of the rotational pass solder layer profile and visual image that can be stored and played back on the user's electronic device (eg, laptop).

[0563] In one embodiment, inspection performed by inspection detector 5056 in conjunction with color camera 5112 can be used as a reference for AUT weld inspection. In one embodiment, the inspection performed by the 5056 inspection detector in conjunction with the 5112 color camera can be used as a "go, don't go" (pass/fail (or check) test) for rotational and hot-pass welds . In one embodiment, if a rotational defect is found, the solder joint can be cut and prepared at the same station, long before the warning fails, after all passes have been deposited, so a significant waste of production time can be avoided.

[0564] In one embodiment, the 5004 internal welding system includes a feedback system that is configured to be operatively linked to a plurality of sensors and one or more 5140 processors. In one embodiment, one or more 5140 processors are configured to analyze the data provided by the plurality of sensors. In one embodiment, one of the plurality of sensors includes a temperature sensor that is configured to provide an indication of the temperature(s) of the solder joint and/or monitor the temperature during the soldering process. In one embodiment, one of the plurality of sensors includes a solder material sensor that is configured to monitor the use of solder material during the soldering process. In one embodiment, one of the plurality of sensors can include sensors that are configured to monitor the speed and timing of the welding process.

[0565] FIG. 41 shows a front perspective view of the welding head assembly 5500, while FIGS. 42 and 43 show the rear perspective view of the 5500 weld head assembly. FIGs. 44-46 show a left side perspective view, a right side perspective view, and a sectional view of the 5500 weld head assembly, where some components of the 5500 weld head assembly are not shown for clarity.

[0566] In one embodiment, in the illustrated embodiment, the center section 5008 may have three 5502 welding torches. In another embodiment, the center section 5008 may have two 5502 welding torches. In yet another embodiment, the center section 5008 may have only one 5502 welding torch. In one modality, the number of welding torches may vary.

[0567] In one embodiment, the 5500 welding head assembly includes the 5502 welding torch and a 5504 welding jacket assembly. In one embodiment, the 5502 welding torch includes a 5503 welding tip. 5500 Welding Head Assembly (the 5502 Welding Torch and the 5504 Welding Coil Housing Assembly) is carried by the 5004 internal welding system frame or frame assembly.

[0568] In one embodiment, the 5502 welding torch is constructed and arranged to feed or guide a 5507 consumable electrode wire in the welding area/zone. Consumable electrode wire 5507 is supplied from a source (eg, a wire spool or spool) through wire feed system 5044. In one embodiment, welding torch 5502 is constructed and arranged to be connected to a power supply (for example, a constant voltage power supply). In one embodiment, an electrical arc forms between a consumable electrode wire 5507 and tubes 1022a, 1022b, which heats tubes 1022a, 1022b, causing them to melt and stick together. In one embodiment, together with the 5507 electrode wire consumable, a shielding gas is fed through the 5502 welding torch, which protects the welding process from contaminants in the air. In one embodiment, shielding gas is fed to the welding area/zone through the tip of the welding torch which may include a 5505 gas nozzle. In one embodiment, the 5507 electrode may extend beyond the end of the nozzle. of gas 5505.

[0569] In one embodiment, the shielding gas stored in the drive section 5010 is brought to the wired feed assembly 5020 by a hose/shield gas line for distribution to one or more 5502 welding torches. , the shielding gas control valve 5042 is configured to receive shielding gas from the rear swivel joint 5072 (for example, through the rear slip ring 5080, the rotating hub 5078, and the front slip ring 5016). In one embodiment, shielding gas control valve 5042 is configured to control the flow of shielding gas to welding torch 5502 through a shielding gas line. In one embodiment, each 5502 welding torch has a corresponding 5042 shielding gas control valve connected to it. In one embodiment, shielding gas control valve 5042 is configured to supply shielding gas to the corresponding 5502 welding torch when receiving signals from wired power electronics module 5046.

[0570] In one embodiment, the welding torch 5502 is configured to be carried by the inner welding system frame assembly 5004 and configured to create a weld at the end of the second end of the first tube 1022a. In one embodiment, welding torch 5502 is configured to be positioned internally within first tube 1022a and/or second tube 1022b to provide an internal welding operation. In one embodiment, internally positioned welding torch 5502 is mounted (positioned over) and connected to rotating hub 5078.

[0571] In one embodiment, the 5502 welding torch can have at least three degrees of freedom. In one embodiment, the articulation degrees of freedom allow the 5502 welding torch to be very effective and efficient in filling interface profiles optimally and when needed.

[0572] Degree of freedom generally refers to the freedom of movement of the 5502 welding torch in three-dimensional space. Translational motion or displacement generally refers to linear motion or displacement along the three mutually perpendicular X, Y, and Z axes.

[0573] In an embodiment, the term "position" as used in this document generally refers to the movement of translation or displacement. In a modality, position can be relative or absolute.

[0574] In one embodiment, the coordinate system may include: a Y axis that is aligned substantially parallel to the longitudinal axis AA (as shown in FIG. 8) of tubes 1022a, 1022b; an 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 RR (as shown in FIG. 8) of tubes 1022a, 1022b. For example, translational movement along the X axis generally refers to a forward and backward movement. Translation movement along the Y axis generally refers to left-to-right movement. The translational movement along the Z axis generally refers to an up and down movement.

[0575] Rotational motion or displacement generally refers to rotation of these same three mutually perpendicular X, Y, and Z axes. The rotation of the three mutually perpendicular X, Y, and Z axes is often referred to as yaw (Z axis), tilt (Y axis), and roll (X axis). For example, the rotation movement about the X axis generally refers to a left or right tilt movement. The rotational movement around the Y axis generally refers to a backwards or backwards (backward) tilting movement. The rotational movement about the Z axis generally refers to a left or right rotational movement.

[0576] In an embodiment, the term orientation as used in this document generally refers to rotational movement or displacement. In a modality, the orientation can be relative or absolute.

[0577] In one embodiment, the at least three degrees of freedom may include two translational motions of the 5502 Welding Torch along two of the three mutually perpendicular X, Y, and Z axes, and a rotational motion of the 5502 Welding Torch approximately of one of the same three mutually perpendicular axes X, Y, and Z.

[0578] In one embodiment, the two translational movements of the 5502 Welding Torch along two of the three mutually perpendicular X, Y, and Z axes may include an up and down movement of the 5502 Welding Torch and a movement of the 5502 welding torch from side to side (eg left to right). In one embodiment, the up and down movement of the welding torch 5502 may be referred to as a radial (i.e., substantially parallel to the radial axis RR of tubes 1022a, 1022b) movement of the welding torch 5502 and side by side ( from left to right) the movement of welding torch 5502 may be referred to as an axial movement (i.e., substantially parallel to the longitudinal axis AA of tubes 1022a, 1022b) of welding torch 5502.

[0579] In one embodiment, the single rotational movement of the 5502 Welding Torch about one of the same three mutually perpendicular X, Y, and Z axes may include a forward or backward (rear) tilting movement of the 5502 Weld Twist .

[0580] In one embodiment, welding torch 5502 is mounted for movement around a pivot point P (as shown in FIGS. 54, 56 and 58) at or adjacent to welding tip 5503 of welding torch 5502 of such that a solder assembly created on solder tip 5503 generally coincides with pivot point P. In one embodiment, pivot point P is positioned forward of solder tip 5503. For example, in one embodiment, a 5502 welding torch is designed to rotate about pivot point P (as shown in FIGS. 54, 56 and 58) where the wire from electrode 5507 makes contact with tube 1022a, 1022b. In one embodiment, welding torch 5502 is mounted for movement so that it pivots about an axis that is close to the tip of welding torch 5503. In one embodiment, the axis passes through pivot point P and is substantially parallel to the longitudinal axis AA of tubes 1022a, 1022b.

[0581] In one modality, the 5502 welding torch is operatively linked to one or more 5596 welding torch motors. In one modality, one or more 5596 welding torch motors and the 5502 welding torch are configured to be positioned within an interior of the first and/or second tube 1022a, 1022b. In one embodiment, one or more welding torch motors 5596 are configured to move welding torch 5502 relative to first and second tube engagement structures 5052, 5054 after being secured relative to first tube and second tube 1022a , 1022b, respectively.

[0582] In one embodiment, one or more 5140 processors are configured to control one or more 5596 welding torch motors to control a position and orientation of the 5502 welding torch. For example, as will be described in detail below, one or more 5596 welding torch motors may include the 5512 radial welding torch motor which is configured to control the radial position and orientation of the 5502 welding torch, the 5550 axial welding torch motor which is configured to control the axial position and the 5502 Welding Torch Orientation; and the 5588 Tilt Welding Torch Motor which is configured to control the tilt position and orientation of the 5502 Welding Torch.

[0583] In one embodiment, motors 5030 and 5074 are configured to move welding torch 5502 circumferentially over interface region 5136 and also to move inspection detector 5056 relative to interface region 5136 simultaneously with the welding torch 5502. In one embodiment, the 5502 welding torch follows inspection detector 5056. In one embodiment, the front and rear rotation motors 5030 and 5074 are configured to rotate the rotating hub 5078 and rotate the 5502 welding torches, the detector inspection camera 5056 and inspection camera 5112, all positioned and connected to rotating hub 5078. In one embodiment, front and rear rotation motors 5030 and 5074 may be interchangeably referred to as circumferential welding torch motors.

[0584] In one embodiment, one or more processors 5140 are operatively linked with one or more drive motors 5030 and 5074 to rotate the first bracket 5142 relative to the second bracket 5144 so as to rotate the first tube 1022a relative to the second tube 1022b, based on instructions from one or more 5140 processors.

[0585] In one embodiment, motors 5030 and 5074 are configured to move welding torch 5502 circumferentially over interface region 5136 and are also configured to move inspection camera 5112 relative to interface region 5136 simultaneously with the torch of 5502 welding torch. In one mode, the 5502 welding torch follows the 5112 inspection camera. In one mode, the 5112 inspection camera follows the 5502 welding torch.

[0586] In one embodiment, motors 5030 and 5074 are configured to move welding torch 5502 circumferentially over interface region 5136 and are also configured to move inspection camera 5112 and inspection detector 5056 with respect to the region of 5136 interfaces simultaneously with the 5502 welding torch. In one modality, the 5502 welding torch follows both the 5056 inspection detector and the 5112 inspection camera. In one modality, the 5502 welding torch follows the 5056 inspection detector and leads the 5112 inspection camera.

[0587] In one embodiment, the motors 5030 and 5074 are configured to drive the 5502 welding torch in a first direction of rotation during root pass welding and to drive the 5502 welding torch in a second direction, as opposed to first direction, during hot pass welding.

[0588] In one embodiment, the motors 5030 and 5074 are configured to drive the 5502 welding torch at least 360° with respect to the axis of the tube AA (as shown in FIG. 8) in order to complete a spin pass weld continuous in rotation. In one embodiment, 360° rotation of the welding torch 5502 with respect to the axis of the tube AA (around the inner surface of the tube) is possible because the welding torch 5502 is mounted on the rotating hub 5078 (i.e. configured for rotation axial).

[0589] In one embodiment, one or more 5596 welding torch motors are configured to move the 5502 welding torch longitudinally (as shown in FIGS. 48 and 49) within tubes 1022a, 1022b, toward and away from the inner surface 5130, 5132 (as shown in Figure 33) of tubes 1022a, 1022b. In one embodiment, one or more 5596 welding torch motors are configured to move the 5502 welding torch angularly with respect to the weld (as shown in FIGS. 56 and 58). In one embodiment, motors 5030 and 5074 are configured to move welding torch 5502 circumferentially along interface region 5136.

[0590] In one embodiment, the 5500 weld head assembly includes a 5506 radial positioning system that is configured to allow radial movement of the 5502 welding torch, a 5508 axial positioning system that is configured to allow axial movement of the 5502 welding torch and a 5510 tilt positioning system configured to allow tilt movement of the 5502 welding torch.

[0591] In one embodiment, the 5504 torch housing assembly is constructed and arranged to enclose the 5502 welding torch, the 5506 radial positioning system, the 5508 axial positioning system, and the 5510 tilt positioning system therein. In one embodiment, the 5504 torch housing assembly is configured to protect the 5502 welding torch components and various components of its 5506, 5508, and 5510 positioning systems from welding heat and spatter.

[0592] In one embodiment, the torch shell assembly 5504 can include a base member 5509 and two side shell members 5511 and 5513. For example, the base member 5509 can be attached to the side shell members 5511 and 5513. using any suitable clamping mechanism (eg clamping members 5527). In one embodiment, torch shell assembly 5504 may include a first transverse shell member 5522 and an opposite second transverse shell member 5523 that are constructed and arranged to connect side shell members 5511 and 5513 together at their portions. of upper extremities. For example, the first and second transverse shell members 5522, 5523 can be attached to the side shell members 5511 and 5513 using any suitable clamping mechanism (eg, clamping members 5525).

[0593] In one embodiment, referring to FIGS. 41-46, welding torch 5502 is mounted for movement by radial positioning system 5506 such that welding tip 5503 is configured to move to and away from welding surface 5130, 5132 of tubes 1022a , 1022b. In one embodiment, one or more processors 5140 are configured to control one or more welding torch motors 5512 to adjust a radial distance from the weld tip 5503 from within tubes 1022a, 1022b to the interface region 5136.

[0594] In one embodiment, one or more 5140 processors are configured to control one or more 5512 welding torch motors to move the 5503 weld tip radially out of the 5136 interface region after rotational pass welding to accommodate the weld material deposited in the rotational pass weld and provide a hot pass weld on top of the rotational pass weld within tubes 1022a, 1022b (closest to the longitudinal axis AA).

[0595] In one embodiment, one or more 5140 processors that are configured to control one or more welding torch motors may be part of the 5046 wired power electronics module.

[0596] In one embodiment, the 5506 Radial Positioning System is configured to allow the 5502 Welding Torch to radially direct variations in tube shape to adjust the distance of the solder tip part (eg, tube) to passes multiples (eg rotational welding and hot pass procedures) and to retract from tubes 1022a, 1022b when the internal welding system is following.

[0597] In one embodiment, the 5506 Radial Positioning System is configured to provide the 5502 Welding Torch with a radial movement of 1.25 inches. In one embodiment, welding torch 5502 is movable by radial positioning system 5506 between a normal, non-elevated and an elevated configuration. As shown in FIG. 43, welding torch 5502 was created (for the raised configuration) by radial positioning system 5506 so that welding torch 5502 is positioned at the correct/desired/predetermined distance from tubes 1022a, 1022b for the welding procedure.

[0598] In one embodiment, the 5506 radial positioning system may include a linear actuator. In one embodiment, radial positioning system 5506 can include radial (electric) welding torch motor 5512, a link bolt 5514, and a link nut 5516. In one embodiment, the motor 5512 is configured (e.g., wired). mechanically) to rotate connecting screw 5514. In one embodiment, the 5512 motor is configured to rotate clockwise or counterclockwise so as to cause the 5502 welding torch to be raised or lowered substantially parallel to the radial axis RR ( as shown in Fig. 8) of tubes 1022a, 1022b. In one embodiment, the 5512 motor is configured to be connected directly to turn connecting screw 5514. In another embodiment, the 5512 motor is configured to be indirectly connected, for example, through a series of gears or a gearbox, to turn the connection screw 5514.

[0599] In one embodiment, the connecting bolt 5514 includes wires machined on its outer surface and extending along its length. In one embodiment, connector nut 5516 is constructed and arranged to be threaded onto connector bolt 5514 and includes complementary wires machined into its interior surface.

[0600] In one embodiment, radial positioning system 5506 includes two front vertical guide rod members 5518 and 5520 that are positioned parallel to and on either side of tie bolt 5514. In one embodiment, guide rod members Front verticals 5518 and 5520 are each connected to base member 5509 of torch housing assembly 5504 at one end thereof and connected to first transverse housing member 5522 at the other end thereof. In one embodiment, the end portions of the front vertical guide rod members 5518 and 5520 are received in openings formed in the base member 5509 of the torch housing assembly 5504 for connecting the front vertical guide rod members 5518 and 5520 to the base member 5509 of casing assembly 5504. In one embodiment, the end portions of the front vertical guide rod members 5518 and 5520 are received in apertures formed in the first transverse casing member 5522 for connecting the vertical guide rod members 5518 and 5520 to the first transverse shell member 5522.

[0601] In one embodiment, an end portion of connecting bolt 5514 (which is opposite its end portion connected to motor 5512) is constructed and arranged to pass through an opening 5534 in the first transverse shell member 5522.

[0602] In one embodiment, radial positioning system 5506 includes two rear vertical guide rod members 5600 and 5602 that are positioned parallel to tie bolt 5514 and two front vertical guide rod members 5518 and 5520. In one embodiment, rear vertical guide rod members 5600 and 5602 are each connected to base member 5509 of torch housing assembly 5504 at one end thereof and connected to second transverse housing member 5523 at 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 for connecting the rear vertical guide rod members 5600 and 5602 to the base member 5509 of housing assembly 5504. In one embodiment, the end portions of the rear vertical guide rod members 5600 and 5602 are received in apertures formed in the second transverse housing member 5523 for connecting the vertical guide rod members rear 5600 and 5602 to the second transverse shell member 5523.

[0603] In one embodiment, 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 portions of end of transverse radial positioning member 5524. In one embodiment, transverse radial positioning member 5524 and the two vertical radial positioning members 5526 of radial positioning system 5506 are configured to be movable during radial movement of the welding torch 5502.

[0604] In one embodiment, the transverse radial positioning member 5524 may have protruding end portions 5528 that are configured to mate with notches or protruding end portions that receive the openings 5530 of the two vertical radial positioning members 5526. , after the protruding end portions 5528 of the transverse radial positioning member 5524 are received in the notches or protruding end portions that receive the openings 5530 of the two vertical radial positioning members 5526, the transverse radial positioning member 5524 and the radial positioning member two vertically the members 5526 can then be securely connected together using any suitable clamping mechanism (eg clamping members 5532).

[0605] In one embodiment, the transverse radial positioning member 5524 includes openings for receiving vertical guide rod members 5518 and 5520 therethrough. This configuration allows the transverse radial positioning member 5524 to be slidable to positions fitted in the front vertical guide rod members 5518 and 5520. In one embodiment, the connecting bolt 5514 is configured to pass through a central opening 5536 of the positioning member. radial transverse 5524.

[0606] In one embodiment, radial positioning system 5506 also includes two rear radial positioning members 5604 and 5606. In one embodiment, two vertical radial positioning members 5526 are connected to two rear radial positioning members 5604 and 5606. In one embodiment, the two rear transverse radial positioning members 5604 and 5606 and the two vertical radial positioning members 5526 of radial positioning system 5506 are configured to be movable during radial movement of the welding torch 5502.

[0607] In one embodiment, each rear radially positioning member 5604 and 5606 has end portions that are configured to engage with end portions of their corresponding vertical radially 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 can then be securely connected to the its corresponding radial vertical positioning member 5526 using any suitable clamping mechanism (eg clamping members 5608).

[0608] In one embodiment, rear radial positioning members 5604 and 5606 include openings for receiving rear guide rod members 5600 and 5602, respectively, therethrough. This configuration allows the rear radial positioning members 5604 and 5606 to be slidable into positions adjusted on the rear vertical guide rod members 5600 and 5602.

[0609] In one embodiment, the link nut 5516 is configured to interlock with a portion of the transverse radial positioning member 5524 so that rotation of the link nut 5516 is prevented along with the link bolt 5514. link nut 5516 is prevented from rotating along with link bolt 5514, therefore, link nut 5516 is configured to move link bolt 5514 up and down. In one embodiment, link nut 5516 is interlocked and positioned in central opening 5536 of transverse radial positioning member 5524. In one embodiment, link bolt 5514 is configured to pass through an opening of interconnected link nut 5516.

[0610] In one embodiment, the two radially positioning vertical members 5526 are connected to each other using the front and 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 lower portions of the two vertical radial positioning members 5526 using any suitable clamping mechanism (eg clamping members 5614). Rear transverse support member 5612 is constructed and arranged to be connected to the rear and lower portions of the two vertical radial positioning members 5526 using any suitable clamping mechanism (e.g., clamping members 5616).

[0611] In one embodiment, the solder assembly 5500 also includes two vertical positioning members 5538 and an upper positioning member 5540. In one embodiment, the two vertical positioning members 5538 are connected to end portions of the upper positioning member 5540. In one embodiment, the end portions of the upper positioning member 5540 may have an L-shaped configuration. In one embodiment, the corresponding connecting portions of the two vertical positioning members 5538 may include complementary shape configurations that are configured to engage with the L-shaped configurations of the end portions of the upper positioning member 5540. In one embodiment, after the L-shaped configurations of the end portions of the upper positioning member 5540 is coupled with the complementary shape configurations of the corresponding connecting parts of the two vertical positioning members 5 538, the upper positioning member 5540 and the two vertical positioning members 5538 can then be securely connected to each other using any suitable clamping mechanism (e.g., clamping members 5542).

[0612] In one embodiment, the 5508 axial positioning system is configured to allow the 5502 welding torch to move axially to hold the 5502 welding torch on the welding bevel as the 5502 welding torch travels around the pipe and allows it to 5502 welding torch to oscillate inside the welding bezel if necessary to completely fill the bevel.

[0613] FIG. 47 shows the 5502 welding torch positioned in a normal centered axial position. In one embodiment, the 5508 axial positioning system is configured to provide the 5502 welding torch with an axial rotation of +/- 1 inch. For example, as shown in FIGS. 48 and 49, the 5502 welding torch was moved by the 5508 axial positioning system at +1 inch axial displacement and -1 inch axial displacement, respectively, so that the 5502 welding torch is positioned at the correct/desired distance/ of the tube for welding.

[0614] FIGs. 50 and 51 show a left side perspective view and an exploded view of the 5500 solder head assembly, where some components of the 5500 solder head assembly are not shown for clarity. FIG. 52 shows a bottom perspective view of the upper positioning member 5540 of the solder head assembly. FIG. 53 shows a top view of the 5500 solder head assembly, where some components of the 5500 solder head assembly are not shown for clarity.

[0615] In one embodiment, referring to FIGS. 50-53, the axial positioning system 5508 can be a linear actuator. In one embodiment, the 5508 axial positioning system may include the 5550 axial welding torch motor (electricity), a 5552 link bolt, and a 5554 link nut. In one embodiment, the structure, configuration, and operation of each one of the 5550 motors, the 5552 link bolt and the 5554 link nut of the 5508 axial positioning system is similar to the 5512 engine, the 5514 link bolt and the 5516 link nut of the 5506 radial positioning system and therefore not will be described in great detail in this document. In one embodiment, when the 5552 link bolt is rotated by the 5550 motor, the 5554 link nut is driven along the threads.

[0616] In one embodiment, the axial positioning system 5508 includes two horizontal guide rod members 5556 and 5558 that are positioned parallel to and on either side of the horizontally positioned bolt 5552. horizontal guide rod 5556 and 5558 are connected to upper positioning member 5540 at both ends thereof. In one embodiment, the end portions of horizontal guide rod members 5556 and 5558 are received in openings formed in upper positioning member 5540 for connecting horizontal guide rod members 5556 and 5558 with upper positioning member 5540. In one embodiment, at least one end portion of each of horizontal guide rod members 5556 and 5558 includes a projecting member 5560 that is configured to be received in a corresponding projecting member receiving portion 5562 formed in the opening of the positioning member. top 5540 for securing horizontal members of guide rods 5556 and 5558 with top positioning member 5540.

[0617] In one embodiment, the 5500 welding head assembly includes a 5564 welding torch frame that is configured to receive the 5502 welding torch thereon. In one embodiment, welding torch frame 5564 includes three horizontally extending apertures 5566, 5568, and 5570 and a vertically extending aperture 5572 formed therein. In one embodiment, horizontal guide rod members 5556 and 5558 are configured to pass through apertures 5566 and 5570 of welding torch frame 5564, respectively. In one frame, horizontally positioned connector screw 5552 is configured to pass through opening 5568 of welding torch frame 5564. In one frame, welding torch 5502 is configured to pass through opening 5572 of welding torch frame 5564. In one embodiment, welding torch frame 5564 may include a support portion 5574 that is configured to support portions of welding torch 5502 when welding torch 5502 is received in opening 5572 of welding torch frame 5564. .

[0618] In one embodiment, a portion 5584 of the welding torch frame 5564 is configured to engage with a portion 5586 of the welding torch 5502 so as to prevent any rotation of the welding torch 5502 when the welding torch 5502 is received at the opening 5572 of the 5564 welding torch frame.

[0619] In one mode, the 5550 motor is configured (eg mechanically connected) to turn 5552 connecting screw. In one mode, the 5512 motor is configured to rotate clockwise or counterclockwise in order to cause the left or right side movement of welding torch 5502 substantially parallel to the axial axis AA (as shown in figure 8) of tubes 1022a, 1022b. In one embodiment, the 5550 motor is configured to be indirectly connected, for example, through a series of gears 5576, 5578, and 5580, to turn connecting bolt 5552. That is, the 5550 motor comprises an output shaft 5582 and the 5550 motor is operatively connected to link bolt 5552 through gears 5576, 5578, and 5580 which engage output shaft 5582 of motor 5550. In one embodiment, gear 5576 is connected to output shaft 5582 of motor 5550, the gear 5580 is connected or connected to link screw 5552 and gears 5576 and 5580 are coupled together through gear 5578. When connecting motor 5550 to link screw 5552 through gears 5576, 5578 and 5580, link screw 5552 rotates when the 5550 engine runs. In another embodiment, the 5550 motor is configured to be directly connected (ie without the gear arrangement) to turn the 5552 link screw.

[0620] In one embodiment, the connector nut 5554 is configured to interlock with a portion of the welding torch frame 5564 such that the connector nut 5554 is prevented from rotating along with the connector screw 5552. the link nut 5554 is prevented from rotating together with the link bolt 5552, therefore the link nut 5554 is configured to travel/movement from side to side (i.e. substantially parallel to the axial direction YY as shown in Fig. 53 ) with connector screw 5552. In one embodiment, connector nut 5554 is interlocked and positioned in opening 5568 of weld torch frame 5564. In one embodiment, connector screw 5552 is configured to pass through an opening in the interlocking nut 5554.

[0621] In one embodiment, the 5510 tilt positioning system is configured to allow the 5502 welding torch to change its tilt angle in the plane of displacement to account for changes in the weld direction relative to the direction of gravity. In one embodiment, the tilt angle of the 5502 welding torch can be changed to accommodate the force of gravity. In one modality, the tilt angle of the 5502 welding torch can be adjusted to compensate for the different orientation due to gravity. In one embodiment, the angular orientation of the 5502 welding torch is controlled based on the profile of the interface region. In one modality, the tilt angle of the 5502 welding torch can be adjusted based on the weld profile data instantly. In one embodiment, the tilt angle of the 5502 welding torch can be adjusted based on the weld profile data instantly to accommodate and/or compensate for other welding conditions (ie, not just the force of gravity).

[0622] As the welding torch is able to articulate during the welding operation, it is able to take into account the gravitational forces acting on the welding assembly as the welding torch rotates on the fixed tube. Specifically, the angle of the welding torch can change when operated by at least one welding torch motor (that is, the 5588 welding coil ignition motor), based on whether the weld is an upward-facing torch. against the force of gravity or down with the force of gravity. One or more motors (for example, the 5588 Weld Coil Ignition Motor) may also change the weld angle within the plane of rotation based on the specific location within the up or down displacement of the welding torch. It should be appreciated that, as the welding torch can be articulated for some modes, it can be tilted better to accommodate the force of gravity and does not need to be adjusted in a fixed position under the assumption, for example, that it would only be traveling downwards. , with the force of gravity. In some embodiments, as noted above, the present application contemplates that welding can be performed while the welding torch is moving up (against gravity) or down (with gravity). In addition, the welding torch can be articulated based on the different rotation position (for example, a welding operation conducted at 10 degrees from TDC may ideally have slightly different requirements than a welding conducted at 90 degrees from neutral. higher due to (for example) gravitational forces applied to the solder pool, as well as the tendency for the solder group to adhere to the inner surface of the tube differently at different positions in the tube to be welded.

[0623] In one embodiment, the 5030 and 5074 motors driving the inspection detector 5056 also rotate the 5502 welding torch circumferentially around a rotational plane to create the weld along the 5136 interface region. 5588 tilt positioning motor that angularly articulates the 5502 welding torch generally within the rotational plane. In one embodiment, the angular orientation of the 5502 welding torch is controlled based on the torch position. In one embodiment, welding torch 5502 is configured to rotate along the weld seam around the plane of rotation.

[0624] In one embodiment, the 5502 welding torch can be configured such that the 5502 welding torch can include a different tilt angle of twist for every 90° of rotation. For example, in one modality, the 5502 welding torch can include a tilt angle 1 when performing the welding procedure on a section 1 boundary from the 2 o'clock position to the 5 o'clock position, the 5502 welding torch can include a tilt angle 2 when performing the welding procedure at a section boundary 2 from the 5 o'clock position to the 8 o'clock position, the 5502 welding torch can include a tilt angle 3 when performing the welding procedure at a section limit 3 from the 8 o'clock position to the 11 o'clock position, and the 5502 welding torch can include a tilt angle 4 when performing the welding procedure at a section 4 limit from the 11 o'clock position to the position of 2 hours. In one embodiment, welding torch 5502 can be configured such that welding torch 5502 can include a different tilt angle of twist for every 30° of rotation. In one embodiment, welding torch 5502 can be configured such that welding torch 5502 can include a different torch tilt angle for every 60° of rotation. In one embodiment, welding torch 5502 can be configured such that welding torch 5502 can include a different tilt angle of twist for every 120° of rotation. In one embodiment, welding torch 5502 can be configured such that welding torch 5502 can include a different angle of inclination for any desired degrees of rotation.

[0625] In one embodiment, the 5502 welding torch can be configured to have a continuously variable torch tilt angle to compensate for or accommodate the continuously changing orientation of the welding torch due to gravity. In one embodiment, the 5502 welding torch can be configured to progressively change the tilt angle of the torch based on where the welding torch is (ie, the position of the welding torch along the circumferential weld).

[0626] FIG. 54 shows that the 5502 welding torch is positioned in a normal and not tilted position. In one embodiment, the 5510 tilt positioning system is configured to provide the 5502 welding torch with +/- 5° angular tilt. For example, as shown in FIGS. 55 and 56, the 5502 Welding Torch has been moved by the 5510 Tilt Positioning System at +5° of angular tilt so that the 5502 Welding Torch is positioned at the correct/desired/pre-determined distance from the tube for welding. As shown in FIGS. 57 and 58, the 5502 welding torch was moved by the 5510 inclined positioning system at - 5° angular inclination, respectively, so that the 5502 welding torch is positioned at the correct/desired/pre-determined distance from the tube for welding . In another embodiment, the 5510 tilt positioning system is configured to provide the 5502 welding torch with +/- 7° of angular tilt. In one embodiment, the 5510 tilt positioning system is configured to provide the 5502 welding torch with +/- 5° angular tilt.

[0627] In one embodiment, a circumferential arc between the pivot point P and an impact point PI (as shown in FIGS. 56 and 58) of the inspection radiation beam over the interface region remains generally constant during an inspection process. welding. In one embodiment, one or more 5140 processors are aware of a constant arcuate distance between pivot point P (eg, solder tip) and inspection point PI, such that one or more 5140 processors are configured to control the articulation and swivel of the 5502 Welding Torch based on the pre-weld profile inspection data.

[0628] The 5502 Welding Torch setting that allows the 5502 Welding Torch to rotate around pivot point P allows the 5502 Welding Torch angle to be changed during welding without affecting the speed at which the Welding Torch 5502 is following. For example, this is especially useful for welding systems with multiple welding torches. In one modality, the welding torches will not have their angles changed at the same time, in which case it would be beneficial for the torch angle to be changed without any adverse effect on other weld marks.

[0629] In one embodiment, tilt positioning system 5510 includes tilt weld torsional motor 5588, guide rail members 5544, and guide rollers 5546. In one embodiment, guide rail members 5544. are configured to be engaged with guide rollers 5546 to facilitate tilt positioning of welding torch 5502. In the illustrated embodiment, guide rollers 5546 may include two upper and two lower guide rollers. In one embodiment, tilt positioning system 5510 includes a guide rail member 5544 and its associated four guide rollers 5546 positioned on opposite sides of the welding torch assembly 5500.

[0630] In one embodiment, 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 rail member. corresponding guide 5544 using any suitable clamping mechanism (eg clamping members 5548). This configuration allows each vertical radial positioning member 5526 to be connected to the corresponding vertical positioning members 5538 through the coupling of the corresponding guide rail member 5544 and guide rollers 5546.

[0631] In one mode, the 5588 motor is configured (eg mechanically connected) to rotate a 5590 gear. In one mode, the 5588 motor is configured to rotate clockwise or counterclockwise so as to cause motion of the 5502 welding torch forward or backward tilt. In one embodiment, the 5588 motor is configured to be connected, for example, through gear 5590, to guide rail member 5544. That is, the 5588 motor comprises an output shaft 5592, and gear 5590 is connected to output shaft 5592 of motor 5588. By connecting motor 5588 to guide rail member 5544 through gear 5590, guide rail 5544 moves when motor 5588 runs .

[0632] In one embodiment, guide rail member 5544 is configured to guide upper and lower guide rollers 5546. In one embodiment, upper and lower guide rollers 5546 are angled against guide rail member 5544 of such that the upper and lower guide rollers 5546 are configured to cause the corresponding vertical positioning member 5538 to move (attached to it) and thus allow the welding torch 5502 to change its tilt angle in the plane of displacement.

[0633] In one embodiment, the configuration of the two opposite vertical positioning members 5538 connected to each other via the upper positioning member 5540 such that movement in one of the vertical positioning members 5538 (i.e., caused by the 5588 motor) causes a similar movement in the other vertical positioning member 5538. The configuration with the two horizontal guide rod members 5556 and 5558 connected to the upper positioning member 5540 at both its ends also facilitates translation of the movement of one of the vertical positioning members 5538 to the other.

[0634] The operation of the 5506 radial positioning system is discussed in detail below. When the 5514 link bolt is rotated by the 5512 motor, the 5516 link nut is driven along the threads. In one embodiment, the direction of movement of the link nut 5516 depends on the direction of rotation of the link bolt 5514 by the 5512 motor.

[0635] As the link nut 5516 is interlocked into the opening 5536 of the transverse radial positioning member 5524, the transverse radial positioning member 5524 is configured to shift/move (up or down) the link bolt 5514 together with the link 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) to shift/move the transverse radial positioning member 5524 .

[0636] Furthermore, 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) (low) movement of the two vertical radial positioning members 5526.

[0637] 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 sliding engagement between the rear radial positioning members 5604 and 5606 and the rear vertical guide rod members 5600 and 5602 also help (up or down) shift/move the two vertical radial positioning members 5526.

[0638] As discussed above, each vertical radial positioning member 5526 is connected with corresponding vertical positioning members 5538 through the engagement of corresponding guide rail member 5544 and guide rollers 5546. downward) movement of each vertical radial positioning member 5526 also causes (up or down) movement of its corresponding vertical positioning member 5538. As the two vertical positioning members 5538 are securely connected, the upper 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 5540.

[0639] As the 5502 welding torch is connected to the upper positioning member 5540 through the 5552 horizontal connecting screw, the two horizontal guide rod members 5556 and 5558 and the 5564 welding torch frame, the (para up or down) movement of upper positioning member 5540 also causes (up or down) movement of welding torch 5502. Thus welding torch 5502 is mounted for movement by radial positioning system 5506 in such a way that solder tip 5503 is configured to move forward and away from the solder surface of tubes 1022a, 1022b.

[0640] The operation of the 5508 axial positioning system is discussed in detail below. When the 5552 link bolt is rotated by the 5550 motor through the 5576, 5578, and 5580 gears, the 5554 link nut is driven along the threads. In one embodiment, the direction of movement of the link nut 5554 depends on the direction of rotation of the link bolt 5552 by the 5550 motor.

[0641] As link nut 5554 is interlocked into opening 5568 of welding torch frame 5564, welding torch frame 5564 is configured to shift/move (side-by-side) along with link nut 5554. The sliding engagement between the 5564 welding torch frame and the horizontal rod members 5556 and 5558 also facilitates this (side by side) shifting/moving of the 5564 welding torch frame. The sliding engagement between the two horizontal rod members 5556 and 5558 Welding Torch Frame and 5564 Welding Torch Frame also help (side by side) shifting/moving of 5564 Welding Torch Frame (and 5502 Welding Torch). In one embodiment, the amount of axial movement of the welding torch frame 5564 is restricted by an elongated opening 5594 in the upper positioning member 5540.

[0642] The operation of the 5510 tilt positioning system is discussed in detail below. When gear 5590 is rotated by motor 5588, guide rail member 5544 is driven along teeth. In one embodiment, the direction of movement of guide rail member 5544 depends on the direction of rotation of gear 5590 by motor 5588.

[0643] In one embodiment, the upper and lower guide rollers 5546 that are angled towards the guide rail 5544 are configured to cause the corresponding vertical positioning member 5538 (connected to the guide rollers 5546) to move/tilt .

[0644] In one embodiment, the configuration of two vertical positioning members 5538 connected to each other via the upper positioning member 5540 is such that movement in one of the vertical positioning members 5538 (i.e., caused by the 5588 motor) generates a similar movement in the other vertical positioning member 5538. The configuration with the two horizontal guide rod members 5556 and 5558 connected to the upper positioning member 5540 at both its ends also facilitates translation of the movement of one of the vertical positioning members 5538 to the other.

[0645] When the vertical positioning members 5538 and the upper positioning member 5540 (along with the two horizontal guide rod members 5556 and 5558) are moved/titrated, this movement allows the welding torch 5502 (connected to two horizontal guide rod members 5556 and 5558 through welding torch frame 5564) change the tilt angle of the 5502 welding torch in the plane of displacement.

[0646] As noted in this document, the welding torch is mounted to move in such a way that, when driven by the 5888 tilted welding torch motor, it is pivoted or rotated around a point that meets at or slightly in front of the welding torch tip. For example, the tip of the welding torch can hinge over a point on the weld assembly it creates during a weld operation. As a result, the position of the weld set will not change relative to a radius drawn to the weld set, regardless of the fact that the welding torch can be articulated by the tilted welding torch motor. Thus, the length of the arc between the weld set and the point at which the radiation beam emitted from the inspection laser falls on the inner surface of the tubes to be welded (for example, in the region of the interface) remains constant as the measurement that the orientation motors rotate the welding torch and inspection laser independently of the welding torch articulation by the tilted welding torch motor. And since the orientation and speed motors are also controlled and known by one or more processors, one or more of these processors can control the weld parameters in a specific region of the interface region, knowing the fixed arc length and based on the Processor calculation of the weld profile detected in the region just in front of the weld tip. In one embodiment, the drive motors are provided with angle encoders operatively linked to one or more processors to allow the one or more processors to determine the rotational position of the motors and therefore of the clamps and tubes as well. In another embodiment, the inspection detector signals (for example, the inspection laser) are used to detect the movement of the tube being welded, with the signals being used by one or more processors, knowing the fixed arc length, to control the torch in the appropriate location corresponding to the determined position of the welded torch. In another embodiment, the welding torch pivot point does not need to be in the forward position or at the welding tip, and the arc length between the welding assembly and the laser beam inspection point at the interface regions it doesn't need to remain constant. Instead, one or more processors, receiving welding torch tip position information from one or more welding torch motors and/or the inspection detector, are used to calculate the actual welding tip position in Real-time ("accurately") tube relationship to control one or more welding torch motors to position the welding torch tip in the desired location based on profile data received from the inspection detector.

[0647] As mentioned in this document, the welding torch is mounted to be moved or driven by one or more motors in a generally radial direction, along the longitudinal axis of the tip of the welding torch, towards or away from the surface internal part of the tube to be welded. It should be appreciated that since the longitudinal axis of the welding torch (eg through the tip of your welding torch) is likely not aligned with the radius of the tube to be welded (taken off the center axis) or with the radius of the rotating center hub, due to the fact that the welding torch is typically tilted in a forward welding direction (and articulated by the 5588 tilted welding torch motor when referring to the "radial" motion of the welding torch and to its tip towards and away from the inner surface of the tube (eg at the interface region), this radial movement is being used in the context described above. For example, this radial movement of the welding torch can be considered as if referring to the longitudinal movement of the welding torch along the axis of the tip of the welding torch. Since the welding torch is mounted for movement by at least one welding torch motor, and specifically by the welding torch motor solder 5512 radial, to enable the torch tip to move in the direction and in the opposite direction from the weld surface, the weld tip can be moved beyond the interface region after each weld pass to accommodate the build-up of weld material . After the first and second tube engagement structures are secured to the tubes, the welding torch can be used to complete a full root weld pass, with the "root" weld pass being the first weld applied between the tube ends (eg a total of 360 degrees of soldering). Upon completion of the root weld pass, the weld tip can be moved (retracted) slightly in the opposite direction from the inner surface of the tubes (and in particular in the opposite direction of the weld material from the applied root weld pass) so that the second weld pass (also referred to as the "hot" pass weld) can be driven with the solder tip at a suitable distance from the material of the root weld pass.

[0648] In one embodiment, one or more 5140 processors operating motors 5030 and 5074 and one or more 5502 welding torches to generate a complete circumferential weld along the 5136 interface region by rotating one or more 5502 welding torches to the along the 5502 interface region in a single direction of rotation, until the complete circumferential weld is completed.

[0649] In one embodiment, one or more welding torches 5502 includes a plurality of welding torches. In one embodiment, at least one of a plurality of welding torches is in an upwardly rotating direction, while at least one other plurality of welding and welding torches is in a downwardly rotating direction.

[0650] In one mode, the weld tip is configured to point in a weld direction. In one modality, the welding torch is always pointing in the direction of travel. That is, basically, the solder tip is generally pointing in the travel direction. In one embodiment, the torch tilt angle is slightly greater when the 5502 welding torch is acting in an upward welding procedure (when the 5502 welding torch is welding in an upward rotation direction) and the tilt angle of the welding torch is slightly smaller when acting in a downward welding procedure (when the 5502 welding torch is welding in a downward rotation direction).

[0651] In one modality, the internal welding system is configured to perform the down weld procedure (ie, a weld in the downward rotation direction) when using a short arc welding procedure.

[0652] In one embodiment, when the internal welding system is configured to perform the upward welding procedure (ie, a weld in the upward direction of rotation), the productivity and weld quality can be improved. In one embodiment, the up-weld procedure is configured to provide an option to weld both sides of the tube at the same time instead of the down-weld procedure being performed on each side in succession. For example, it could be a multiple welding torch operation and have multiple weld overlays. Alternatively, this can provide an option to weld 360° in one continuous pass to produce a weld with only one overlap. In one modality, customer requirements and pipe size may determine which approach will be used.

[0653] In one modality, unless there is a quality requirement to have only one weld overlay joint, the weld can be done with as many welding torches as necessary, as far as they fit inside the tube. In one embodiment, the internal welding system 5004 may include four welding torches, six welding torches, or eight welding torches with half of the welding torches welding in the downward direction of rotation and the other half of the welding torches performing the weld in the upward rotation direction. In one embodiment, half of these welding torches are configured to perform the welding procedure in a clockwise direction and the other half of the welding torches are configured to perform the welding procedure in a counterclockwise direction. In one embodiment, four torches of internal welding system 5004 can be positioned 90° apart from each other and are configured to rotate 90° each. In one embodiment, six torches of internal welding system 5004 can be positioned 60° apart from each other and are configured to rotate 60° each. In one embodiment, eight torches of internal welding system 5004 can be positioned 45° apart from each other and are configured to rotate 45° each. In one embodiment, internal weld system 5004 may include two weld marks positioned 180° apart from each other and are configured to rotate 180° each. In embodiment, gap welding system 5004 can include a welding torch configured to rotate 360°.

[0654] The ability to weld up and down can improve weld operating speed (weld transfer time) and also improve weld quality (taking into account gravitational forces at different locations). In addition, where multiple welding torches are provided, welding can occur both up and down at the same time (eg circumferentially separated welding torches, moving in the same direction of rotation and simultaneously applying the welding material) , with at least one welding torch moving up while at least one other moving down. This is time efficient, for example, compared to down-welding each side of the pipe in sequence. Alternatively, in one modality, a single welding torch can be used to perform a single 360 degree weld to provide a continuous weld, without overlapping weld portions. This overlap would occur when more than one welding torch is used and the end of each welding portion of a trailing welding torch needs to connect and slightly overlaps with the beginning of the welding portion applied by a welding torch in front of the breakout welding torch. As a result, for some applications where it may be desired to avoid parts of the weld overlap (which make the weld pass slightly less uniform at the overlap points), 360-degree continuous weld can be useful.

[0655] In one modality, the welding torches all point in a forward weld direction. In other words, they are lightly connected in the direction of the weld so that the tip of the welding torch "pushes" the weld instead of dragging the weld. This is true whether the welding torch is positioned internally, as in some embodiments, or externally, as in other embodiments described in this document. This is illustrated in relation to the internal welder as shown in FIG. 56A. In one modality, the welding torch tips are pointing at an angle θ (for example, a "lead angle") between 3 degrees and 7 degrees. The principal angle θ is defined as an angle measured between a line (radius) R from the axial center of the tubes that are welded to the tip of the welding torch (or welding assembly), as shown in FIG. 56A (the line R can also be thought of as the radius taken from the axial center of the rotating hub 5078 to the tip of the torch or welding assembly) and a line through the longitudinal axis A of the tip of the welding torch. In the illustration of FIG. 56A, the welding torch is being rotated counterclockwise as represented by arrow D. This bond angle θ can be changed by operating the 5588 tilted welding torch motor as the welding torch is moved circumferentially around the inside of the tubes by the orientation motor. It is envisioned that the leading angle θ will be slightly larger (eg 6 degrees) when the welding torch is traveling up and slightly smaller (eg 4 degrees) when traveling down. Also, in one modality, the main angle θ can change continuously along the displacement of a particular welding torch. In another modality, the tube can be divided into sectors, with the weld angle θ being changed based on the sector. For example, when considering the full 360 degrees or the movement to match the movement of the clock hand, the tube can be divided into several hour sectors: 2-5, 5-8, 8-11, 11-2. One or more engines can be operated by one or more processors to shift across sector boundaries.

[0656] As will be appreciated by FIG. 56A, welding is being performed counterclockwise in the depiction shown. For clockwise welding, one or more 5140 processors sends a signal to one or more torch motors so that gear 5590 is rotated and welding torch 5502 is pivoted (eg around point P) of so that the shaft through the torch (line A) is moved to the opposite side of the radial line R. Thus, angle θ will be negative for clockwise welding. This will allow the welding torch to point in a forward direction ("pushing in" the welding assembly) when welding in a clockwise direction.

[0657] In one embodiment, as shown in FIGS. 60A-63, the 5004 indoor welding system can include a WT welding torch, a C camera, and two inspection detectors L1 and L2. In one embodiment, the WT welding torch and the C camera are 180° apart. In one modality, the angle between camera and WT welding torch may vary.

[0658] In one modality, one of the two inspection detectors L1 and L2 can be a main inspection detector that is configured to drive the WT welding torch during the welding process and also to provide pre-weld data. In one modality, the other of the two inspection detectors L1 and L2 can be an inspection detector that is configured to track the WT welding torch during the welding procedure and provide post weld data.

[0659] In one modality, inspection detector L1 and welding torch WT are separated by an angle of 20°. In one modality, inspection detector L2 and welding torch WT are separated by an angle of 20°. In one modality, the angle between the L2 inspection detector and the WT welding torch and the angle between the L1 inspection detector and the WT welding torch can vary.

[0660] In one modality, the angle between L2 inspection detector and WT welding torch and the angle between L1 inspection detector and WT welding torch can be adjustable. For example, in one modality, when L1 is a main inspection detector, the angle between the L1 inspection detector and the WT welding torch is 20° or less and the angle between the L2 leak inspection detector and the welding torch. WT weld is greater than 20°. In one modality, when L2 is a main inspection detector, then the angle between the L2 inspection detector and the WT welding torch is 20° or less and the angle between the L1 leak inspection detector and the WT welding torch is greater than 20°.

[0661] In an embodiment as shown in FIG. 60A, inspection detector L1 is positioned in its home position. In one embodiment, referring to FIG. 60B, the WT welding torch starts the welding process when the WT welding torch is positioned at the initial WT. In one modality, the WT welding torch is configured to travel in a clockwise direction (as indicated by arrow T1) during the welding process. In one embodiment, referring to FIG. 61, the WT welding torch ends the welding process when the WT welding torch reaches the WT interrupt. In one embodiment, a WB1 weld bead formed by the WT welding torch as it travels from the initial WT to the stop of the WT in a clockwise direction, indicated by the arrow T1. In one embodiment, as shown in FIGS. 60B and 61, the WT torch follows the inspection detector L1 during its travel from the initial WT to the stop of the WT in a clockwise direction, indicated by the arrow T1. After the welding process, the WT welding torch is moved counterclockwise (ie, in opposition to the direction of the arrow T1) so that the inspection detector L2 is positioned back to its home position, home WT.

[0662] In one embodiment, referring to FIG. 62, the WT welding torch starts the welding process when the WT welding torch is positioned on the initial WT. In one modality, the WT welding torch is configured to travel counterclockwise (as indicated by arrow T2) during the welding process. In one embodiment, referring to FIG. 63, the WT welding torch ends the welding process when the WT welding torch reaches the WT interrupt. In one modality, a WB2 weld bead formed by the WT welding torch as it travels from the initial WT to the stop of the WT in a counterclockwise direction, indicated by the arrow T2. In one embodiment, as shown in FIGS. 62-63, the WT torch follows the inspection detector L2 during its travel from the initial WT to the stop of the WT in a counterclockwise direction, indicated by the arrow T2. After the welding process, the WT welding torch is moved in a clockwise direction (ie, in opposition to the direction of the T2 arrow), so that the L1 laser is positioned back to its home position, home WT.

[0663] In one embodiment, as shown in FIGS. 64-69, the 5004 indoor welding system can include dual welding torches WT1 and WT2, a camera C and an inspection detector L. In one embodiment, the inspection detector L and the welding torch WT1 are separated by an angle of 20th. In one modality, inspection detector L and welding torch WT2 are separated by an angle of 20°. In one modality, inspection detector L and camera C are separated by an angle of 180°.

[0664] In an embodiment as shown in FIG. 64, inspection detector L is positioned in its home position. In one embodiment, referring to FIG. 65, Welding Torch WT1 starts the welding process when Welding Torch WT1 is positioned in WT1start. In one modality, the WT1 welding torch is configured to travel clockwise (as indicated by arrow T1) during the welding process. In one embodiment, referring to FIG. 66, Welding Torch WT1 ends the welding process when Welding Torch WT1 reaches WT1 interrupt. In one embodiment, as shown in FIG. 66, a WBWT1 weld bead is formed by the WT1 welding torch as it travels from the start WT1 to the stop of WT1 in a clockwise direction, indicated by the arrow T1. In one embodiment, as shown in FIGS. 64-66, the WT1 torch follows the inspection detector L during its travel from the initial WT1 to the stop of WT1 in a clockwise direction, indicated by the arrow T1. After the welding procedure, the WT1 welding torch is moved counterclockwise (ie, in opposition to the direction of the arrow T1) so that the inspection detector L is positioned back to its home position, as shown in FIG. 67.

[0665] In one embodiment, referring to FIG. 68, the WT2 welding torch starts the welding process when the WT2 welding torch is positioned at the initial WT2. In one modality, the WT2 welding torch is configured to travel counterclockwise (as indicated by arrow T2) during the welding process. In one embodiment, referring to FIG. 69, the WT2 welding torch ends the welding process when the WT2 welding torch reaches the WT2 interrupt. In one embodiment, a weld bead WBWT2 is formed by the welding torch WT2 as it travels from the initial WT2 to the stop of WT2 in a counterclockwise direction, indicated by the arrow T2, as shown in FIG. 69. In one embodiment as shown in FIGS. 68-69, the WT2 torch follows the inspection detector L during its travel from the initial WT2 until the stop of WT2 counterclockwise, indicated by the arrow T2. After the welding procedure, the WT2 welding torch is moved counterclockwise (ie, in opposition to the direction of the arrow T2) so that the inspection detector L is positioned back to its home position, as shown in FIG. 64 and 67.

[0666] In one embodiment, the 5004 indoor welding system may include a welding torch and an inspection detector. In one modality, the angle between the inspection detector and the welding torch can be 20° or less. In one embodiment, the inspection detector and welding torch can be separated by a 3-inch arc length AL (as shown in figure 64). In one modality, the inspection detector and welding torch can be separated by a 4-inch arc length AL. In one modality, the angle between the inspection detector and the welding torch is 19°. In one modality, the angle between the inspection detector and the welding torch is 16°. In one modality, the angle between the inspection detector and the welding torch is 14°. In one modality, the angle between the inspection detector and the welding torch is 12°.

[0667] FIG. 70 shows a schematic diagram showing compressed air flow through internal welding system 5004, where some components of internal welding system 5004 are not shown for clarity and to better illustrate other components and/or system features of internal solder 5004.

[0668] Referring to FIG. 70, compressed air tank 5128, brake cylinder 5133, drive wheel cylinder 5137, brake valve 5190, and drive wheel valve 5192 are shown in drive section 5010 of internal welding system 5004. Rear swivel joint 5072, rear clamp control valve 5062, rear clamp 5144, and front clamp 5142 are shown in center section 5008 of internal welding system 5004. Front swivel joint 5032 and front clamp control valve 5018 are shown in the frontmost section 5006 of internal welding system 5004.

[0669] In one embodiment, the compressed air tank 5128 has two separate fluid communication lines connected through a valve 5113. In one embodiment, the compressed air tank 5128 is in fluid communication through fluid communication lines with the 5190 brake valve (and 5133 brake cylinder), 5192 steering wheel valve (and 5137 drive wheel cylinder), 5062 rear clamp control valve (and 5144 rear clamp), the rear swivel union 5072, front swivel union 5032, front clamp control valve 5018 (and front clamp 5142), and compressor 5029.

[0670] Compressed air stored in compressed air tank 5128 is sent through the fluid line to a 5194 valve. A portion of the compressed air received by the 5194 valve is sent to the 5190 brake valve and the remaining portion of the received compressed air The 5194 valve is sent to a 5196 valve. The 5190 brake valve is in fluid communication through lines 5198 and 5199 with the 5133 brake cylinder. In one embodiment, the 5190 brake valve is configured to supply compressed air to activate the brake cylinder 5133 when it receives signals from the electronic module of the drive section 5118. Compressed air operates the brake cylinder 5133 which through its operation provides a braking force to the 5122 drive rollers. 5133 brake and 5190 brake valve may be referred to as a brake system that is configured to protect the structure of the 5004 internal welding system from movement to a desired location within the tubes 1022a, 1022b. In one embodiment, the brake system that is configured to protect the structure of inner welding system 5004 from movement at the desired location within tubes 1022a, 1022b can include a wheel/roller lock. In one embodiment, the wheel/roller lock is configured to prevent one or more of the rollers 5122 from preventing movement of the structure of the internal welding system 5004. In one embodiment, the brake system may also include an engine lock. In one embodiment, the motor lock is configured to prevent rotation of the 5124 drive motors that drive the 5122 rollers for locomotion of the frame of the 5004 internal welding system.

[0671] A portion of the compressed air received by valve 5196 is sent to drive wheel valve 5192 and the remaining portion of compressed air received by valve 5196 is sent to valve 5198. Drive wheel valve 5192 is in communication of fluid through lines 5200 and 5201 with drive wheel cylinder 5137. In one embodiment, drive wheel valve 5192 is configured to supply compressed air to activate drive wheel cylinder 5137 when it receives signals from the electronics module. of drive section 5118. Compressed air operates the drive wheel cylinder 5137 which through its operation provides a transmission force to the drive rollers 5122. In one embodiment, the drive wheel cylinder 5137 may be operatively connected to a shaft with 5122 transmission rollers on it. In one embodiment, the drive wheel cylinder 5137 may be operatively connected to the shaft through one or more gear arrangements.

[0672] In one embodiment, drive wheel cylinder 5137 and brake cylinder 5133 are retracted while loading internal welding system 5004 into the tubes. In one embodiment, drive wheel cylinder 5137 is retracted only when internal welding system 5004 is withdrawn from the tubes. In one embodiment, the drive wheel cylinder 5137 is extended to accelerate or decelerate (the passage of) the internal welding system 5004 in the tubes.

[0673] A portion of the compressed air received by valve 5198 is sent to the rear swivel union 5072 and the remaining portion of the compressed air received by valve 5198 is sent to the rear clamp control valve 5062. The rear clamp control valve 5062 is in fluid communication via 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 compressed air to activate and operate the rear clamp 5144 when it receives signals from the center section electronics module 5064.

[0674] The compressed air outlet by the rear swivel union 5072 is sent to the front swivel union 5032. The compressed air outlet by the front swivel union 5032 is sent to a valve 5204. A portion of the compressed air received by the valve 5204 is sent to front clamp control valve 5018 and the remaining portion of the compressed air received by valve 5204 is sent to compressor 5029. In one embodiment, compressor 5029 is configured to recharge the system (e.g., fill the tank with compressed air ) using the compressed air received.

[0675] Front clamp control valve 5018 is in fluid communication through lines 5206 and 5207 with front clamp 5142. In one embodiment, fluid communication line 5206 is used to extend the front clamp 5142 and the fluid communication line 5207 is used to retract front clamp 5142. In one embodiment, front clamp control valve 5018 is configured to supply compressed air to actuate and operate front clamp 5142 when it receives signals from the electronics module front 5014.

[0676] FIG. 71 shows a schematic diagram showing power flow that includes weld power, communication data, and control data through internal welding system 5004, where some components of internal welding system 5004 are not shown for reasons of clarity and to better illustrate the other components and/or features of the 5004 internal welding system.

[0677] Referring to FIG. 71, the frontmost electronics module 5014, the front rotation motor 5030, the front position sensor 5022, the front clamp control valve 5018, the front sliding ring 5016, the wire feed electronics module 5046 of the assembly. 5020 Wire Feed, 5044 Wire Feed Systems, and 5042 Shield Gas Control Valve are shown in the frontmost section 5006 of Inner Welding System 5004. The 5078 Rotating Hub, 5502 Welding Torches, Detectors inspection camera 5056, inspection camera 5112, front clamp 5142 and rear clamp 5144, rear slip ring 5080, center section electronics module 5064, rear position sensor 5076, rear clamp control valve 5062, and the 5074 rear rotation motor is shown in the center section 5008 of the 5004 internal welding system. The 5116 batteries, the 5118 transmission section electronic module, the 5190 brake valve, the transmission wheel valve. s are 5192 and 5124 drive motors are shown in the 5010 drive section of the 5004 internal welding system.

[0678] In one embodiment, weld power is received by internal welding system 5004 from umbilical 5034. In one embodiment, weld power from umbilical 5034 is supplied to weld torches 5502 through front slide ring 5016.

[0679] In one embodiment, the 5116 batteries of the 5010 transmission section are configured to supply power to all electronic modules in the indoor welding system 5004, including forward electronics module 5014, wired power electronics module 5046 , the center section electronics module 5064 and the transmission section electronics module 5118. In one embodiment, the batteries 5116 of the transmission section 5010 are configured to supply power to all electrical transmission motors in the internal welding system 5004. including the 5030 front rotation motor, the 5044 wire feed systems motors, the 5074 rear rotation motor, the 5124 drive motors, the 5550 thrust welding torch motor, the 5512 radial welding torch motor, and the 5588 slanted welding torch motor.

[0680] In one mode, battery power 5116 is supplied directly to rear slip ring 5080, center section electronics module 5064, and transmission section electronics module 5118. In one mode, battery power 5116 is supplied to Front Slip Ring 5016 through Rear Slip Ring 5080. That is, the power of the 5116 batteries is transferred from the Rear Slip Ring 5080 to the Front Slip Ring 5016. In one modality, the power of the 5116 batteries is supplied from the Front Slip Ring 5016 for the most forward electronics module 5014 and the wired power electronics module 5046.

[0681] In one embodiment, power from the 5116 batteries is supplied from the forward electronics module 5014 to the front rotation motor 5030 and from the wired feed electronics module 5046 to the motors of the 5044 wired feed systems. In one mode, battery power 5116 is supplied from center section electronics module 5064 to rear rotation motor 5074. In one mode, battery power 5116 is supplied from drive section electronics module 5118 to drive motors 5124. In one embodiment, power from batteries 5116 is supplied from the wired power electronics module 5046 to the thrust welding torch motor 5550, the radial welding torch motor 5512, and the tilt welding torch motor 5588.

[0682] In one embodiment, the 5116 batteries are also configured to supply power to the 5112 inspection camera and the 5056 inspection detectors. For example, the power of the 5116 batteries is supplied from the wired power electronics module 5046 to the 5112 inspection camera and the 5056 inspection detectors.

[0683] In one embodiment, the 5116 batteries are also configured to supply power to the front position sensor 5022 and the rear position sensor 5076. For example, the power from the 5116 batteries is supplied from the more advanced electronics module 5014 to the sensor from the front position 5022 and from the center section electronics module 5064 to the rear position sensor 5076.

[0684] In one embodiment, the 5116 batteries are also configured to supply 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, battery power 5116 is supplied from the forward electronics module 5014 to the front clamp control valve 5018, from the wire feed electronics module 5046 to the drive control valve. shielding gas 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 to the drive wheel valve 5192.

[0685] In one embodiment, the internal soldering system 5004 is configured to receive and send communication signals through umbilical 5034 to the external computer system (eg, having one or more processors). In one embodiment, a received communication signal may travel from umbilical module 5034 to the furthest electronics module 5014 and then to wire feed electronics module 5046 via the front slide ring 5016 and then to the center section electronics module 5064 through the rear slip ring 5080 and then to the transmission section electronics module 5118.

[0686] In one embodiment, a communication signal may travel (in the opposite direction to the received signal) from the transmission section electronics module 5118, then to the central section electronics module 5064, then to the wire feed electronics module 5046 through the rear slip ring 5080 and then to the frontmost electronics module 5014 through the front slip ring 5016 and to the umbilical (and to the external computer system with one or more processors).

[0687] In one or more embodiments described above, and as appreciated by FIG. 71, one or more of the 5140 processors are operatively associated with the inspection detector 5056, for example, the inspection laser (or optionally several inspection detectors 5056 where more than one is provided) via a communication line or lines rigid cables 5056a that transmit signals from the inspection laser 5056 to one or more processors 5140. The wired communication line has (i) a moving portion 5056b that moves with the inspection detector(s) 5056 while the inspection laser transmits the inspection beam along the interface region and (ii) a stationary portion 5056c that remains fixed during the movement of the movable portion 5056b. The system further comprises the front sliding ring 5016 described above (which may, from a perspective, be considered part of the wired communication line) which provides an interface between a section of the movable portion 5056b and a section of the fixed portion 5056c of the line. communication to allow signals to pass from the mobile portion 5056b to the stationary portion 5056c.

[0688] It should be appreciated that the wired communication line or lines (5056a) (including its mobile and stationary portions) are also configured (or, alternatively, configured if wireless communications are provided to the 5056 inspection detectors communicate with one or more processors) to transmit power to the 5056 inspection detectors through the 5016 slip ring.

[0689] The slip ring 5016 comprises an outer stator 5016a and an inner rotor 5016b (see figure 26). The 5016b inner rotor and the 5016a stator have a 5016k bearing between them. The stator 5016a is fixedly mounted relative to the central frame 5068 (see FIGS. 23 and 24), while the rotor 5016b is connected to the rotating hub 5078 at its central axis (see, for example, Figure 24). The 5016b rotor is rotated together with the 5078 rotating hub when the hub is activated for rotation. The stator 5016a is connected to the stationary portion 5056c of the hard wired communication line and the rotor 5016b is connected with the moving portion 5056b of the rigid wired 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 therethrough. Passage 5016d allows the passage of other conduits or lines therethrough, and specifically, for example, pneumatic lines from the front rotary joint (such as external compressed air lines that will be communicated to compressed air tank 5128).

[0690] As can be appreciated, the link between the inspection detector 5056 and one or more processors 5140 may, in some embodiments, also travel through other components. For example, as shown in FIG. 71, the communication line of inspection detector 5056 may travel through wired power electronics 5046 before being received by slip ring 5016.

[0691] The slip ring 5016 allows the movable portion 5056b of the communication line to move with the rotating hub 5078 as the hub 5078 rotates during a check operation of inspection detector 5056, during a pre-welded check of the tube interface region before a weld operation, as well as during the instantaneous check of the tube interface region during a weld operation.

[0692] It should also be appreciated that the 5016 slip ring is also configured to couple the communication link between one or more 5140 processors and the 5112 inspection camera, in addition to providing power to the 5112 inspection camera. same line or same 5056a rigid wired communication lines. One or more 5140 processors are configured to receive camera inspection data from the 5112 inspection camera before, subsequently, or during a weld operation. The mobile portion 5056b moves with the camera (and the rotating hub 5078), while the camera checks the interface region and the stationary portion 5056c remains fixed during the movement of the mobile portion 5056b which communicates with the camera 5112.

[0693] It should further be appreciated that the same slip ring 5016 (and/or slip ring 5080) is configured to communicate power to other components that can rotate with the rotating hub 5078. For example, as illustrated in FIG. 35B, 5502k welding power lines to supply welding power to 5502 welding torches, and 5550k power and command lines to control and power one or more 5550, 5512, 5588 welding torch motors to control the welding 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 rigid wired power line to the 5502k weld power line is labeled 5112c and the movable portion of the weld power line is labeled 5112b. It will be appreciated that they may alternatively be shown showing additional lines on the same slip ring 5016 or shown in connection with a separate slip ring.

[0694] Likewise, a 5550k hard wired communication line can be provided through the 5016 slip ring to provide command (and control) as well as power to the 5550, 5512, 5588 torch motors. and with no need for redundancy, the moving portion 5550m is from this line with wire 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 the slip ring 5016 (or other slip ring) can be used to transmit power and communication to the welding torches 5502 as the welding torches are rotated with the rotating hub 5078 and as they are fed. and controlled to create a weld during a weld operation.

[0695] As shown in FIG. 35B (and various other figures), swivel hub 5078 has a generally hollow cylindrical portion 5078a. The middle of the cylindrical portion, in a region generally axially aligned with welding torches, lasers and camera, has a plurality of openings or slits 5078b therethrough. Apertures 5078b allow the movable power lines and communication lines of the slip ring 5016 (and optionally the slip ring 5080) to pass radially outward from the interior 5078c of the rotating hub 5078 to the exterior of the hub 5078 for connection to the torches. of welding, lasers and camera.

[0696] It should be appreciated that while the rotating hub 5078 shown and described in this document has a generally cylindrical configuration, the hub may be of a different shape. The swivel hub can be of any tubular shape (for example, with a hollow square or triangular configuration, just as an example). In addition, the rotating hub can also be interchangeably termed a "swiveling frame".

[0697] As shown and described above, the inspection detector 5056 is mounted on the outside of the tubular hub, the tubular hub having opposing ends and a radial opening 5078b between the ends. Movable portion 5056b of power and communication lines extending from front slide ring 5016 and wire feed electronic module 5046 extend through interior 5078c of tubular hub 5078, through radial opening 5078b and connected with a or more 5056 inspection detectors.

[0698] As can also be appreciated from FIGS. 24 and 35B, a pneumatic line 5032a carrying a shielding gas (an inert gas) passes through the rear swivel joint 5072, through the opening 5080d in the slip ring and travels through the hollow interior 5078c of the rotating hub 5078 to one of the valves. of shielding gas 5042 (see figure 72), the valves being mounted on the wired supply electronics module 5046 (see figure 71) which is mounted on the rotating hub 5078 for rotation with it. Pneumatic line 5032a, which is a movable line that moves with the rotation of swivel hub 5078, after connecting with shielding gas valves 5042, folds back and again extends through hollow interior 5078c of the swivel hub 5078 (thus two lines 5032a are shown in figure 24). Pneumatic line 5032a passes through one or more of openings 5078b so as to be directed into proximity with the tip of welding torch 5502. Pneumatic line 5032a shown in FIG. 35B comprises movable portions of the pneumatic line which will rotate with the rotation of the rotating hub. 5078.

[0699] FIG. 25 is a partial cross-sectional view of the front swivel 5032, which is of essentially the same construction as the rear swivel 5072. The front swivel 5032 is used to communicate compressed air from an external source 5029 to a compressed air tank at edge 5128. The front swivel joint comprises a stator 5032d and a rotor 5032e. The 5032e rotor is mounted on the 5032d stator by 5032f spherical bearings. 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 the movable portion 5072d connecting with the rotor or rear swivel joint 5072. The movable portion 5072d of the pneumatic line passes through the central passage 5016d of the slip ring 5016 to be introduced into the interior 5078c of the rotating hub 5078 and then to the rotor of the rear rotating union 5072.

[0700] It should be appreciated that while the front slip ring 5016 is illustrated in FIG. 26 and front swivel joint 5032 is illustrated in FIG. 25, the same settings for each will apply to the rear swivel joint 5072 and the rear slip ring 5080.

[0701] The manner in which the movable portion of the pneumatic line passes through the central passage 5016d of the slip ring 5016 can also be appreciated from the sectional view of FIG. 24, which illustrates this attribute in the context of how this applies to rear slip ring 5080 and rear swivel 5072. Specifically, rear swivel 5072 has an outer stator 5072a and an inner rotor 5072b. The rotor 5072b receives compressed air from a rotating pneumatic supply line 5072d (see figures 24 and 70; it should be appreciated that figure 70 is a schematic drawing and line 5072d is drawn schematically in figure 70, but passes through the interior 5078c of the rotating hub as shown in figure 24). Swivel supply line 5072d is connected at its opposite end to front swivel joint rotor 5032. Specifically, external supply tank 5029 first passes compressed gas through the front swivel joint stator 5032 and then exits through the swivel joint rotor Front swivel 5032. Front swivel joint 5032 has its rotor operatively connected to swivel hub 5078 so as to be jointly swivel. Swivel supply line 5072d passes from rotor of front swivel 5032 to rotor 5072b of rear swivel 5072. Compressed air is passed through stator 5072a of rear swivel to a stationary pneumatic supply line 5072f extending therefrom . Fixed pneumatic supply line 5072f is connected via valves to compressed air tank 5128, which receives compressed air from external supply tank 5029 periodically when tank 5128 is depleted. As seen in FIG. 24, swivel feed line 5072d passes from rotor 5072b through center opening 5080d in rear slide ring 5080. Movable pneumatic feed line 5072d then passes through passage 5078c within swivel hub 5078 for connection with front swivel 5032.

[0702] As seen in FIG. 24, the 5080 rear slip ring has an inner rotor 5080r, an outer stator 5080s, and a bearing 5080m between them.

[0703] As can also be appreciated from FIGS. 24, 72, rear swivel joint 5072 also has another stationary line 5072g which receives shielding gas from shielding gas tanks 5262 to be described in more detail later. The shielding gas passes from stator 5072a to rotor 5072b and then out of the rotor through movable pneumatic line 5032a. Movable pneumatic line 5032a passes through opening 5080d in slip ring and passage 5078c. Pneumatic line 5032a moves with rotation of swivel hub 5078. The opposite end of pneumatic line 5032a connects to shield gas valves 5042 and then folds back (i.e., the two lines 5032a shown in figure 24) and passes to welding torches 5502. As it travels to welding torches 5502, movable pneumatic line 5032a passes through openings 5078b in rotating hub 5078, as can be appreciated in FIG. 72.

[0704] Although not described in detail in this document, it should be appreciated that provision of the shielding gas through the rear swivel 5072 will also apply to the purge gas passage of the purge gas tanks 7070 through the rear swivel 7072 , as shown in FIG. 94, described later.

[0705] In FIG. 25, the front swivel joint 5032 is illustrated as having two inlet and outlet ports. As shown, only one of the ports for communicating compressed air through the pneumatic line (stationary portion 5032c and mobile portion 5072d) is used. The other ports are not functional for the front swivel joint, but both ports will be used for the 5072 rear swivel, as will be appreciated from the description above.

[0706] It should also be appreciated that, in some embodiments, wireless communication can be provided to/from the inspection detector, camera and/or welding torch, in which case the use of a slip ring for a given functionality can be passed.

[0707] In one embodiment, the communication signals may not traverse the entire communication path between the umbilical 5034 and the electronic module of the transmission section 5118 and may travel between specific devices/modules of the communication path.

[0708] In one modality, all electronics modules in indoor welding system 5004, including forward electronics module 5014, wire feed electronics module 5046, center section electronics module 5064, and center section electronics module 5118 transmission may include a memory, a secondary storage device, and one or more processors configured to perform system controls. In one embodiment, all electronic modules in the 5004 internal welding system can be configured to receive, process, store, retrieve, and transmit signals (sensor or control) and data. In one embodiment, these electronic modules can contain other components. For example, various circuits, such as, for example, power supply circuits, signal conditioning circuits, solenoid transmitter circuits and/or any other circuit known in the art can be incorporated into the electronic modules. In one embodiment, all electronic modules in the 5004 internal welding system can be configured to transmit control signals used to direct the operation of operatively connected devices and receive data and other (sensor) signals from operatively connected devices.

[0709] For example, the forward 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 electronics module 5014 is configured to transmit control signals to control the operation of the front rotation motor 5030 and front clamp control valve 5018 and receive sensor signals from the front position sensor 5022.

[0710] In one embodiment, the electronic wire feed module 5046 is operatively coupled to the shielding gas control valve 5042, the motors of the wire feed systems 5044, the axial welding torch motor 5550, the motor of the radial welding torch 5512 and tilt welding torch motor 5588. In one embodiment, wire feed electronic module 5046 is configured to transmit control signals to control the operation of shielding gas control valve 5042, the motors of the 5044 wire feed systems, the 5550 axial welding torch motor, 5512 radial welding torch motor, and 5588 tilt welding torch motor.

[0711] 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 tail 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 the rear clamp control valve 5062 and to receive sensor signals from the rear position sensor 5076.

[0712] In one embodiment, the 5118 drive section electronics module is operatively coupled to the 5124 drive motors, the 5190 brake valve, and the 5192 drive wheel valve. In one embodiment, the 5118 drive section electronics module is configured to transmit control signals to control the operation of the 5124 drive motors, the 5190 brake valve, and the 5192 drive wheel valve.

[0713] FIG. 72 shows a schematic diagram showing the flow of shielding gas through the 5004 internal welding system, where some components of the 5004 internal welding system are not shown for the sake of clarity and to better illustrate the other components and/or the characteristics of the 5004 internal soldering system.

[0714] In one embodiment, an inert/shielding gas supply line is configured to direct the inert/shielding gas from the inert/shielding source 5262 to a region between the first and second clamp 5142, 5144 and toward a region near the 5503 weld tip of the 5502 welding torch to reduce oxygen in the vicinity of the 5503 weld tip during a welding operation.

[0715] Referring to FIG. 72, shielding gas tanks 5262 are shown in transmission section 5010 of internal welding system 5004. In one embodiment, a high pressure regulator 5264 may be positioned in transmission section 5010 of internal welding system 5004. In one embodiment, the high pressure regulator 5264 can be positioned in the center section 5008 of the inner welding system 5004. In one embodiment, the rear swivel joint 5072, welding torches 5502, swivel hub 5078, front and rear clamps 5142, 5144 and front and rear clamps 5142 and 5144 are shown in center section 5008 of internal welding system 5004. In one embodiment, front and rear seals 5146 and 5148 can be positioned in center section 5008 of internal welding system 5004. 5042 shield gas valves are shown in the frontmost section 5006 of the 5004 internal welding system.

[0716] In one embodiment, the 5262 shielding gas tanks are configured to be maintained at a pressure of 500-2400 psi. Shield gas tanks 5262 are in fluid communication through fluid communication lines with rear swivel 5072. In one embodiment, shroud gas tanks 5262 are in fluid communication with rear swivel 5072 via a 5266 valve and the 5264 high pressure regulator. In one embodiment, the 5264 high pressure regulator is configured to automatically shut off the purge gas flow at a pressure of 75 psi. That is, the 5264 high pressure regulator is typically adjusted to reduce the pressure in the 5262 shield gas tanks to about 75 psi in the fluid communication line downstream of the 5264 high pressure regulator and the 5072 rear rotary union to the 5042 shielding gas valves.

[0717] 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 from the fluid communication lines to the rear swivel 5072 and then through the fluid communication lines from the rear swivel 5072 to the shield gas valves 5042. In one embodiment, the shield gas control valve 5042 is configured to control the flow of shielding gas from the 5502 welding torch through a 5268 shielding gas line. In one embodiment, each 5502 welding torch has a corresponding 5042 shielding gas control valve connected thereto. In one embodiment, shielding gas control valve 5042 is operatively connected to receive control signals from wired power electronic module 5046. In one embodiment, shielding gas control valve 5042 is configured to supply the shielding gas. corresponding welding torch protection when receiving signals from the 5046 wired power electronics module.

[0718] In one embodiment, the transmission section 5010 of the internal welding system 5004 may include the purge gas tanks, the 5262 shield gas tanks, and the compressed air gas tanks. In one embodiment, the shielding gas from the 5262 shielding gas tanks is used only to supply shielding gas to the 5502 welding torches. purge in the purge gas chamber. In one embodiment, compressed air is used to inflate seals 5146 and 5148 and to expand clamps 5142 and 5144.

[0719] In one embodiment, the drive section 5010 of the internal welding system 5004 may include the compressed gas tanks and the purge/shield gas tank. That is, the shielding and purging gas are the same. In one embodiment, compressed air from the compressed air gas tanks is used to inflate seals 5146 and 5148 and to expand clamps 5142 and 5144. In one embodiment, seals 5146 and 5148 are optional on the 5004 internal welding system. In one embodiment, the shielding gas from the 5502 welding torches and the purge gas from the purge gas chamber are supplied from the same gas tank with purge/shielding gas. In one embodiment, supplying the purge gas to the purge gas chamber is optional.

[0720] In one embodiment, drive section 5010 of internal welding system 5004 may include only purge/shield gas tanks (ie, no compressed air gas tanks). This can be the case with small internal welding systems. In one embodiment, the purge/shield gas tanks are configured to supply the purge/shield gas to the 5502 welding torches, the purge/shield gas to the purge gas chamber, and the purge gas /shield to inflate seals 5146 and 5148 and to expand clamps 5142 and 5144. In one embodiment, seals 5146 and 5148 are optional on internal welding system 5004. In one embodiment, supplying the purge gas to the gas chamber. purge gas is optional.

[0721] FIGS. 72A, 72B and 72C show close-up views of an inner welding torch used in a prior art system and inner welding system 5004, respectively, where the tubes have a space alignment and radial displacement (Hi-Lo); for example, as shown in FIG. 72A, tubes 1022a, 1022b have a space and radial displacement (Hi-Lo) of 1 millimeter.

[0722] As shown in FIG. 72B, in the prior art system, the raised edge of the tube protects the left side of the solder groove, causing reduced solder penetration. As shown in FIG. 72C, one or more processors 5140 associated with internal welding system 5004 are configured to receive weld profile data (e.g., before, during and subsequent to the welding process) and are configured, based on the received weld profile data. , to move the inner welding torch 5502 and/or to tilt the outer welding torch 5502 to achieve full penetration of the weld. Thus, the weld profile data from the 5004 internal welding system can be used to make a better weld.

[0723] In one embodiment, one or more 5140 processors are configured to receive profile data related to the solder from the 5136 interface region between the first tube 1022a and the second tube 1022b of the field system 5000. In one embodiment, the data from Related profiles are based on a check of the 5136 interface region between tubes 1022a, 1022b. In one embodiment, one or more 5140 processors are configured to compare one or more characteristics of related profile data to one or more related profile characteristics data to generate a response to the 5000 field system. In one embodiment, one or more 5140 processors are configured to transmit the response to the 5000 field system to cause the 5000 field system to perform one or more operations based on the response. In one embodiment, one or more 5140 processors are configured to transmit a signal to the 5000 field system to interrupt the soldering related procedure, change or develop a soldering protocol, save or analyze the 5136 interface region profile data, save or further analyze the pre-weld profile data, save or further analyze the post-weld profile data, assert or modify a version of yourself, etc.

[0724] In one embodiment, one or more processors 5140 are operatively associated with inspection detector 5056 to profile the 5136 interface region between tubes 1022a, 1022b. In one embodiment, welding torch 5502 is configured to create a weld at the interface region 5136 between tubes 1022a, 1022b based on the profile of the interface region 5136 between tubes 1022a, 1022b. In one embodiment, the welding torch (e.g., of the external welding system 7500) is configured to create a weld between tubes 1022a, 1022b based on the profile of the interface region 5136 between tubes 1022a, 1022b.

[0725] In one embodiment, one or more 5140 processors are configured to receive inspection data from the inspection detector 5056 before, subsequently, or during a weld operation. In one embodiment, one or more processors 5140 are configured to receive inspection data from camera 5112 before, subsequent to or during a weld operation. In one embodiment, one or more processors 5140 are configured to receive inspection data from inspection detector 5056 and camera inspection data from inspection camera 5112 prior to, subsequent to or during a weld operation.

[0726] In one embodiment, inspection camera 5112 is configured to scan the weld interface region 5136 after a weld operation. In one embodiment, inspection camera 5112 is configured to send signals to one or more processors 5140 based on verification. In one embodiment, one or more processors 5140 are configured to determine a characteristic of the soldered interface region 5136 based on signals from the inspection chamber 5112.

[0727] In one modality, one or more 5140 processors are configured to analyze the data to automatically detect undercuts or other shape deviations.

[0728] In one embodiment, if a characteristic of the 5136 interface region is greater than a predetermined threshold, it may be referred to as an undesirable characteristic of the 5136 interface region. In one embodiment, if the characteristics of the 5136 interface region is greater Rather than a predetermined threshold and a difference between the characteristic and the predetermined threshold being in 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 within a predetermined acceptable/allowable range, the undesirable characteristic of the region is determined. 5136 interface needs correction.

[0729] In one embodiment, if a feature of the 5136 interface region is less than a predetermined threshold, it may be referred to as an undesirable feature of the 5136 interface region. In one embodiment, if the features of the 5136 interface region is less than a predetermined threshold and a difference between the characteristic and the predetermined threshold being in 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 within a predetermined acceptable/allowable range, the undesirable characteristic of the region is determined. 5136 interface needs correction.

[0730] In one embodiment, if a feature of the 5136 interface region is not within a predetermined range, it may be referred to as an undesirable feature of the 5136 interface region. In one embodiment, if a feature of the 5136 interface region is not within a predetermined range and is in an acceptable/allowable range, it is determined that the undesirable characteristic of the 5136 interface region does not need correction. In one embodiment, if a feature of interface region 5136 is not within a predetermined range and is not in an acceptable/allowable range, it is determined that the undesirable feature of interface region 5136 does not need correction.

[0731] In one embodiment, one or more 5140 processors are configured to receive electronic signals (eg, generated by the inspection detector receiver 5136) to determine whether the undesirable feature of the 5136 interface region should be corrected. In one embodiment, in response to the detection of one or more undesirable features of the interface region 5136, one or more processors 5140 are configured to send instructions to motor 5030, 5074 which controls an axially rotating position of one of the tubes to make motor 5030 , 5074 rotating one of the tubes 1022a, 1022b with respect to the other tube 1022a, 1022b to correct the undesirable characteristic. In one embodiment, the motor 5030, 5074 is configured to move a radially extending clamp 5142, 5144.

[0732] In one embodiment, the 5502 welding torch, operatively linked to one or more 5140 processors, is configured to perform a welding operation to weld tubes 1022a, 1022b together with one or more 5140 processors that detect that they do not exist undesirable features.

[0733] In one embodiment, one or more 5140 processors are configured to interact with inspection detector 5056 to scan the 5136 interface region between tubes 1022a and 1022b to determine a profile of the 5136 interface region between tubes 1022a and 1022b before a weld procedure and generate pre-weld profile data based on that. In one embodiment, one or more of the 5140 processors are configured to interact with inspection detector 5056 to scan the entire 5136 interface region between tubes 1022a, 1022b to generate the pre-weld profile data before the weld material is applied to weld the two tubes 1022a, 1022b together. In one embodiment, one or more processors 5140 are configured to interact with inspection detector 5056 to scan interface region 5136 to obtain pre-weld profile data subsequent to the first clamp 5142 and the second clamp 5144 that fits with the first tube and second tube 1022a, 1022b, respectively.

[0734] In addition, or alternatively, one or more 5140 processors are configured to interface with the 5112 inspection camera, the X-ray radiography inspection device, the gamma-ray inspection device, the ultrasonic inspection device, the magnetic particle inspection device, the eddy inspection device or other inspection devices to check the 5136 interface region between the tubes 1022a, 1022b to determine the profile of the 5136 interface region before the welding operation.

[0735] The pre-weld check/inspection procedure is the same for the 3001 internal lashing welding system and the 7001 purge and inspection system and therefore will not be described again with reference to the 3001 internal welding system and the purge and inspection system 7001.

[0736] In various embodiments, the "pre-weld" profile data described in this document refers to data obtained from the inspection detector (for example, by an inspection laser) that verified the interface region between two tubes to be welded before removal of the activated welding torch to start fixing the tubes together. This pre-weld profile data is communicated to one or more processors to determine if the tubes are sufficiently aligned before any weld material is deposited in the interface region. In one embodiment, if a misalignment is detected, for example, by determining by one or more processors that the misalignment is outside an acceptable misalignment value, one or more of the processors are configured to send signals to the bases that fit with the outer surfaces of the tubes. One or both bases can be adjusted based on the pre-weld profile data output signals to adjust the relative positioning between the tubes to bring the interface region alignment to an acceptable misalignment value.

[0737] It should be appreciated that, due to minor inconsistencies in tube structures, absolutely perfect alignment is often (and typically) not achieved. However, this perfect alignment is unnecessary as long as the alignment is within a proper tolerance for a good weld.

[0738] In one modality, pre-weld profile data may include tube ovality/roundness data. In one embodiment, the tube ovality/roundness data may include the location and size of the minimum inside diameter, the location and size of the maximum inside diameter, the average tube inside diameter, the average tube wall thickness, the location and size of minimum wall thickness and/or location and size of maximum wall thickness. In one embodiment, the tube ovality/roundness data can include a comparison between each location and the minimum inner diameter size, the maximum inner diameter location and size, the minimum wall thickness location and size, and the location and the maximum wall thickness size and their respective default values. In one embodiment, the tube ovality/roundness data can include a comparison between each average tube inner diameter and each average tube wall thickness, as well as their respective predetermined values. In one embodiment, the tube ovality/roundness data can include tube inside diameter deviations at all locations on the tube circumference based on the comparison.

[0739] In one embodiment, the pre-weld profile data may include the pipe bevel profile data. In one embodiment, the pipe chamfer profile data can include the pipe chamfer geometry. In one embodiment, the pipe bevel profile data may include a comparison between each of the pipe bevel sizes and shapes, the pipe bevel root (ground) face thickness, the pipe bevel bevel angle , the tube bevel offset and the tube bevel root angle, as well as their respective default values. In one embodiment, the tube bevel profile data can include tube tube bevel offsets at all locations of the tube circumference based on the comparison.

[0740] In one embodiment, pre-weld profile data may include alignment and weld joint data. In one embodiment, the weld joint and alignment data can include data on the gap between the adjacent inner ends of the tubes (after tube alignment). In one embodiment, the weld joint and alignment data can include data about the gap between the pipe chamfers (after the pipe alignment). In one embodiment, the weld joint and alignment data can include the location and size of the minimum gap, the location and size of the maximum gap, and/or the mean gap. In one embodiment, the weld joint and alignment data may include a comparison between each of a minimum gap location and size and maximum gap location and size, as well as their respective default values. In one embodiment, the weld joint and alignment data may include a comparison between the mean range and their respective predetermined values. In one embodiment, the weld joint and alignment data can include tube offsets at all locations on the tube circumference based on the comparison. In one embodiment, the weld joint and alignment data may include the minimum differences in height between the tubes (eg what is acceptable alignment), etc.

[0741] In one embodiment, one or more 5140 processors are configured to interact with inspection detector 5056 to check the 5136 interface region subsequent to the first clamp 5142 and the second clamp 5144 that fits with the first tube and the second tube 1022a, 1022b, respectively. In one embodiment, one or more processors 5140 are configured to be operatively connected to the first tube engaging structure 5052 and the second tube engaging structure 5054. In one embodiment, one or more processors 5140 are configured to operate the first tube engaging structure 5054. tube engagement 5052 and/or the second tube engagement structure 5054 based on the pre-weld profile data to change the interface region 5136 between the tubes 1022a, 1022b prior to the weld operation.

[0742] In one embodiment, one or more processors 5140 are configured to change the interface region 5136 between tubes 1022a, 1022b prior to the welding operation by driving the first engagement structure of the tube 5052 and/or the second engagement structure of tube 5054 to change the roundness (or ovality) of the first tube 1022a and/or the second tube 1022b based on the pre-weld profile data. For example, in one embodiment, one or more 5140 processors are configured to change the 5136 interface region between tubes 1022a, 1022b prior to the welding operation by selectively driving one or more 5157 clamp holders from 5142 and/or 5144 clamps to change the roundness of the first tube 1022a and/or the second tube 1022b based on the pre-weld profile data.

[0743] In one embodiment, one or more processors 5140 are configured to change the 5136 interface region between tubes 1022a, 1022b prior to the welding operation by driving the first coupling structure of the tube 5052 and/or the second coupling structure of tube 5054 to axially rotate and/or move first tube 1022a and/or second tube 1022b based on pre-weld profile data. In one embodiment, one or more processors 5140 are configured to change the interface region 5136 between tubes 1022a, 1022b prior to the soldering operation by rotating a tube 1022a or 1022b with respect to one another 1022a or 1022b.

[0744] In one modality, one or more 5140 processors are configured to develop a weld protocol based on the pre-weld profile data. In one embodiment, the welding protocol includes a welding speed and welding torch position protocol.

[0745] In one embodiment, one or more 5140 processors are configured to operate the bases 5330 (as shown in Figures 10A and 10B) or 6010A and 6010B (as shown in FIG.73) to supply the inlet tube 1022a at the second end of tube 1022b (after internal welding system frame assembly 5004 is positioned at the second end of tube 1022b) based on the pre-weld profile data to change the 5136 interface region between tubes 1022a, 1022b prior to the operation of welding. In one embodiment, one or more processors 5140 are configured to control externally positioned rollers 5332, bases 5330 to supply inlet tube 1022a at the second end of tube 1022b (after internal welding system frame assembly 5004 is positioned in the second end of the first tube 1022b) based on the pre-weld profile data.

[0746] In one embodiment, one or more processors 5140 are configured to operate bases 5330 (as shown in Figures 10A and 10B) or 6010A and 6010B (as shown in FIG.73) to generate a relative movement between the first tube 1022a and the second tube 1022b based on the pre-weld profile data to change the interface region 5136 between the tubes 1022a, 1022b prior to the welding operation. In one embodiment, an outer surface 5346 and/or 5348 (as shown in Figure 2G) of the first tube 1022a and/or the second tube 1022b is coupled to adjust the relative positioning of the tubes 1022a, 1022b in the case of pre-profile data. -Welding determine the need for an adjustment. In one embodiment, bases 5330 (as shown in Figures 10A and 10B) and 6010A and 6010B (as shown in Figure 73) are operated by one or more processors 5140 (or otherwise controlled) to engage external surfaces 5346 and/ or 5348 (as shown in Figure 2G) of first tube 1022a and/or second tube 1022b to adjust the relative positioning of tubes 1022a, 1022b in case the pre-weld profile data determines the need for adjustment.

[0747] In one embodiment, the first clamp and/or the second clamp 5142, 5144 are released to allow adjustment of the relative positioning of tubes 1022a, 1022b in case adjustment of the pre-weld profile data adjustment is required. In one embodiment, the first and second clamps are internally positioned clamps and are released to allow adjustment of the relative positioning of tubes 1022a, 1022b in the event that adjustment of the pre-weld profile data adjustment is required. In one embodiment, the first and second clamps are externally positioned clamps and are released to allow adjustment of the relative positioning of tubes 1022a, 1022b in the event that adjustment of pre-weld profile data adjustment is required. In one embodiment, the first and second clamps include both the internally placed clamps and the externally positioned clamps. In one embodiment, the internally and externally positioned clamps are released to allow adjustment of the relative positioning of tubes 1022a, 1022b in the event that adjustment of pre-weld profile data adjustment is required.

[0748] In one embodiment, adjustment of the relative positioning of tubes 1022a, 1022b (based on pre-weld profile data) can be performed automatically by the 5140 processors that control the externally positioned rollers 5332 (as shown in Figures 10A and 10B ) or performed by an operator using a crane and clamps (internal and/or external). In one embodiment, adjusting the relative positioning of tubes 1022a, 1022b (based on pre-weld profile data) may also be referred to as realigning tubes 1022a, 1022b.

[0749] In one embodiment, adjusting the relative positioning of tubes 1022a, 1022b (based on pre-weld profile data) may include an adjustment along the longitudinal axis of tubes 1022a, 1022b and/or an adjustment along the radial axis of tubes 1022a, 1022b. In one embodiment, adjusting the relative positioning of tubes 1022a, 1022b (based on pre-weld profile data) can include adjusting the position and adjusting the orientation of tubes 1022a, 1022b. In one embodiment, adjusting the relative positioning of tubes 1022a, 1022b (based on pre-weld profile data) can include upward and downward movement and longitudinal movement (along the longitudinal axis of tubes 1022a, 1022b).

[0750] In one modality, the internal and/or external clamp(s) (which secure the tubes 1022a, 1022b during the pre-welding process) is/are released and a crane, rollers  positioned externally 5332 , electronically controlled or other such devices can be used to maneuver the pipe based on pre-weld profile data. In one embodiment, the inner and/or outer clamp(s) (which secure the tubes 1022a, 1022b during the pre-welding process) is/are released prior to the realignment procedure. In one embodiment, after realignment of tubes 1022a, 1022b, tubes 1022a, 1022b are secured back using external and/or internal clamps.

[0751] In one embodiment, a new tube to be welded 1022a can be rotated around its longitudinal axis relative to the previous tube that was welded 1022b, based on the pre-weld profile data that was obtained from the detector. inspection (eg inspection laser) 5056. Specifically, pre-weld profile data can be used to determine that, in some cases, the relative rotational positions of tubes 1022a and 1022b can be changed to make a better match for welding. For example, if each of the tubes 1022a, 1022b has a slight ovality to them, thus combining with the tubes so that the major axis of each of the two tubes is generally aligned and the minor axis of each of the two tubes is generally aligned, can have an overall beneficial effect. Thus, in one embodiment, inspection detector 5056 can generate signals that are processed by one or more processors 5140 to determine a more beneficial rotational position for inlet tube 1022a to be welded. This rotation can be accomplished by one or more 5140 processors by activating the front rotation motor 5030 to rotate tube 1022a prior to a weld operation. In particular, to rotate the inlet tube 1022a, the central frame 5068 remains rotatably fixed relative to the previously welded tube. This fixed rotational relationship between the center frame 5068 and the tube 1022b is achieved by causing the rear clamp 5144 to be actuated by one or more processors 5140 to securely engage with the inner surface of the tube 1022b to prevent relative rotation between they. In addition to the 5144 rear clamp and 5068 center frame being fixed rotationally relative to the tube, the 5074 rear rotation motor is not activated by the 5140 processor and the motor rod is blocked by rotation. As a result of the front rotation motor being blocked from rotation, the entire swivel hub 5078 remains pivotally fixed relative to the center frame 5068 and the tube 1022b. The 5030 front rotation motor is then activated. Its rod rotates to drive the gear train, as shown in Fig. 19 and described above, so that the teeth of gear 23 pivotally engage with gear tooth 5023 of sprocket 5021. wire 5020 (which is fixed to swivel hub 5078) and swivel hub 5078 are fixed from rotation, front rotation motor 5030 and gear 5023 operatively connected thereto are driven circumferentially along sprocket 5021. rotary drive placed over the front slew motor 5030 pivots across the forward frame 5026 to which the motor 5030 is connected. Rotation of the frontmost section frame 5026, in turn, rotates front clamp 5142. Clamp 5142 rotates around swivel hub 5078 on bearings 5108, 5098 which are between clamp 5142 and swivel hub 5078. clamp 5142 is extended and weighs the inner surface of tube 1022a, tube 1022a is rotated to the location determined by one or more processors 5140 based on verified pre-weld information received from inspection detector 5056. During rotation of tube 1022a , if an outer base (5330, 6010A, 6010B) fits into the outer surface of the tube, the rollers 5332 on the outer base (5330, 6010A, 6010B) are instructed by the 5140 processor(s) to optionally be in a freewheeling state , where they are passive or, optionally, one or more motors operatively connected with the 5332 rollers are instructed by the other 5140 processor(s) to drive themselves to the 5332 rollers at a proportional rotation speed (similar or equal) the speed at which the front rotation motor 5030 drives the rotation from within tube 1022a. This latter approach provides rotational forces to tube 1022a both inside and outside the tube, although in some embodiments any driving force alone may suffice.

[0752] In the embodiment just described, clamps 5142 and 5144 are engaged with associated tubes 1022a and 1022b to prevent relative rotation between frame 5026 and tube 1022a and to prevent rotation between central frame 5068 and tube 1022b. In one or more modalities, however, clamps 5142 and 5144 need not be responsible for this function. Rather, the wheels operatively associated with both frames can be configured to engage the associated tubes with enough friction and/or external force to prevent relative rotation between the tubes and the frames. In one modality, the wheels effect or allow locomotion between the frames and the tubes, allow a generally longitudinal movement only between the frames and the tubes and avoid the relative rotational movement between them. This can be true for wheels on one or more of the frames. The wheel hitch option can be used on only one of the frames, on both frames and can optionally be used in combination with the attachment methodology for one or both frames.

[0753] The tube rotation techniques described in this document can also be used to return the frames to a desired "initial" or "primary" rotation position after a welding operation is completed and a new tube is entered for the next check. pre-welding.

[0754] In one embodiment, one or more of the 5140 processors are configured to send the pre-weld profile data to a remote processor for further processing.

[0755] In one embodiment, one or more 5140 processors are configured to interact with inspection detector 5056 to scan the 5136 interface region between tubes 1022a, 1022b to determine the profile of the 5136 interface region between tubes 1022a and 1022b during a weld operation, in a region of the interface before the weld material is deposited on it and generates instantaneous profile data.

[0756] The check/instant inspection procedure is the same for the 3001 internal lashing welding system and the 7001 purge and inspection system and therefore will not be described again with reference to the 3001 internal welding system and the 7001 internal welding system. purging and inspection 7001.

[0757] In many embodiments, instantaneous profile data refers to data obtained from the inspection detector during a weld operation. For example, instant profile data is taken from a position immediately in front of (in front of) the region being welded (for example, 1-6 inches in front of the region to be welded). In particular, the inspection detector checks the interface region in the region to be welded so as to provide profile data of the interface region immediately upon deposition of the weld material. It should be appreciated that the profile of the interface region between the tubes may change slightly as more of an interface area is welded together. In other words, the sequential welding itself can slightly alter the alignment/positioning of the tubes in the interface region in the portions of the interface region still to be welded. The inspection detector measures the profile of the interface region immediately in front of the welding torch deposition weld material in the already welded regions of the interface region and the inspection detector signals are received and used by the processor(s) to produce signals/instructions to the welding torch and/or its motors to control various parameters of the welding torch to adapt the weld to the tubes as they are being welded. Welding torch parameters may include one or more of the following characteristics: wire feed speed, wire consumption, oscillation width, oscillation waveform, oscillation amplitude, weld time, gas flow rate, levels of welding arc power, welding current, welding voltage, welding impedance, welding torch travel speed, welding torch welding tip position along tube axis, angular positioning of welding tip welding torch with respect to its rotational plane and/or the distance from the welding tip of the welding torch to the inner surfaces of the tubes to be welded.

[0758] In one modality, snapshot weld profile data can include high-low (Hi-Lo) data. In one modality, high-low (Hi-Lo) can often refer to a height difference between the edges of the bevel after alignment. In one embodiment, the high-low (Hi-Lo) data may include a comparison between each location and the size of the minimum height difference and the location and size of the maximum height difference and their respective predetermined values. In one embodiment, the high-low (Hi-Lo) data may include a comparison between the mean height difference and the respective predetermined value. In one modality, the high-low (Hi-Lo) data can include deviations of tube height difference at all locations on the circumference of the tubes based on the comparison.

[0759] In one embodiment, instant weld profile data may include weld joint characteristic. In one embodiment, snapshot weld profile data can include weld joint width and weld joint root gap.

[0760] In one embodiment, one or more 5140 processors are configured to generate weld signals to control the 5502 welding torch based on instantaneous profile data. In one embodiment, one or more 5140 processors are configured to control a position and speed of the 5502 welding torch based on snapshot profile data during a weld operation. In one embodiment, the 5588 welding motor is operatively linked to one or more 5140 processors to control an angle of the 5502 welding torch during the welding operation.

[0761] In one embodiment, one or more 5140 processors are configured to instruct one or more 5512 torch motors to move the 5503 solder tip beyond the 5136 interface region after each solder pass to accommodate accumulation of solder material . In one embodiment, one or more of the 5140 processors are configured to control the 5550 axial welding torch motor to control axial movement of the 5502 welding torch (i.e., moving the 5503 welding tip beyond the 5136 interface region) .

[0762] In one embodiment, one or more 5140 processors are configured to generate an initially plotted weld profile based on the pre-weld profile data and modify/adapt the initially plotted weld profile based on the snapshot profile data.

[0763] In one mode, the wire feed speed, the oscillation width, the power levels of the welding arc and/or the distance from the 5503 welding tip of the 5502 welding torch to the tube surfaces to be welded can be controlled based on snapshot profile data.

[0764] In one embodiment, one or more 5140 processors are configured to interact with inspection detector 5056 to scan the 5136 interface region between tubes 1022a and 1022b to determine the profile of the 5136 interface region between tubes 1022a and 1022b subsequent to a weld operation and generate post-weld profile data based on this. In one embodiment, post-weld profile data is obtained with inspection detector 5056 positioned within first tube 1022a and/or second tube 1022b, without disengaging from first tube engaging structure 5052 or second engaging structure. tubes 5054 of the inner surface 5130 of the first tube 1022a or the inner surface 5132 of the second tube 1022b, respectively.

[0765] The post-weld check/inspection procedure is the same for the 3001 internal lashing welding system and the 7001 purge and inspection system and therefore will not be described again with reference to the 3001 internal welding system and the purge and inspection system 7001.

[0766] In addition, or alternatively, one or more 5140 processors are configured to interface with the 5112 inspection camera, the x-ray radiography inspection device, the gamma-ray inspection device, the ultrasonic inspection device, the magnetic particle inspection device, the eddy inspection device or other inspection devices for checking the 5136 interface region between the tubes 1022a, 1022b to determine the profile of the 5136 interface region subsequent to the welding operation.

[0767] In one embodiment, the post-weld profile data may include profile(s) of 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 can include weld shape characteristics such as misalignment, weld bead concavity, and bead angle.

[0768] In one embodiment, one or more of the 5140 processors are configured to cause, based on the post-weld profile data, another weld operation to be performed at the 5136 interface region between the tubes 1022a, 1022b.

[0769] Certain weld variables/parameters have well-known relationships. That is, a change in one welding variable/parameter has a corresponding change in the other welding variable/parameter. Welding variable/parameters such as welding current, welding voltage, welding torch travel speed and heat absorption are all connected. For example, if the welding current increases and all other welding variables/parameters remain constant, the voltage should decrease. Also, if the welding torch travel speed increases and all other welding variables/parameters remain constant, heat absorption should decrease. In one embodiment, one or more of the 5140 processors are configured to analyze the collected data (eg, before, subsequently, or during a weld operation) to detect problems and make process/parameter changes. In one modality, based on analysis and detection, one or more of the 5140 processors are configured to disable the 5004 internal welding system for maintenance, as needed, to prevent a recurrence.

[0770] In one modality, all data points collected/received by one or more of the 5140 processors before, subsequently, or during a weld operation are compared to their corresponding ideal weld values (gold standard). If process variables differ by more than a defined/predetermined threshold, these differences can be flagged. If the differences persist for a period longer than the maximum amount of deviation allowed, the weld process can be stopped so that the weld can be repaired. Over time, optimal weld values and allowable limits can be improved as more weld data is collected.

[0771] In a modality, one or more of the processors can be configured to see what occurred just before the branch occurred and determine if there is a deficiency in the control loop programming that allowed the branch to occur. If so, one or more of the processors can send an updated control loop program to the 5004 internal soldering system and see if the change improves the performance of the 5004 internal soldering system.

[0772] In one mode, one or more of the processors can also be configured to monitor commands that are sent to the 5004 internal welding system by the operator. If these commands are determined to cause weld defects, one or more of the processors are configured to send a message to the operator to stop providing commands to the 5004 internal welding system. If the commands are determined to prevent weld defects, one or more of the processors are configured to send a message to all operators instructing them to start using the commands.

[0773] In one modality, one or more of the processors are configured to collect and analyze Non-Destructive Test (NDT) data. In one modality, the locations where weld defects are detected can be compared to weld parameters that were recorded at the same location, even if the defect is small enough not to require repair. In one modality, one or more of the processors may be aware of weld defects that would not be included in a traditional inspection report. This gives one or more processors a very good statistical sample of each weld parameter and the resulting weld quality. This statistical model can be used to determine the best settings for each weld parameter, as well as the allowable deviation from the setting. These new parameters can be communicated directly to the 5004 internal welding system as each new NDT check improves the statistical model.

[0774] In one embodiment, as described in this document, the 5138 computer system (comprising one or more 5140 processors) may be a local computer system to the 5000 field system. In another embodiment, as described in this document, computer system 5138 may be a computer system positioned remotely from field system 5000 (e.g. remote computer system 13704 or other remote computer system) and may be linked in communication with field system 5000 or with a local computer system of the same.

[0775] In one embodiment, one or more of the 5140 processors may receive (via a receiver) inspection data associated with an inspection of the 5136 interface region between tubes 1022a, 1022b of the 5000 field system (e.g., raw data inspection devices, 2D or 3D image data or other inspection data). One or more inspection devices used for inspection may include 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, 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, ultrasonic inspection data, inspection data of magnetic particles, eddy inspection data, temperature inspection data or other inspection data.

[0776] In one embodiment, one or more of the 5140 processors may automatically generate a response comprising profile data for the 5136 interface region (e.g., pre-weld profile data, snapshot 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 5000 field system. In an embodiment, for example, where the received inspection data is based on a verification of the interface region before a solder operation, one or more processors 5140 may use the received inspection information to generate a response comprising pre-weld profile data for the interface region 5136 and transmit (via a transmitter) the information of the pre-weld profile for the 5000 field system. In one modality, where inspection data received is based on a check of the interface region during a weld operation, one or more of the 5140 processors may use the received inspection information to generate a response comprising instantaneous weld profile data for the 5136 interface region and transmit (via a transmitter) the instantaneous profile information to the 5000 field system. where the received inspection data is based on a region check subsequent to a weld operation, one or more of the 5140 processors may use the received inspection information to generate a response comprising post-weld profile data for the 5136 interface region and transmitting (via a transmitter) the post-weld profile data to the 5000 field system.

[0777] In one embodiment, one or more of the 5140 processors can automatically generate a response comprising one or more welding protocols or other operating protocols based on the received inspection data and transmit (via a transmitter) the operating protocols as control operation data for the 5000 field system. For example, upon receipt of the operation logs, the 5000 field system can perform one or more operations based on the received operation logs. In another embodiment, one or more of the 5140 processors may generate profile data based on the received inspection information to obtain the profile data for the 5136 interface region (e.g., pre-weld profile data, snapshot profile data, post-weld profile data or other profile data). In another embodiment, one or more processors 5140 may use the profile data to obtain the welding or other operating protocols and transmit (via a transmitter) the operating protocols to the 5000 field system.

[0778] In one modality, one or more 5140 processors can generate a welding protocol or other operating protocol based on inspection data associated with one or more other tubes (other than tubes 1022a, 1022b), data related to parameters (eg, welding or other parameters) used to perform one or more operations (eg, welding or other operations) on other pipes, data related to observations of operations, or other data. By way of example, one or more of the 5140 processors may obtain inspection data from one or more field systems and analyze the inspection data to determine if and which tubes are defective. Processors can 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 elsewhere in this document). Based on the comparison, one or more 5140 processors can generate the welding protocol or other operating protocol so that the operating protocol avoids or otherwise resolves the circumstances (probably causing the defect) when the operating protocol is used for one or more subsequent operations (for example, subsequent operations that are the same or similar to the performed and observed operation).

[0779] In one embodiment, one or more 5140 processors can obtain pre-weld profile data for the 5136 interface region (between tubes 1022a, 1022b), where the pre-weld profile data is based on a region check interface 5136 on the 5000 field system prior to a weld operation. By way of example, one or more processors may receive the pre-weld profile data from the 5000 field system. By way of another example, one or more 5140 processors may generate the pre-weld profile data based on the inspection data received from the 5000 field system. Upon acquisition, one or more 5136 processors may analyze the pre-weld profile data to generate a response to the 5000 field system. In one embodiment, one or more 5140 processors may compare one or more characteristics of pre-weld profile data (eg pipe ovality/roundness characteristics, pipe bevel profile characteristics, weld joint alignment and mounting characteristics, or other characteristics) with one or more pre-weld profile characteristics acceptable presets. Based on the comparison, 5140 processors can transmit (via a transmitter) a response as control operation data to the 5000 field system indicating whether the 5000 field system should begin welding operation.

[0780] For example, the response may specify that the 5136 interface region is within specifications for the weld operation, indicating that the 5000 field system should begin the weld operation. The answer may additionally or alternatively comprise one or more welding protocols for the welding operation. As another example, the response may specify that the 5136 interface region is not within specification, indicating that the 5000 field system should not perform the weld operation on the 5136 interface region in its current state. In a use case, the response might indicate a need to change the 5136 interface region prior to the weld operation (for example, a need to realign tubes 1022a, 1022b or other alternations). Thus, the response may cause the 5000 field system to operate a 5000 field system pipe-engaging structure to change the 5136 interface region prior to the welding operation so that the 5136 interface region is within the specifications for the welding operation.

[0781] In one embodiment, one or more 5140 processors may compare one or more profile data characteristics (obtained based on a check of the 5136 interface region in the 5000 field system) with one or more predefined profile characteristics to determine one or more matching characteristics. Based on the corresponding characteristics, for example, one or more 5140 processors can automatically determine one or more welding protocols to weld the 5136 interface region between tubes 1022a, 1022b and transmit (via a transmitter) one or more welding protocols to the 5000 Field System to have the 5000 Field System perform a weld operation in the 5136 interface region based on one or more weld protocols. For example, a welding protocol can comprise one or more input parameters, for example: wire feed speed, wire consumption, oscillation width, oscillation wave, oscillation amplitude, weld time, gas flow rate , welding arc power levels, welding current, welding voltage, welding impedance, welding torch travel speed, welding torch weld tip position along the tube axis, angular positioning of the welding torch welding of the welding torch with respect to its plane of rotation, or the distance from the weld tip of the welding torch to the inner surfaces of the tubes to be welded, or other parameters.

[0782] In one embodiment, one or more 5140 processors can obtain instantaneous profile data for the 5136 interface region (between tubes 1022a, 1022b), where the instantaneous profile data is based on a check of the 5136 interface region in the 5000 field system before a welding operation. By way of example, one or more 5140 processors may receive (via a receiver) the instantaneous profile data from the 5000 field system. By way of another example, one or more 5140 processors may generate the instantaneous profile data based on on inspection data received from the 5000 field system. Upon acquisition, one or more 5140 processors can analyze the snapshot profile data to generate a response to the 5000 field system. In one embodiment, one or more of the 5140 processors can compare a or more features of the instantaneous profile data (eg, tube ovality/rounding characteristics, tube bevel profile characteristics, weld joint alignment and mounting characteristics, weld shape characteristics, or other characteristics) with one or more features of acceptable preset profiles (eg preset pre-weld profiles, preset post-weld profiles or other profiles). Based on the comparison, the 5140 processors can transmit a response to the 5000 field system comprising instant updates as to one or more weld characteristics for the welding operation. For example, the response might cause the 5000 field system to control a welding torch based on updates to the welding characteristics during the welding operation.

[0783] In one embodiment, one or more 5140 processors can obtain post-weld profile data for the 5136 interface region (between tubes 1022a, 1022b), where the post-weld profile data is based on a region check interface 5136 on the 5000 field system subsequent to a weld operation. By way of example, one or more 5140 processors may receive (via a receiver) the post weld profile data from the 5000 field system. By way of another example, one or more 5140 processors may generate the post weld profile data - weld based on inspection data received from the 5000 field system. Upon acquisition, one or more 5140 processors can analyze the snapshot profile to generate a response to the 5000 field system. In one modality, one or more 5140 processors can compare one or more characteristics of the post-weld profile data (e.g., weld shape characteristics or other characteristics) with one or more acceptable pre-weld profile characteristics. Based on the comparison, 5140 processors can transmit (via a transmitter) a response to the 5000 field system indicating whether a result of the welding operation is acceptable. Additionally or alternatively, one or more 5140 processors may automatically determine one or more welding protocols for a subsequent operation (for example, an operation that repairs or compensates for a defect resulting from the welding operation, an operation that normally follows the welding operation. welding if no significant defects are detected, etc.) and includes one or more welding protocols in the transmitted response.

[0784] For example, if the weld operation is for a root pass, the response may specify that the root pass layer resulting from the weld operation is within specification and the response may specify that the preparation for a weld operation subsequent soldering to a heat pass is about to start. Thus, the response might cause the 5000 field system to start performing the heat pass operation in the 5136 interface region. For example, the response might specify that the resulting root pass layer is not within specifications. In a use case, for example, the response might specify that the 5000 field system should not proceed with the heat pass operation until further notice. In another use case, the response may specify that the 5000 field system should proceed with a different welding protocol (instead of the one pre-planned for the heat pass operation), where the different welding protocol repairs or compensates for the fact that the resulting root pass layer is not within specification.

[0785] In an embodiment, where one or more 5140 processors are local to the 5000 field system (for example, part of a local computer system to the 5000 field system), one or more 5140 processors 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 tubes 1022a, 1022b. The inspection data transmitted may comprise, for example, one or any combination of the types of inspection data described in this document. In one embodiment, one or more processors 5140 may receive (via a receiver) a response from the remote computer system that responds to the transmission of inspection data to the remote computer system (e.g., a response comprising predefined profile data. weld, instantaneous profile data, post-weld profile data, an assertion of transmitted profile data, a welding or operating protocol, an alert indicating a defect, or other data). In one embodiment, the response may originate from inspection data transmitted and additional data received by the remote computer system. For example, additional data may relate to observations of one or more operations performed on other tubes, inspection of other tubes, one or more input parameters used to perform the observed operations, or other data (as described in this document). In this way, for example, one or more operations in a field system (for example, the 5000 field system or another field system) can be managed based on previously unavailable large data sets with data from the same field system and /or other field systems. For example, data sets (which include data on observing operations on other tubes, inspection of other tubes, input parameters for performing observed operations, or other data from the same field system or other field systems) can be used to generate and select one or more welding or operating protocols for subsequent operations (as described in this document) to prevent or reduce weld defects or create better welds for current and future customers. As another example, the large dataset from different field systems can be used to improve your inspection and analysis (as described in this document) to provide current and future customers with better products (eg, reducing weld defects , detecting defects early in the process, etc.).

[0786] In one embodiment, when one or more 5140 processors are local to the 5000 field system (for example, part of a local computer system to the 5000 field system), one or more 5140 processors may transmit a profile from the interface region 5136 between the tubes 1022a, 1022b to a remote computer system (e.g., a derived profile based on a check of the interface region 5136). In response, one or more processors 5140 may receive (via a receiver) an assertion of the interface region profile or a modified version of the 5136 interface region profile from the remote computer system. In one embodiment, one or more processors may cause a welding torch of welding system 5004 to create a weld at interface region 5136 based on the assertion or modified version of the profile of interface region 3136.

[0787] For example, one or more 5140 Field System 5000 processors can cause one or more inspection devices to inspect the 5136 interface region between tubes 1022a, 1022b to obtain inspection data (e.g. raw data from the inspection devices, 2D or 3D image data or other inspection data). Inspection devices used for inspection may include one or any combination of the types of inspection devices described in this document. The inspection data obtained may respectively comprise one or any combination of the inspection data types described in this document. By way of another example, one or more processors 5140 can profile the interface region 5136 based on the obtained inspection data, but can also transmit the inspection data to the remote computer system to evaluate the inspection data. 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 5140 processor(s) with an assertion of the 5136 interface region profile, an indication that the provided profile is inaccurate, or other response. Additionally or alternatively, if the provided profile is inaccurate, the remote computer system may respond with its own modified version of the 5316 interface region profile derived from the remote computer system's evaluation of the inspection data. In response to receiving an assertion, for example, one or more 5140 processors may cause a 5004 welding system welding torch to begin or continue a welding operation based on its determined 5136 interface region profile to create the welding in the 5316 interface region. If, however, a modified version of the profile is received, one or more 5140 processors can cause a 5004 welding system welding torch to start or continue a weld operation based on the modified version of the profile to create the weld in the 5316 interface region.

[0788] In one embodiment, when one or more 5140 processors are local to field system 5000 (for example, part of a computer system local to field system 5000), one or more 5140 processors may interact with an inspection laser of the welding system 5004 to verify the 5136 interface region between the tubes 1022a, 1022b to determine a profile of the 5136 interface region prior to a weld operation and generate pre-weld profile data based on the verification. In another embodiment, one or more processors 5140 can transmit the pre-weld profile data to a remote computer system. In response, one or more processors 5140 may receive (via a receiver) an assertion of the pre-weld profile data or a modified version of the pre-weld profile data from the remote computer system. In one embodiment, one or more processors may operate tube engaging structure 5052 and/or tube engaging structure 5054 based on the statement or modified version of the pre-weld profile data to change the interface region 5136 between the tubes before the welding operation.

[0789] By way of example, one or more 5140 processors of the 5000 field system can cause one or more inspection devices to inspect the 5136 interface region between tubes 1022a, 1022b to obtain inspection data prior to an operation. welding at the 5136 interface region. Inspection devices used for inspection may include one or any combination of the inspection device types described in this document. The inspection data obtained may respectively comprise one or any combination of the inspection data types described in this document. One or more 5140 processors can generate pre-weld profile data based on the obtained inspection data, but can also transmit the inspection data to the remote computer system to evaluate the inspection data. One or more 5140 processors can transmit their generated pre-weld profile data to the remote computer system for accuracy verification. Based on its own assessment of the inspection data, the remote computer system may respond to the 5140 processor(s) with an assertion of the pre-weld profile data, an indication that the supplied pre-weld profile data is inaccurate, or otherwise answer. Additionally or alternatively, if the supplied pre-weld profile data 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 tubes 1022a, 1022b are misaligned and an assertion of the pre-weld profile data is received, one or more processors 5140 can cause the engagement structures to tubes 5052, 5054 realign tubes 1022a, 1022b prior to a weld operation to create the weld at the 5136 interface region. If, however, a modified version of the preweld profile data is received, one or more 5140 processors may , instead, use the modified version to perform subsequent operations, such as using the modified version to determine if realignment is necessary and how it should be performed, to select a weld protocol to be used to create a weld in the 5136 interface region , etc.

[0790] In one embodiment, when one or more 5140 processors are local to field system 5000 (for example, part of a computer system local to field system 5000), one or more processors can develop a protocol based on the assertion or modified version of the pre-weld profile data (received from the remote computer system). For example, if the pre-weld profile data assertion is received, one or more 5140 processors can use their generated pre-weld profile data to develop a weld protocol to be used to perform a weld operation in the interface region 5136. As another example, if the modified version of the pre-weld profile data is received, one or more 5140 processors can use the modified version to develop a weld protocol to be used to perform a weld operation in the region of interface 5136.

[0791] In one embodiment, when one or more 5140 processors are local to field system 5000 (for example, part of a computer system local to field system 5000), one or more 5140 processors may interact with an inspection laser of welding system 5004 to verify the interface region 5136 between tubes 1022a, 1022b to determine a profile of the interface region 5136 during a weld operation and generate instantaneous profile data based on the verification. In another embodiment, one or more processors 5140 can transmit (via a transmitter) the instantaneous profile data to a remote computer system. In response, one or more processors 5140 may receive (via a receiver) an assertion of the snapshot profile data or a modified version of the snapshot profile data from the remote computer system. In one embodiment, one or more processors 5140 can control a welding torch of welding system 5004 based on the assertion or modified version of the snapshot profile data during the welding operation.

[0792] By way of example, one or more 5140 processors of the 5000 field system can cause one or more inspection devices to inspect the 5136 interface region between tubes 1022a, 1022b to obtain inspection data during a welding operation at interface region 5136. Inspection devices used for inspection may include one or any combination of the inspection device types described in this document. The inspection data obtained may respectively comprise one or any combination of the inspection data types described in this document. One or more 5140 processors can generate instantaneous profile data based on the obtained inspection data, but can also transmit the inspection data to the remote computer system to evaluate the inspection data. One or more 5140 processors may transmit their generated snapshot 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 5140 processor(s) with an assertion of the instantaneous profile data, an indication that the supplied instantaneous profile data is inaccurate, or another 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.

[0793] As a further example, if instantaneous profile data assertion is received, one or more 5140 processors can use their generated instantaneous profile data to update the welding parameters used to control the system protocol welding torch 5004 (to perform the weld operation in the 5136 interface region) as the weld operation is being performed. As a further example, if the modified version of the snapshot profile data is received, one or more 5140 processors can use the modified version to update the weld parameters that are used to control the 5004 welding system protocol welding torch (to perform the weld operation in the 5136 interface region) as the weld operation is being performed.

[0794] In one embodiment, when one or more 5140 processors are local to field system 5000 (for example, part of a computer system local to field system 5000), one or more 5140 processors may interact with an inspection laser of welding system 5004 to verify the interface region 5136 between tubes 1022a, 1022b to determine a profile of the interface region 5136 subsequent to a weld operation and generate post weld profile data based on the verification. In another embodiment, one or more processors 5140 can transmit the post-weld profile data to a remote computer system. In response, one or more processors 5140 may receive (via a receiver) an assertion of the post-weld profile data or a modified version of the post-weld profile data from the remote computer system.

[0795] By way of example, one or more 5140 processors of the 5000 field system can cause one or more inspection devices to inspect the 5136 interface region between the tubes 1022a, 1022b to obtain inspection data subsequent to an operation of welding at the 5136 interface region. Inspection devices used for inspection may include one or any combination of the inspection device types described in this document. The inspection data obtained may respectively comprise one or any combination of the inspection data types described in this document. One or more 5140 processors can generate post-weld profile data based on the obtained inspection data, but can also transmit the inspection data to the remote computer system to evaluate the inspection data. One or more 5140 processors can transmit their generated post-weld profile data to the remote computer system for accuracy verification. Based on its own assessment of the inspection data, the remote computer system may respond to the 5140 processor(s) with an assertion of the pre-weld profile data, an indication that the supplied post-weld profile data is inaccurate, or otherwise answer. Additionally or alternatively, if the supplied post weld profile data 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 evaluation of the inspection data.

[0796] In one embodiment, when one or more 5140 processors are local to field system 5000 (for example, part of a computer system local to field system 5000), one or more 5140 processors can cause, based on the assertion or modified version of the post-weld profile data (received from the remote computer system), another welding operation to be performed at the 5136 interface region between the tubes. For example, if the post-weld profile data assertion is received, one or more 5140 processors can use their generated post-weld profile data to determine if the result of a weld operation has one or more defects, if the region interface 5136 is ready for the next stage of operations or other determinations. In a use case, for example, when completing a root pass operation in the 5316 interface region, the post-weld profile data from the root pass layer in the 5316 interface region may reveal that the root pass layer it is insufficiently thick. In response, the post-weld profile data can be used to determine welding parameters for a welding operation to repair insufficient thickness or welding parameters for a heat passing operation to produce a heat passing layer (in root passage layer) which compensates for the insufficient thickness of the root passage layer. As a further example, if the modified version of the pre-weld profile data is received, one or more 5140 processors can use the modified version to perform the above process in place of their generated post-weld profile data.

[0797] In one modality, welding parameters that affect weld quality can include voltage, current, welding torch travel speed, wire feed speed, gas flow, etc. In one modality, other welding parameters that affect weld quality can include impedance, temperature, etc.

[0798] In one modality, the voltage used during the welding process can affect the weld bead width and the weld bead shape. In one mode, voltage is measured in volts. In one embodiment, the welding system may include a voltage sensor configured to measure the voltage of the power source that is used to create the welding arc.

[0799] In one modality, the current used during the welding process can affect the penetration of the weld bead. In one mode, current is measured in amps. In one embodiment, the welding system may include a current sensor configured to measure current from the power source that is used to create the welding arc.

[0800] In one embodiment, the weld feed speed is a rate of displacement of a welding electrode, during the welding procedure, along with a joint to be welded. In one embodiment, the welding electrode is supplied from a welding torch. In one modality, the welding speed can be controlled by controlling the welding torch that supplies the welding electrode. In one embodiment, the weld speed during the welding procedure can affect weld bead size and/or weld bead penetration. In one modality, weld speed is measured in millimeters/seconds or inches/minutes.

[0801] In one embodiment, the wire feed/usage speed utilization is at a rate at which the weld electrode material/fill material is being consumed (or supplied in the weld) during the welding process. In one embodiment, wire feed speed is measured in millimeters/seconds or inches/minutes. In one embodiment, the welding system may include a wire feed speed sensor configured to detect a flow of material from the welding electrode.

[0802] In one embodiment, the rate of change in coil weight allows the welding system to measure the rate at which welding wire 5007 feeds the weld. In one embodiment, the feed motor runs at a set/predetermined rate, but the wheel driving wire 5007 may slip due to slight variations in wire 5007 or due to wear on the feed wheel itself. These slips can be temporary in nature, and their presence can be recorded and used in the quality control feedback loop. If slippage is persistent, one or more 5140 processors can be configured to increase the feed motor speed to compensate. Over time, the rate of speed overdrive must be increased. In some cases, it will not be possible to compensate, and the 5004 Welding System will be taken from service for maintenance. In one embodiment, tracking the rate of increase of the overdrive rate across all soldering systems allows one or more processors to determine the best threshold for the maximum allowable overdrive ratio. This configuration can then be transmitted to all active welding systems. In one embodiment, one or more 5140 processors can be configured to update the value at any time as data becomes available to minimize process interruptions and minimize the frequency of machine downtime for maintenance.

[0803] In one embodiment, the welding system may include a gas flow sensor configured to detect the flow rate of the shielding gases used in the welding procedure. In one embodiment, the shielding gas can be an active gas configured to shield the molten solder group. In one embodiment, the gas flow sensor is configured to provide a signal proportional to the gas flow rate in the shielding gas line. In one embodiment, one or more 5140 processors of the 5000 Field System are configured to stop welding if the shielding gas gas flow rate is not within a predetermined gas flow range.

[0804] In one embodiment, the tubes are preheated prior to the welding procedure. In one embodiment, the tube temperature can be monitored by one or more temperature sensors in the welding system. In one modality, one or more temperature sensors are configured to measure the tube temperature at each point along the weld. In one embodiment, one or more 5140 processors of the 5000 Field System are configured to stop the welding procedure if tube temperatures are not within a predetermined temperature range.

[0805] In one embodiment, the welding system may include an impedance sensor that is configured to detect an electrical input impedance of the welding system.

[0806] In one modality, the filler/welding electrode/wire material must be used for each pass of the solder. For example, the only difference between two spools of wire is a 0.1 millimeter difference in wire diameter. If the wire spool manufacturer's label has been smudged or faded, the wrong spool may be loaded into the welding system. An RFID tag on the coil has a coil identifier. In one embodiment, the RFID tag on the coil can be read by a sensor in the welding system. If the RFID tag has the wrong coil identifier, the welding system is configured to not feed wire material and prompt the user to change to the correct wire.

[0807] In one mode, the coil weight can be monitored by one or more 5140 field system 5000 processors. If the solder wire runs out during a soldering process, the voltage signal the processor uses to manage the distance between the solder tip and the workpiece reaches zero. In response, the processor moves the tip closer to the part, which causes the tip to touch the molten weld metal and cause a copper inclusion defect. Therefore, knowing the exact weight of wire remaining in the coil helps the welding system to avoid starting a weld run that requires more welding wire than is available. Also, if the spool weight stops changing, this could be an indication of an empty spool or a faulty wire feed mechanism. In either case, one or more 5140 processors of the 5000 Field System are configured to stop the welding process.

[0808] In one modality, one or more 5140 processors of the 5000 Field System are configured to track the weight of each coil in real time. Each solder pass in a solder joint requires a different amount of wire due to the change in diameter and change in the width of the solder groove to be filled.

[0809] If one or more 5140 Field System 5140 processors determines that a coil will exhaust a wire that is too small to complete the next solder pass, but would have enough wire to complete a different solder pass, one or more 5140 processors of the 5000 field systems can be configured to inform one operator to remove the coil and hand it over to a different operator. For example, the coil starts with 10 kilos of wire and the solder run through the soldering system requires 1.3 pounds of wire. The soldering system will be able to complete its solder passes at 7 solder joints before the coil is low on wire.

[0810] When this coil is removed after the 7th solder pass, this coil will have 0.9 lb of wire to waste. If there is another solder pass that requires, for example, 1.1 kg of wire, then one or more 5140 processors of the 5000 Field System are configured to alert the operator to remove the coil after only 6 passes of solder. In that case, the bobbin will have 2.2 pounds of wire left. This coil can then be used for the solder run which only needs 1.1 kg of wire to complete 2 solder runs (and does not waste any wires).

[0811] In one embodiment, the 5507 solder wire passes through the 5503 solder tip. The 5503 solder tip tip also has a high welding current. Both factors cause wear of the 5503 Weld Tip bore. As this happens, the contact point inside changes, which inherently affects the arc characteristics and therefore the quality of the weld. In one modality, welding parameters such as voltage, current, wire feed, power and impedance are monitored in real time. This data is sent to a tablet via one or more processors to be analyzed for signature comparison of the aforementioned variables due to the computationally intensive nature of the analysis. When the analysis detects an impending problem, the 5004 internal welding system and the operator receive a message to change the 5503 weld tip before the next weld. In addition, this data can be used in the quality control feedback loop. In one modality, the results of the quality control feedback loop can be used to update the weld tip decay signatures instantly.

[0812] In one embodiment, the exemplary solder parameters used for the up and down solder procedures are shown in FIG. 72D. For example, in one embodiment, at least one plurality of welding torches 5502 welds in an upwardly rotating (i.e., upward) direction of rotation, while at least one other plurality of 5502 welding torches welds in a downwardly rotating direction. (ie, in descending). In one embodiment, the weld parameters shown in this document are exemplary and in no way optimized or inclusive of anything that might need to change during these welding procedures. In one modality, the travel speed for the down welding procedure is 13.5 inches/minute and for the ascending procedure is 10.0 inches/minute. In one embodiment, the amplitude of the transverse groove oscillation is 0.09 inches for the down weld procedure and 0.15 inches for the up weld procedure. In one embodiment, the oscillation speed is 160 beats per minute for the down weld procedure and 130 beats per minute for the up weld procedure. In one embodiment, the waveform 1 control (i.e., related to wire feed speed) is from 400 for the down weld procedure to 370 for the down weld procedure. In one embodiment, the solder passes were soldered at 16.5V with the control voltage from the power supply.

[0813] The operation of the 5004 internal welding system is now described. In one embodiment, the 5004 internal welding system is configured to be operated through a repeat operation cycle.

[0814] After it is determined that a weld has been completed at the current weld joint, one or more of the 5140 processors are configured to send communication signals to the 5046 wired power electronics module to control (via control signals) the 5512, 5550, 5588 welding torch motors to retract the 5502 welding torches to their original stowed positions. One or more 5140 processors are also configured to send communication signals to the forward section electronics module 5014 to control/turn off (via control signals) the front clamp control valve 5018 to retract the first hitch frame 5052 to the original retracted position and sending communication signals to the center section electronics module 5064 to control/disable (via control signals) the front clamp control valve 5062 to retract the second hook structure 5054 to the original retracted position. The 5004 internal welding system (including 5502 welding torches and 5144, 5142 clamps) must be moved to the next weld joint.

[0815] In one embodiment, one or more of the 5140 processors are configured to send communication signals to the 5118 transmission section electronics module to control (via control signals) the 5124 transmission motors to accelerate the internal welding system 5004 to travel at a predetermined speed and then decelerate and stop at the next weld joint. In one embodiment, the predetermined speed at which the 5004 internal welding system accelerates can be 6 ft/second.

[0816] When the second coupling structure 5054 is positioned on the next weld joint, the transmission section electronics module 5118 sends communication signals to the wire feed electronics module 5046 to verify alignment with the end of the tube. In one embodiment, electronic wire feed module 5046 is configured to operate (activate) one or more inspection detectors 5056 to measure where the second hook structure 5054 is relative to the end of the tube. In one embodiment, the rotating hub 5072 may not be operated when one or more inspection detectors 5056 are measuring where the second engagement structure 5054 is relative to the end of the tube.

[0817] In one modality, one or more wired feed electronics modules 5046 are configured send the measured data remotely to the transmission section electronics module 5118. In one modality, the transmission section electronics module 5118 is configured to controlling (via control signals) the drive motors 5124 to move the first and second hitch structures 5052, 5054 by the measured distance data.

[0818] In one embodiment, when the second coupling structure 5054 is properly aligned and positioned relative to the end of the tube, the transmission section electronics module 5118 is configured to send communication signals to the center section electronics module 5064 of that internal welding system 5004 is in position at the next weld joint. In one embodiment, center section electronics module 5064 controls (opens via control signals) rear clamp control valve 5062 to elevate second hook structure 5054 and secure old/existing pipe.

[0819] The next/new tube segment 1002a is then introduced and slid over the frontmost section 5006 of internal welding system 5004 into position by the work crew. At this time, one or more processors 5140 are configured to send communication signals to wire feed electronics module 5046 to operate one or more inspection detectors 5056 to verify tube alignment. In one embodiment, one or more 5140 processors can rotate the 5078 rotating hub to take measurements at multiple locations.

[0820] If the tube alignment data is within a predetermined tolerance, the wire feed electronics module 5046 sends communication signals to the furthest electronics module 5014 to drive the front clamp 5142. In one embodiment, the module forward electronic 5014 controls/opens (via control signals) the front clamp control valve 5018 to raise the first hitch frame 5052 and secure the new pipe segment 1002a.

[0821] If the tube alignment data is not within the predetermined tolerance, the wire feed electronics module 5046 sends communication signals (a message) to one or more 5140 processors that identify the misalignment between the tubes 1022a, 1022b. In one embodiment, this information can be transmitted to a crane operator via traditional crane operator hand signals or by an electronic signal to a computer screen terminal in the crane cab.

[0822] After the tubes are secured, one or more 5140 processors are configured to send communication signals to the wired feed electronics module 5046 to operate one or more inspection detectors 5056 to measure distance and radial displacement (Hi- Lo) at a plurality of points along the circumference of the solder joint. In one embodiment, this data is communicated to one or more 5140 processors and compared to allowable tolerances.

[0823] If the joint fit (ie, the space and radial offset (Hi-Lo)) is within a predetermined tolerance, one or more 5140 processors or the 5046 wired feed electronics module send communication signals to the operator indicating that welding can begin, or send communication signals to the 5046 wired feed electronics module to automatically start the welding procedure.

[0824] If the joint fit (ie the space and radial offset (Hi-Lo)) is not within the predetermined tolerance, an alert is sent to the operator, who can restart the tightening sequence or override the alert. In one embodiment, the 5004 internal welding system is configured to weld up to 4 millimeters of space and radial displacement (Hi-Lo).

[0825] In one embodiment, the wired feed electronics module 5046 is configured to automatically start the welding procedure. In one embodiment, one or more 5140 processors are configured to send communication signals through umbilical 5034 to a welding source to connect the welding power source to the 5502 welding torch(es). Wired Feed Electronics Module 5046 is configured to control/move one or more 5502 welding torches radially, axially and/or angularly to a suitable welding position. In one embodiment, the electronic wire feed module 5046 moves one or more welding torches 5502 radially, axially and/or angularly the correct working distance of the tube and the center of the weld joint measured by one or more inspection detectors 5056 .

[0826] In one embodiment, the wired power electronics module 5046 is also configured to operate (turn on) the 5042 shield gas valve(s) to supply shield gas to the torch(es) Weld Feed System 5502 and operate the 5044 Weld Feed System motors to begin feeding the welding wire or electrode into the 5502 Welding Torch.

[0827] In one embodiment, the wire feed electronics module 5046 sends communication signals to both the forward section electronics module 5014 and the center section electronics module 5064 to initiate rotation of the rotating hub 5078. In this embodiment, wire feed electronics module 5046 sends communication signals to both forward section electronics module 5014 and center section electronics module 5064 to synchronize front rotation motor 5030 and rear rotation motor 5074. In one embodiment, the frontmost 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 5030 front and 5074 rear rotation motor are configured to rotate the 5078 swivel hub while keeping the front and rear clamps 5142, 5144 stationary. In one embodiment, a rotating cube 5078 continues to rotate for the entire length of the weld.

[0828] In one embodiment, the wired feed electronics module 5046 is configured to operate one or more inspection detectors 5056 to locate the center of the weld joint and move the 5502 welding torch axially to follow the weld joint.

[0829] In one embodiment, the wired power electronics module 5046 is configured to measure the voltage of the welding power. The measured voltage data can be used by the wired power electronics module 5046 to determine the distance of the 5502 welding torch from the tube. In one embodiment, the wire feed electronics module 5046 is configured to adjust the welding torch 5502 radially to maintain a constant distance of the welding torch 5502 from the tube. In one embodiment, electronic wire feed module 5046 can oscillate welding torch 5502 axially to improve weld quality.

[0830] In one embodiment, the wired feed electronics module 5046 is configured to change the tilt angle of the 5502 welding torch to whose base the portion of the weld is being welded. For example, the tilt angle of the 5502 welding torch in the displacement plane is adjusted to compensate for gravity.

[0831] In one embodiment, the wired feed electronics module 5046 can be configured to vary the wire feed speed or send communication signals to the weld source (via umbilical 5034) to vary the base weld current in the measurement data of one or more inspection detectors 5056.

[0832] In one embodiment, the welding procedure can be performed by a welding torch in a welding pass rotating 360°. In one modality, the weld start and stop position can be anywhere along the weld joint.

[0833] In one embodiment, the welding procedure can be performed with N evenly spaced 5502 welding torches where the 5078 rotating hub rotates (360/N) degrees to deposit a weld pass. In one embodiment, the welding procedure can be performed with N evenly spaced 5502 welding torches where the rotating hub 5078 rotates (2 times (360/N) degrees to deposit two weld passes. For example, in one embodiment, when the 5004 internal welding system has three evenly spaced 5502 welding torches, the 5078 swivel hub rotates 120° to deposit one weld pass and rotates 240° to deposit two weld passes.

[0834] When the 5502 welding torches reach a point where the previous 5502 welding torch has begun its weld pass, one or more inspection detectors 5056 detects the existing weld bead and the wire feed electronic module 5046 is configured to move the 5502 welding torches radially to compensate.

[0835] In one embodiment, the two weld passes can be deposited as described above with a gap between the weld passes for a full laser inspection and a visual post weld inspection. In one embodiment, welding can be done at 360° with N unequally separated torches 5502 with each welding torch 5502 depositing a successive weld pass for a total of N weld passes at 360° plus the distance of the first torch from the In the torch.

[0836] Once a weld has been determined to have been completed, one or more of the 5140 processors are configured to send communication signals to the 5046 Wired Power Electronics Module to control (via control signals) the 5512 Welding Torch Motors , 5550, 5588 to retract the 5502 welding torches to their original retracted positions. For example, 5502 welding torches can be retracted back to their home positions for each axis (radial, axial, slanted).

[0837] In one embodiment, rotating hub 5078 continues to rotate while wire feed electronics module 5046 operates one or more inspection detectors 5056 and a 2D camera 5112 to inspect weld quality. In one embodiment, if certain types of solder defects (eg, under-fill, under-reinforced) are discovered, one or more 5140 processors are configured to send communication signals to the 5046 wired feed electronics module to move a torch solder 5502 to that location and apply additional solder material to repair the defect.

[0838] Once inspection and repairs are complete and verified by the operator, the operator can send communication signals to the forward electronic module 5014 to control/switch off (via control signals) the front clamp control valve 5018 to retract the first hitch frame 5052 to the original retracted position and send communication signals to the center section electronics module 5064 to control/disable (via control signals) the front clamp control valve 5062 to retract the second hitch frame 5018. 5054 to the original, retracted position.

[0839] In offshore piping applications, angular and positional tube alignment errors can be corrected by sending control signals from one or more 5140 processors to brackets 5330 or brackets 6010A and 6010B (to control associated rollers 5332) .

[0840] In one embodiment, the purge and inspection system 7001 or the internal welding system 5004 may include a clamp that is constructed and arranged to secure the inner surface of the first tube 1022b. In one embodiment, the bases 5330 or the bases 6010A and 6010B are configured to move the second tube/inlet tube 1022a into position. In one embodiment, one or more 7062 or 5140 processors are configured to interact with inspection detector 5056 or 7042 to check alignment between the tubes and send control signals to bases 5330 or bases 6010A and 6010B to correct any errors tube alignment (angular or positional). In one embodiment, the control signals from one or more of the 5140 processors are configured to adjust the relative positioning between the tubes (to correct for alignment errors). In one embodiment, this procedure can be used on thin or thick walled tubes that have a very low (<20) diameter to wall thickness ratio, as no amount of clamping force can significantly change the shape of the underside tube. D/t.

[0841] In one embodiment, the 7001 purge and inspection system or the 5004 internal welding system may include two clamps. For example, a clamp is constructed and arranged to attach to the inner surface of first tube 1022b. In one embodiment, bases 5330 or bases 6010A and 6010B are configured to move the second tube/inlet tube 1022a into position. In one embodiment, the second clamp is constructed and arranged to attach to the inner surface of the second tube/inlet tube 1022a. In one embodiment, one or more of the 7062 or 5140 processors are configured to interact with the inspection detector 5056 or 7042 to verify alignment between the tubes. For example, if the alignment is not good, the second clamp releases the second tube 1022a. One or more 7062 or 5140 processors are configured to send control signals to the 5330 bases or the 6010A and 6010B bases to correct any tube alignment errors (angular or positional). In one embodiment, control signals from one or more processors 5140 are configured to adjust the relative positioning between the tubes (to correct for alignment errors), for example, by changing the positioning of tube 1022a. The procedure can continue until acceptable tube alignment is achieved by the inspection detector or a pre-set number of attempts (eg 10), at which time the second tube 1022a is rejected and a new second tube is moved into place.

[0842] In one embodiment, the crane and clamp alignment are used in the ground piping alignment and welding process. In land-based piping applications, the piping angular alignment error can be corrected by providing instructions to the crane operator and the positioning alignment error can be corrected by instructing workers to place a shim between the clamp and the pipe.

[0843] In one embodiment, the purge and inspection system 7001 or the internal welding system 5004 may include a clamp that is constructed and arranged to secure the inner surface of the first tube 1022b. In one embodiment, the crane operator moves the second tube/inlet tube 1022a to a position and workers position the outer clamp around the joint. In one embodiment, one or more of the 7062 or 5140 processors are configured to interact with the inspection detector 5056 or 7042 to verify alignment between the tubes. If the 5056 or 7042 inspection detector detects angular alignment/pipe alignment error, instructions are sent to the crane operator to correct the angular alignment and pipe alignment error and workers release the clamp while the pipe is being moved . If the inspection detector 5056 or 7042 detects a tube alignment error/position misalignment, workers are instructed on the placement and thickness of shims needed to correct the tube alignment error/position misalignment. Workers remove the clamp, position the shim and replace the clamp. The process repeats until the tube alignment is accepted by the inspection detector.

[0844] In one embodiment, the 7001 purge and inspection system or the 5004 internal welding system may include two clamps. For example, a clamp is constructed and arranged to attach to the inner surface of first tube 1022b. In one embodiment, the crane operator moves the second tube/receiver tube 1022a into position. In one embodiment, the second clamp is constructed and arranged to attach to the inner surface of the second tube/inlet tube 1022a. In one embodiment, one or more of the 7062 or 5140 processors are configured to interact with the inspection detector 5056 or 7042 to verify alignment between the tubes. If the 5056 or 7042 inspection detector detects an angular misalignment/tube alignment error, the second clamp releases the second tube and instructions are sent to the crane operator to correct the misalignment. If the 5056 or 7042 inspection detector detects a tube alignment error/position misalignment, the second clamp releases the second tube and instructions are sent to workers for the placement and thickness of shims necessary to correct the tube alignment error. tube/position misalignment. The crane operator moves the second tube away from the first tube and the workers position the shims. The crane operator moves the second tube back into position. The second clamp secures the second tube. The process repeats until the tube alignment is accepted by the inspection detector.

[0845] FIG. 103B shows the tube alignment, welding, and inspection procedures for the 5004 internal welding system.

[0846] In one embodiment, inspection detector 5056 checks 360° of the interface region 5136 between tubes 1022a, 1022b before welding takes place. In one embodiment, during the procedure for generating the pre-weld profile data, inspection detector 5056 is positioned between the clamps and/or seals of internal welding system 5004 and is activated. In one modality, the 5502 welding torch(es) are deactivated during the pre-weld profile data generation procedure. In one embodiment, one or more processors 5140 are configured to interact with inspection detector 5056 to scan interface region 5136 to obtain pre-weld profile data subsequent to the first clamp 5142 and the second clamp 5144 that fits with the first tube 1022a and second tube 1022b, respectively.

[0847] In one embodiment, the bases 5330 (as shown in Figures 10A and 10B) and 6010A and 6010B (as shown in Figure 73) are operated by one or more 5140 processors (or otherwise controlled) to engage external surfaces 5346 and/or 5348 (as shown in Figure 2G) of the first tube 1022a and/or the second tube 1022b to adjust the relative positioning of the tubes 1022a, 1022b in the event that the pre-weld profile data determines the need for adjustment. In one embodiment, an inner surface 5130, 5132 of the first tube 1022a and/or the second tube 1022b is engaged and manipulated by the first clamp 5142 and the second clamp 5144, respectively, to adjust the relative positioning of the tubes 1022a, 1022b in the case of pre-weld profile data determines the need for adjustment.

[0848] In one embodiment, during the procedure to generate instant weld profile data, inspection detector 5056 is positioned between the clamps and/or seals of internal welding system 5004 and is activated. In one embodiment, one or more 5140 processors are configured to control a position and speed of the 5502 (or 7502) welding torch based on instant weld profile data. In one embodiment, the instantaneous inspection/verification procedure is performed during the root weld pass procedure, the hot weld pass procedure, the fill pass weld procedure, and during the casing weld pass procedure. In one embodiment, the optional radiographic inspection procedure (eg 1044, as shown and described in accordance with Figure 1B) can be performed between the instant check/inspection and the hot solder pass procedure and the check/inspection instantaneous and pass-through procedure of coating and filler solder.

[0849] In one embodiment, inspection detector 5056 makes a 360° check of the 5136 interface region between tubes 1022a, 1022b subsequent to a welding operation. In one embodiment, during the procedure for generating the post-weld profile data, inspection detector 5056 is positioned between the clamps and/or seals of internal welding system 5004 and is activated. In one modality, the 5502 welding torch(es) are deactivated during the post-weld profile data generation procedure.

[0850] In one embodiment, a weld inspection procedure (eg 1008 as shown and described in relation to FIG. 1B) can be done after the post weld inspection/verification procedure.

[0851] The procedures of FIG. 103B are described in relation to internal soldering system 5004. However, as shown in FIG. 103B, it is contemplated that the same procedures apply the 3001 internal welding system and the 7001 purge and inspection system, and therefore will not be described again with reference to the 3001 internal lashing welding system and the 7001 purge and inspection system .

[0852] Since, in one or more embodiments, the tube was welded from the inside (ie, the root weld pass was applied from within the tube), the resulting root weld may be greater in that it takes more account of misalignments and/or high-low regions of the tube. In addition, if a hot solder pass (a second layer of solder on top of the root pass layer) is also applied internally, the tube can also receive a positive root application over the root solder pass. A hot solder pass, and even a new internally applied solder pass, can provide a small curved bulge that extends slightly inside the tube to further strengthen the tube. For example, the tube inside diameter could be structured to be slightly smaller in the weld region than the weld tube inside diameter in regions that contain only the tube material without the weld. In one aspect of this application, the hot-flow layer of the solder material has at least a portion disposed closer to the longitudinal axis of the tube than the inner surfaces of the welded tubes in the regions of the welded tubes immediately adjacent to the weld material. on opposite sides of the solder material.

[0853] In some embodiments, the internal welding system 5004 disclosed in this document is configured to weld tubes at least 30' long. In other embodiments, inner welding system 5004, 3001 disclosed herein is configured to weld tubes 26" in diameter or less. In still other embodiments, inner welding system 5004 can weld tubes at least 24" in diameter. . In still other embodiments, the inner welding system 5004 disclosed herein is configured to weld tubes at least 30' long and less than 24' in diameter.

[0854] FIGs. 73-85 show and describe another embodiment of the inner soldering system in accordance with another embodiment of the present application.

[0855] The present patent application provides a system to align and weld the faces of two pipe segments. The system includes an external alignment mechanism and a welding mechanism. External alignment mechanisms can be as sophisticated as the line modules shown in the figures or as simple as a tipton clamp, as illustrated in U.S. Patent No. 1,693,064. The mechanisms used can also be suitable for the construction of pipelines onshore or offshore. U.S. Patent No. 1,693,064 is incorporated herein by reference in its entirety. Whichever mechanism is employed, the external alignment mechanism supports and adjustably positions each segment so that the segments are substantially collinear or aligned axially along their longitudinal axes.

[0856] The external alignment mechanism can support a segment of tube and may include reinforced features that allow the positioning and orientation of the tube to be adjusted. Specifically, the external alignment mechanism can include rollers that allow the tube to move longitudinally. The tube can also be supported by rollers that allow the tube to be rolled around the longitudinal axis and moved up and down. Position and orientation adjustments can be automatic, for example: by engine power or hydraulic power controlled at an operating station or fed to a central controller that automatically controls and aligns segments based on predetermined alignment parameters or feedback from a Internal laser that reads an interface or joint profile.

[0857] The welding mechanism is an internal welding machine that applies a weld (for example, a "GMAW" metal gas arc weld) from inside the pipe segments to a segment face or edge joint and into a V-shaped opening formed by beveled edges of the two pipe segments (other cross-sectional shapes other than V can also be used). The welding mechanism includes a carriage capable of engaging the inner walls of the tube to engage or lock onto the tube in a fixed position and a weld portion supported from the carriage on the tube. Specifically, the inner welder is located within the lined tube and is then placed longitudinally so that a welding head or torch is in longitudinal proximity to the edge joint. The welding mechanism also includes a rotary mechanism for rotating the welding portion with respect to the carriage. The weld head or torch is rotatably supported in the weld portion around the longitudinal axis of the tube so that the torch can closely follow the entire inner joint interface in an orbital rotation. Specifically, during welding, the swivel head torch follows the edge joint around the entire inner circumference of the tube that applies weld material. In addition to circular rotation relative to the carriage, various control members can move the weld head axially along the tube relative to the carriage, radially towards and away from the joint and pivotally around a point or axis (by example, an axis parallel or perpendicular to the longitudinal axis of tube AA). A controller can direct the rotating torches. These degrees of freedom of articulation allow the torch head to be very effective and efficient in filling interface profiles optimally and when needed.

[0858] The welding mechanism also includes a laser tracking mechanism that works in conjunction with the welding portion torch to detect the interface joint profile and/or the weld material profile to apply the weld material to the edge gasket in the proper location and quantity. The laser mechanism examines the weld and sends a signal to the hinged weld head controller to control head movement 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 obtain the desired weld structure/profile.

[0859] In addition to the laser tracking mechanism, the system may include a 2D camera for visual inspection of the weld. The 2D camera mounts to the weld portion and follows the torch so an operator can inspect the weld as it is created by the torch. A visual signal is sent to a screen for the external operator. For example, the 2D camera might be a color camera and a change in color might indicate a weld defect to the operator. A noticeable change in the profile can also indicate a defect.

[0860] Referring to FIGS. 73-75, the system for welding the pipe segments is described as follows. FIG. 73 shows an external alignment mechanism 6010A and 6010B that is capable of supporting, positioning and repositioning various lengths of tubing. Each 6010A and 6010B mechanism can include supports (eg, rollers) on which a length of tubing can be supported. A longitudinal roller 6012 movably supports the pipe segment 6105 so that the segment 6105 can be repositioned along its longitudinal direction defined by arrow A. In addition, the rotating rollers 6014 can rotate about a parallel axis to the AA axis of the support segment 6105 on either side of the segment 6105, allowing them to rotate or adjust the angular orientation of the segment 6105 about the AA axis. The 6010 external alignment mechanism is capable of automatically manipulating multiple segments in various positions and orientations through motors, hydraulic mechanisms, etc. For example, segments can be raised, lowered, rotated, tilted, hinged, etc.

[0861] As shown in FIG. 73, the outer alignment mechanisms 6010A and 6010B support multiple segments 6105, 6110 and adjust their position and orientation until segments 6105, 6110 are aligned so that their longitudinal axes AA are collinear and one end of each of the segments 6105, 6110 Touch the edges of the interface. Specifically, FIG. 74 illustrates an enlarged view of detail 6100 of FIG. 73 where the edges form an interface of the 6120 tube (known as a "snap" joint).

[0862] The pipe alignment and welding system of the present patent application applies a weld to the interior of the 6120 interface from the interior of the slotted segments 6105, 6110. To apply a weld to the interior of the 6120 joint, an internal welding mechanism 6300 is rolled to one end of one of the segments 6105 as shown in FIG. 75. A second segment 6110 is then placed on the outer alignment mechanism 6010B and manipulated until both 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-propelling means to adjust its axial position within the aligned segments 6105, 6110.

[0863] As shown in FIGS. 76-79, weld mechanism 6300 includes a carriage 6301 and a weld portion 6302. Carriage 6301 includes at least one alignment mechanism 6340A, 6340B which is radially expandable to fit the inner surface of segments 6105 or 6110. This expansion and engagement maintains the axial/longitudinal position of the 6300 weld mechanism with respect to segment 6105, 6110 and radially aligns or centers the 6300 weld mechanism within segments 6105, 6110. Carriage 6301 also includes a body 6311 on which swivel mechanism 6335 is supported. Body 6311 is comprised of multiple elongated structural support members extending between alignment mechanism 6340A and 6340B. As discussed below, solder portion 6302 includes a similar mating structure 6313.

[0864] The welding portion 6302 is rotatably connected to the carriage 6301 and extends from one 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 fixed to carriage 6301 and automatically (by means of a motor and gears) rotates the welding portion 6302 relative to carriage 6301 about the longitudinal axis AA. Welding portion 6302 can be braced from carriage 6301 or can 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, solder portion 6302 is rotatable with respect to and between both alignment mechanisms 6340B and 6340C when alignment mechanisms 6340B and 6340C expand to shield the interior of a segment. In addition, carriage 6301 may include a reach rod 6345 which may be structured as an elongated extension of carriage 6301 that an operator can hold to insert/push or retract/pull the 6300 welding mechanism to position it axially within a segment 6105, 6110.

[0865] FIG. 76 shows an enlarged view of section 6200 of FIG. 75 where only segment 6105 is present and segment 6110 is absent. As shown in FIG. 76, welding portion 6302 includes a welding group 6303 comprising a torch 6305, a laser sensor 6310 and a color camera 6320. The welding portion 6302 further has a body 6313 in which the torch 6305 is supported, the 6310 laser sensor and 6320 color camera. The 6310 laser tracks an internal joint of segments 6105, 6110 and detects an interface profile to be used to position the 6305 torch when applying a weld to the joint interface. Body 6313 extends between alignment mechanism 6340B and 6340C. Section 6200 shows welding mechanism 6300 located within segment 6105 with torch 6305 generally pointed radially outward and positioned to apply a weld facing joint 6120. FIG. 77 shows an embodiment of a schematic general sectional view of the welding mechanism 6300 through section BB showing the welding group 6303 facing the insertion direction of the welding mechanism 6300. FIG. 77 also shows a direction of rotation D of welding group 6303 when it is rotated by rotating mechanism 6335. Therefore, a welding action at a particular point along weld joint 6120 will be triggered by laser sensor 6310 followed by torch 6305 and , finally, by the 2D inspection camera 6320.

[0866] FIGs. 82-84 illustrate multiple perspectives of the weld portion 6302. FIG. 82 shows a 6322 wire delivery system. The 6322 wire delivery system includes a 6323 wire spool storage, an optional 6325 wire liner, and a 6330 wire delivery mechanism that is automatically controlled to provide the proper amount of wire to torch 6305. As rotary mechanism 6335 rotates welding portion 6302, wire is supplied to torch 6305 by wire delivery mechanism 322.

[0867] As mentioned above, the 6305 torch can be positioned and oriented in various ways by various mechanisms. The 6305 torch is supported on a manipulator. The manipulator includes a radial positioner, an axial positioner and an articulator. Specifically, a 6307 radial positioner (eg, a rack and pinion) on which the 6305 torch is supported is capable of moving the torch radially towards and away from the inner surface of segments 6105, 6110. In other words, to ae moving away from the interface of segments 6105, 6110 to be welded. In addition, a 6309 axial positioner (eg, a rack and pinion) can move the 6305 torch axially on segments 6105, 6110. The manipulator also includes a 6308 articulator that allows the torch to rotate (e.g., around a axis parallel to the longitudinal axis of segment AA). The rotary movement of the articulator 6308 can be powered by a motor and by gears 6306. For example, the motor can be a stepper motor.

[0868] The torch handler can aggravate the aforementioned limb manipulation movements by dependently supporting the limbs. For example, body 6313 can support the axial positioner, which in turn supports the radial positioner, which in turn supports the articulator, which in turn supports the torch. Likewise, the axial positioner can be supported by the radial positioner. Also, any support order can be used.

[0869] The manipulator members are controlled by a controller that receives as input a series of signals, including a 6310 laser signal, and then processes the information before transmitting a signal to at least the 6307 radial positioner, the 6309 axial positioner , the articulator 6308 and the wire distribution system 6322. The torch 6305 is then continuously repositioned and reoriented in accordance with predetermined controller parameters based on laser signals from the reading of the 6310 profile.

[0870] The operation of the present internal welding system will now be described. FIGs. 73, 80, and 81 illustrate the process of positioning and soldering segments 6105 and 6110 together. In operation, one or more of the following listed steps can be performed such that: a) a segment of tube 6105 is positioned on the tube alignment/support device 6010A; b) the internal welding machine 6300 is then inserted into the tube segment 6105; c) a second segment of tube 6110 is then aligned with segment of tube 6105 and welding mechanism 6300 is pulled forward by reach rod 6345 or automatically driven so that torch 6305 generally lines up with the joint. of faces 6120 of tube segments 6105, 6110; d) the alignment mechanisms 6340A, 6340B (and 6340C, if necessary) are then engaged to secure the welding mechanism 6300 to the tube segments 6105, 6110; e) in one (optional) mode, the 6335 swivel mechanism rotates the 6305 weld head to make an initial check of the 6120 interface joint of the 6105, 6110 pipe segments by the 6310 laser sensor device for a fit ideal; f) if required, steps (c), (d) and (e) may be repeated, i.e. tube segments 6105, 6110 are realigned/rotated and rechecked by laser 6310 to improve "fit"; g) ideally, the internal alignment mechanism 6340C in front of the welding mechanism 6300 is engaged so as to maintain the axial position of the welding mechanism 3600 with respect to the tube sections 6105 and 6110; h) with the 6300 welding mechanism attached to the 6105 and 6110 tube segments, the initial root weld (first weld) cycle so that the 6310 laser checks the 6120 tube interface, the 6305 torch follows the 6310 laser and sending the 6310 laser is used to control the position of the 6305 hinged torch when the position and orientation of the 6305 torch relative to the 6120 interface is controlled to produce a higher quality weld; i) furthermore, for signaling from the 6310, it can also be used an arc current monitoring in the direction of the torch position; j) after completion of a 360° weld, the 6305 weld head is rotated back to the original position; k) profile (using laser 6310) and visual inspections (with 2D color camera 6320) are done in previous step (j) or in a separate inspection; l) After inspection, the 6340A-C alignment mechanisms are released and the 6300 welding mechanism is pulled or driven forward, to the open end of the 6105, 6110 weld tube and with the tip of the 6300 welding mechanism exposed. As (b), the tube segment 6110 is placed on the outer alignment mechanism 6010B and advanced to the next joint; m) steps (c) through (l) are then repeated for complete production.

[0871] 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 segments 6105, 6110 to a more common arrangement of face join 6120. the previous steps can be performed in the order indicated. However, variations in order are also covered.

[0872] In another mode, instead of stopping after the first 360° weld, the rotation continues to place another weld pass, the 6310 laser can be used to inspect and track simultaneously while the 2D color camera on the right continues inspection after the second weld.

[0873] In yet another modality, instead of welding a complete 360° weld, the weld is performed in two 180° halves with the same initial position. This implementation would require laser sensors for tracking or a mechanism to physically oscillate the laser and/or torch in order to maintain the leading position of the tracking sensor in both directions of rotation (ie, rotating the torch and laser to for them to switch positions).

[0874] In one embodiment, the present patent application describes an internal socket welding system 3001. In one embodiment, the internal socket welding system 3001 incorporates all of the features of the internal socket welding system 5004. In one embodiment, the Additional features of the internal plug-in welding system 3001 may include a large capacity battery so that the internal plug-in welding system 3001 can travel long distances and have on-board welding power. In one embodiment, the internal plug-in welding system 3001 is configured to operate autonomously so that there are no cables external to the internal plug-in welding system 3001.

[0875] As a result of the welding power, walking power and other powers needed to be carried on board (the full battery system carried by the frame), the 3001 plug-in internal welding system can be used to traverse very long spans of pipes and carry out a welding operation at such locations. This is feasible as the system does not need to be powered from an external power source.

[0876] In one embodiment, the internal socket welding system 3001 may also include a device for pulling the tubes together to close any gaps. In one embodiment, the device for pulling the tubes together to close any gaps may be referred to as a landing device. In one embodiment, the landing device is constructed and arranged such that one of the braces is configured to be movable relative to the other brace. In one embodiment, the landing device is constructed and arranged to be external to the main welding section. In one embodiment, the landing device is constructed and arranged to be inside the tubes.

[0877] In one embodiment, the internal plug-in welding system 3001 includes the frontmost section 3002, the center section 3004 and the drive section 3006 which are similar to the internal welding system, 5004. In one embodiment, the frame , the configuration, components and operation of the frontmost section 3002, the center section 3004 and the drive section 3006 of the plug-in internal welding system 3001 is similar to the forward section, the center section and the drive section of the internal welding system 5004 described in detail above and therefore the structure, configuration, components and operation of the forward section 3002, the center section 3004 and the drive section 3006 of the plug-in internal welding system 3001 will not be described in detail in this document. In one embodiment, the forward section electronics module 3002, the center section electronics module 3004 and the drive section electronics module 3006 each include one or more processors.

[0878] For example, the plug-in welding system 3001 includes a frame that is configured to be placed within tubes 1022a, 1022b, a plurality of rollers 3125 that are configured to rotatably support the plug-in inner welding system frame. 3001, a drive motor 3124 that drives rollers 3125 to move the frame of the internally fitting welding system 3001 within the tubes 1022a, 1022b, a brake system that secures the frame of the internally fitting welding system 3001 of movement in a desired location within tubes 1022a, 1022b, an inspection detector that is carried by the frame of the plug-in welding system 3001 and configured to detect a characteristic of an interface region between tubes 1022a, 1022b and a carried welding torch. by the frame of the 3001 plug-in inner welding system. In one mode, such as the 5004 inner welding system, the brake system of the inner welding system fittings 3001 may include the clamps of the fitting internal soldering system 3001 which are configured to secure to the tubes 1022a, 1022b, respectively. In one embodiment, such as the internal welding system 5004, the brake system of the internal welding system 3001 can include the brake cylinder and the brake valve of the internal welding system 3001. , the configuration and/or operation of rollers 3125, drive motor 3124, inspection detector, and welding torch of plug-in welding system 3001 are similar to those of internal welding system 5004 and therefore will not be described in detail in this document.

[0879] In one embodiment, the 3001 plug-in internal welding system also includes one or more processors that are operatively connected with the 3124 drive motor, inspection detector, and welding torch. The configuration and operation of one or more processors of the 3001 internal splicing system is similar to that of the 3004 internal splicing system and therefore will not be described in detail in this document.

[0880] In one embodiment, the 3001 plug-in internal welding system is totally unbonded. Specifically, the 3001 plug-in internal welding system does not need to include the reach rod or the umbilical, and all communications to and from the 3001 plug-in internal welding system are completely wireless. In one embodiment, the plug-in welding system 3001 may include a transmitter that is configured to transmit all communication signals completely wirelessly from the plug-in welding system 3001 to the uLog remote processing system and a receiver that is configured to receive all communication signals completely wirelessly from the remote uLog processing system. In one embodiment, one or more processors and/or all electronic modules of the 3001 plug-in internal welding system are configured to communicate fully wirelessly with the remote uLog processing system. In one modality, the inspection detector, inspection camera, all sensors, all motors, all valves and/or other components/members of the 3001 internal welding system are configured to fully wirelessly communicate with the system. uLog remote processing.

[0881] In one embodiment, any information from the internal plug-in soldering system can be wirelessly communicated with systems outside the tube by WiFi, Bluetooth, NFC, by radio frequency, or through cell transmissions, just for example. In some embodiments, where appropriate, information is communicated through the use of repeaters or extenders, where the transmission signal must travel long distances or through curved areas.

[0882] In one embodiment, one or more processors and one or more sensors of the 3001 plug-in internal welding system are configured to monitor the load levels of the onboard welding power supply, onboard travel power supply, and others onboard power supplies. For example, the voltage output of these power sources can be (continuously or at regular intervals) monitored. In one embodiment, the internal plug-in welding system transmitter 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 from onboard power supplies can be used to determine the estimated remaining operating time of the 3001 internal plug-in welding system. slot 3001 can be configured to locally determine the estimated remaining runtime of the slot internal welding system 3001 on the slot internal welding system 3001. In one modality, the remote uLog processing system can be configured to determine the operating time estimated remainder of the 3001 plug-in internal soldering system based on wirelessly transmitted charge/battery life information. In one embodiment, the remote uLog processing system can be configured to transmit the estimated remaining operating time of the plug-in internal welding system 3001 to one or more processors of the plug-in internal welding system 3001. In one embodiment, the plug-in welding system Remote uLog processing can also be configured to transmit (completely wirelessly to the 3001 internal plug-in welding system) additional instructions on the operation of the 3001 internal plug-in welding system based on the estimated remaining runtime of the internal plug-in welding system. snap 3001.

[0883] In one embodiment, one or more processors and one or more sensors of the 3001 plug-in internal welding system are configured to monitor the gas levels of the onboard inert gas supply (shield/purge), the air supply to shipboard and other onboard gas supplies (eg compressed air volume or pressure in onboard compressed air tanks, shield pressure volume or purge gas in onboard protection/purging tanks, etc.). For example, the gas consumption of these gas supplies can be monitored (continuously or at regular intervals). In one embodiment, the internal plug-in welding system transmitter 3001 transmits the monitored gas level information entirely wirelessly to the remote uLog processing system for further processing. For example, monitored gas level information from onboard gas sources can be used to determine the estimated remaining operating time of the 3001 splice welding system. In one embodiment, one or more internal splice welding system processors 3001 can be configured to locally determine the estimated remaining runtime of the internal plug-in welding system 3001 in the plug-in indoor welding system 3001. In one embodiment, the remote uLog processing system can be configured to determine the remaining runtime Estimate of the 3001 Plug-in Internal Welding System based on wirelessly transmitted gas information. In one embodiment, the remote uLog processing system can be configured to transmit the estimated remaining operating time of the plug-in internal welding system 3001 to one or more processors of the plug-in internal welding system 3001. In one embodiment, the plug-in welding system Remote uLog processing can also be configured to transmit (completely wirelessly to the 3001 internal plug-in welding system) additional instructions on the operation of the 3001 internal plug-in welding system based on the estimated remaining runtime of the internal plug-in welding system. snap 3001.

[0884] In one embodiment, one or more processors and one or more sensors of internal socket welding system 3001 are configured to monitor weld wire material levels of internal socket welding system 3001. For example, rotations of the wire feed motor (which dispenses the welding wire) and the weight of the welding wire material remaining in the 3001 internal welding system can be monitored (continuously or at regular intervals) to determine the welding wire material levels. plug-in welding system 3001. In one embodiment, the plug-in welding system transmitter 3001 transmits the monitored weld material level information entirely wirelessly to the remote uLog processing system for further processing. For example, monitored welding wire material level information can be used to determine the estimated remaining operating time of the internal plug-in welding system 3001 (eg, before the welding wire material runs out or goes down threshold level for operating the internal plug-in welding system 3001). In one embodiment, one or more of the Plug In Welding System 3001 processors can be configured to locally determine the estimated remaining runtime of the Plug In Welding System 3001 in the Plug In Welding System 3001. In one embodiment, the Remote uLog processing system can be configured to determine the estimated remaining runtime of the internal plug-in welding system based on wirelessly transmitted weld material level information. In one embodiment, the remote uLog processing system can be configured to transmit the estimated remaining operating time of the plug-in internal welding system 3001 to one or more processors of the plug-in internal welding system 3001. In one embodiment, the plug-in welding system Remote uLog processing can also be configured to transmit (completely wirelessly to the 3001 internal plug-in welding system) additional instructions on the operation of the 3001 internal plug-in welding system based on the estimated remaining runtime of the internal plug-in welding system. snap 3001.

[0885] In one embodiment, the remote uLog processing system receives battery charge data from multiple internal plug-in welding systems at different locations (eg, different locations across the country or across the world) and establishes a baseline of data about them. This database is used by the uLog processing system to determine, based on a large dataset, battery life times based on different operating parameters of the internal welding system. This can be utilized by the uLog processing system and/or one or more processors of the 3001 Plug-in Internal Welding System to anticipate battery lifetimes for various components based on the current operating conditions of those components. This information can be used by one or more processors to reduce or regulate the power consumption of one or more components by modifying one or more operating parameters. For example, welding speed, welding wire speed, voltage and current can be regulated (eg, lowered) to conserve battery power if one or more processors determines that such operating conditions can be modified without adversely affecting the battery. associated operation being performed.

[0886] In one modality, battery life, voltage output, and any of the operating parameters are wirelessly sent to a user interface, such as a computer monitor with a computer display, so they can be monitored by a user.

[0887] In one embodiment, the internal plug-in welding system 3001 also includes the power section 3008 positioned alongside the drive section 3006 (ie, at the rear of the internal plug-in welding system 3001).

[0888] In one embodiment, referring to FIG. 101, the frontmost section 3002 includes the frontmost 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 plug-in welding system 3001 includes the frontmost section frame 3522, the center section frame 3524, the drive section frame 3526 and power section frame 3528. In one embodiment, the frame assembly or frame of the plug-in welding system 3001 is configured to be placed within tubes 1022a, 1022b.

[0889] In one embodiment, the 3008 power section includes a 3010 universal joint, a 3012 motor power supply, a 3014 welding torch power supply, 3016 welding power supplies, and 3018 adjustable wheels.

[0890] In one embodiment, the drive section 3006 can be connected to the power section 3008 through the universal joint 3010. In one embodiment, the universal joint 3010 is constructed and arranged to allow the internal plug-in welding system 3001 to pivot in around the bends in the pipe.

[0891] In one embodiment, the welding torch power source 3014 may include a plurality of welding torch power batteries 3014a-3014e. In one embodiment, the welding torch power source 3014 is configured to power the welding torch(es) 3502. In one embodiment, the welding torch power source 3014 is carried by the system frame assembly. Internal Plug-in Welding Unit 3001. In one mode, the number of welding torch power batteries may vary. In one embodiment, welding torch power source 3014 is configured to supply electrical power to welding torch power sources 3016 to generate a welding arc. In one embodiment, the power source of solder source 3014 is separate from the other electrical systems so that if the power of the soldering torch is depleted, the rest of the plug-in internal solder system 3001 may still be operational.

[0892] In one embodiment, the engine power source 3012 is configured to drive the electric drive motors 3124 in the drive section 3006. In one embodiment, the engine power source 3012 may include a plurality of power batteries from the engine. 3012a-3012e engine. In one embodiment, the motor power source 3012 may also be referred to as the drive power source. In one embodiment, the engine power source 3012 is carried by the frame assembly of the internal plug-in welding system 3001. In one embodiment, the number of engine power batteries can vary. In one embodiment, the motor power source 3012 is used only for the drive (i.e., to supply power to the electric drive motors 3124 in the drive section 3006) so that, in this case, the other battery packs 3014a- 3014 and are depleted, the 3001 inboard sole system will not be trapped in the pipeline.

[0893] In one embodiment, the 3012 engine power source (including the 3012a-e batteries) and the 3014 welding torch power source (including the 3014a-e batteries) are carried by the frame of the internal welding system of snap 3001. In one modality, one or more battery cells (eg, 3012 Motor Power Supply, 3014 Welding Torch Power Supply, 3514 Batteries, etc.) of the 3001 Plug-in Internal Welding System are configured to power the 3124 drive motor, inspection detector and welding torch. In one embodiment, one or more battery cells 3514, 3012 or 3014 of the socket weld system 3001 can include a plurality of independent battery cells. In one embodiment, battery cells 3014, 3014a-e for the welding torch are independent of battery cells 3012, 3012a-e, 3514 for the drive motor and 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, battery cells 3012, 3012a-e are configured to power drive motors 3124, battery cells 3514 are configured to power the inspection detector, and battery cells 3014, 3014a-e are configured to power the 3001 plug-in internal welding system welding torch.

[0894] In one embodiment, referring to FIG. 101, drive motors 3124 are configured to drive drive rollers 3125 so as to move the frame or frame assembly of splice welding system 3001, first tube engaging structure 3127, second tube engaging 3129, and the inspection detector 3130 of the internal socket welding system 3001 along the at least one of the tubes 1022a, 1022b within its interior. In one embodiment, drive rollers 3125 are configured to engage interior surfaces 5130, 5132 of one or more of tubes 1022a, 1022b. In one embodiment, internal splice welding system 3001 includes a plurality of drive rollers 3125 that are configured to rotatably support the frame or frame assembly of splice welding system 3001.

[0895] In one embodiment, the 3016 welding power sources are configured to absorb direct current energy from the 3014 welding torch power source and transform the DC power to the correct voltage and current waveforms for the welding procedure that are performed by 3502 welding torches.

[0896] In one embodiment, the adjustable wheels 3018 are constructed and arranged to be adjusted so that the power section 3008 of the interlocking release system 3001 runs straight and level in the pipeline.

[0897] FIG. 103 shows a schematic diagram showing the energy flow, including weld power, communication data, and data controls through the internal plug-in welding system 3001, where some components of the internal plug-in welding system 3001 are not shown because for clarity and to better illustrate the other components and/or features of the 3001 plug-in internal welding system.

[0898] The communication data flow and data controls through the internal socket soldering system 3001 in FIG. 103 are similar to the communication data flow and data controls through the internal soldering system 5004 in FIG. 71, except for the differences noted below.

[0899] In one embodiment, drive section electronics module 3126 is configured to be operatively connected to drive batteries 3012 positioned/located in power section 3008 of internal plug-in welding system 3001.

[0900] In one embodiment, batteries 3012 of power section 3008 are connected to drive motors 3124 of plug-in internal welding system 3001 via drive section electronics module 3126.

[0901] The weld force flow through the plug-in internal welding system 3001 in FIGS. 103 and 103A is different from the solder flux through the inner solder system 5004 in FIG. 71.

[0902] For example, welding power comes from different directions in internal welding system 5004 and internal plug-in welding system 3001. That is, unlike internal welding system 5004, where welding power comes from the front of the system through its umbilical 5034, the welding power comes from the rear to the internal plug-in welding system 3001. This configuration where the welding power comes from the rear of the plug-in internal welding system 3001 can be made possible by adding a second slip ring or by rotating the solder portion, pushing it back through the tube (which can make access to the solder wire spools difficult for maintenance).

[0903] In one embodiment, welding power is received by welding torches 3502 of the plug-in internal welding system 3001 from power source 3014 of the onboard welding torch. In one embodiment, welding power from the 3014 welding torch power source is supplied to the 3016 welding power supplies. In one embodiment, the 3016 welding power sources are configured to generate a welding arc . That is, the 3016 welding power supplies are configured to absorb direct current energy from the 3014 welding torch power supply and transform the DC power to the correct voltage and current waveforms for the welding procedure that are realized by the 3502 welding torches. In one embodiment, the correct current and voltage waveforms from the 3016 welding power sources are supplied to the 5502 welding torches through the 3512 rear slip ring.

[0904] Like the 5004 internal welding system, in one embodiment, the batteries 3514 of the 3006 drive section are configured to supply power to all electronic modules in the 3001 internal plug-in welding system, including the most advanced electronic module. front, the wire feed electronics module, the center section electronics module and the 3126 drive section electronics module, and are also configured to supply power to all electric drive motors in the 3001 internal plug-in welding system, including the front rotation motor, wire feed systems motors, the rear rotation motor, the axial welding torch motor, the radial welding torch motor and the tilt welding torch motor. In one embodiment, the 3514 batteries are configured to power the inspection chamber and/or inspection detector of the internal plug-in welding system 3001. However, the batteries 3514 of the drive section 3006 are not configured to supply power to the 3124 drive motors of plug-in welding system 3001. In one embodiment, the batteries 3012 of power section 3008 are configured to supply power to the 3124 drive motors of plug-in welding system 3001. In one embodiment, the batteries batteries 3012 of power section 3008 are connected to drive motors 3124 of plug-in welding system 3001 via drive section electronics module 3126.

[0905] In one embodiment, the batteries used in the 3001 plug-in internal soldering system can be electrically connected to obtain a higher content of higher energy and higher current. For example, two 12 volt batteries can be daisy-chained together to get 24 volts. In one modality, both batteries are mounted on the same frame and connected in series. In one embodiment, the batteries can also be connected to one another (eg, through a universal joint or otherwise) so that the batteries can pivot together to maneuver a pipe.

[0906] In one embodiment, the plug-in welding system 3001 may include four batteries of which one battery can be used to drive the plug-in welding system 3001 and the other three batteries can be connected in parallel and can be used for welding procedures on the 3001 internal plug-in welding system.

[0907] In one embodiment, the 3001 internal socket welding system may use internally positioned clamps (positioned inside the tubes) or externally positioned clamps (positioned outside the tubes). For example, in one embodiment, the 3001 internal plug-in welding system may use internal clamps positioned within the tubes during its welding procedures. In one embodiment, the Inner Fitting Welding System 3001 may use externally positioned clamps (positioned outside the tubes) during an internal scanning procedure (where the laser/detector and/or other device is internally configured to scan the weld joint inside the tubes).

[0908] A socket weld is conducted to weld a long run of pipe to another long run of pipe. Generally speaking, the new tube to be welded is at least 120 feet long, and can be over two miles long. The internal plug-in soldering machine disclosed in this document has on-board battery power and can be used to perform a connection in the root solder passage and, optionally, also a hot solder passage of the interior of the tube.

[0909] In one modality, the tubes are externally aligned. Like the internal welding machine described in this document, the plug-in welder can be provided with just a single welding head (with a single welding torch) or a plurality of welding heads (eg anywhere from 2 to 8 , just for example).

[0910] As shown in FIGS. 103C and 103D, and as will be appreciated from the foregoing discussions contained herein, the plug-in welding machine 9000 has a nose cone section 9002 for electronics, support wheels 9004, an onboard welding power supply 9006, and a pair of 9008 clamps that ensure the plug-in internal welder is concentric to the tube. As will be described in more detail later, the plug-in welder includes 9010 clockwise and counterclockwise solder head "cartridges" with individual lasers and 2D color cameras. In FIGS. 103C and 103D, the plug-in welding machine is shown positioned within a slightly curved 9012 tube (e.g., angled 30D) with an internal diameter of 38 inches. As also shown in FIG. 103C and 103D, the socket welder has a 9014 drive and brake system that has 90 degrees of travel to reduce length, as well as an on-board power supply (ie, battery) 9020 for the drive motor and brakes.

[0911] As will be appreciated from FIGS. 103E-J and the description below, the model shown has four weld heads, two that rotate clockwise (9022 and 9024 weld heads) during a weld operation and two that rotate counterclockwise (weld heads 9032 and 9034) during a welding operation. In an alternative embodiment, all 4 solder heads shown are rotated in a single rotational direction as described elsewhere in this order. In addition, in the embodiment shown in Fig. 103E-J, four onboard welding power supplies (eg, batteries), labeled 9042, 9044, 9046, 9048, are provided. The more solder heads/torches provided, the shorter the solder cycle time can be. This is true whether welding is done in a single rotation direction or both clockwise and counterclockwise directions. However, it should be appreciated that turning in a single direction of rotation may be faster than turning clockwise and counterclockwise, the latter of which may employ a reversal of motor direction.

[0912] Each 9022, 9024, 9032 and 9034 welding head has the following equipment: a welding torch, at least one torch motor of the type described above to allow angular, axial and lateral movements of each torch, a wire feeder , wire straightener and wire coil to feed the welding wire material into the welding torch. A laser detector/inspection device of the type described above is also provided to guide the welding torch and inspect the weld. In addition, a color CCD/CMOS camera is used to inspect the weld in the manner described above.

[0913] Each weld head is associated and connected to one of the four power supplies 9042, 9044, 9046, and 9048. The four weld heads and four power supplies are mounted on a 9050 swivel assembly. The swivel assembly performs the same function as the rotating hub 5078 described above. The rotating assembly can be driven by one or more drive motors as described above.

[0914] To carry out a welding operation, the plug-in welding machine is fed into an open end of one of the tubes, for example, the shorter tube or the one with the smallest obstructions to be expelled. The face of the second tube is matched and aligned (outside) with the face of the first tube. The plug-in welding machine is driven to where the weld heads are directly at the pipe interface region. The laser detector provides feedback, and at least one welding torch motor aligns the welding torch tips to the proper position on the interface. The 9008 clamps are actuated and expanded (acts like an expander) to make the binding welding machine concentric with the tubes, and the clamps are engaged to maintain position in the socket welding machine. When the socket welding machine is held by the clamps, the axis of rotation of the rotary mechanism 9050 is coaxial with the longitudinal axis of the tube 9012.

[0915] In one embodiment, welding is achieved by first operating weld heads 9032 and 9034 in a counterclockwise direction. As shown in FIG. 103H, the four solder heads are rotatably spaced 90 degrees apart. Solder heads 9032 start in the direction of the 12-hour hand and 9034 start in the direction of the 9-hour hand as shown in FIG. 103H, as they begin to weld. Rotary assembly 9050 rotates 90 degrees until solder head 9032 ends in the direction of the 9 o'clock hand and solder head 9034 ends in the direction of the 6 o'clock hand (see progression through Figures 103H and 103I). At this point, weld heads 9032 and 9034 stop welding (in figure 103I) and weld heads 9022 and 9024 begin welding (in figure 103I). The one or more orientation motors then rotate the 9050 swivel mount clockwise as shown in Fig. 103J until the 9022 weld head ends in the 3 o'clock direction and the 9024 weld head ends in the 3 o'clock direction. 6 hours. In this way a complete root weld pass is completed.

[0916] After the root weld has been placed, the rest of the weld can be completed from the outside, using automatic welding machines or manually. The expanders or clamps are then disengaged and the plug-in welder is extruded into the open end of the tube.

[0917] In one embodiment, each of power supplies 9042, 9044, 9046 and 9048 comprises a rechargeable battery cartridge that can be inserted into an associated opening 9062, 9064, 9066 and 9068. When inserted into the opening, the cartridge battery electrically connects to its associated solder head. Each battery cartridge can be easily removed for recharging and then replaced.

[0918] As shown, the socket welder has a 9014 self-powered drive and brake mechanism, powered by the onboard welding power source 9020. This socket welder can utilize all attributes of the internal welding machine without the feed capability on board, in several of the previous modes described in this document.

[0919] In this described socket welding mode, it can be seen that a plurality (eg two) of the welding torches are dedicated to clockwise welding, while another plurality (eg two) is dedicated to anti welding. -hourly. Also, as described, all welding torches drive the weld in a downward direction. As such, the welding torches can optionally be fixed at a predetermined welding angle (this is true for any of the internal welding machines described in this document, whether it is an unpeeled fitting type or a tethered fitting type) so that the torch tip is pointing in the forward weld direction (the weld set is being “pushed”). Alternatively, as discussed above in relation to FIG. 56A, the welding torches can be mounted for rotational movement relative to point P, so that the axis of the welding torch A can be positioned on either side of the radial line R. This alternative allows for the same sequence of Welding is used for both clockwise and counterclockwise welding by rotating the welding torch so that it can rotate in the forward welding direction, regardless of whether the weld is conducted in a clockwise or counterclockwise direction.

[0920] In one embodiment, the welding torch is configured to be positioned externally to the first tube 1022a and/second tube 1022b to provide an external welding operation. In one embodiment, the externally positioned welding torch is mounted to an outer surface of tubes 1022a, 1022b.

[0921] In one embodiment, referring to FIG. 86, the present patent application provides purge and inspection system 7001. For example, in one embodiment, the first segment of tube 1022a and the second segment of tube 1022b may each be made completely or in part from some alloy materials. corrosion resistant (CRA) which may require shielding gas on both sides of the weld. In one embodiment, purge and inspection system 7001 may be positioned internally within tubes 1022a, 1022b to provide a purge gas chamber 7054 (as shown in Figure 89) within tubes 1022a, 1022b and around the region of interface 5136 (as shown in Figure 97), while an external 7500 weld system (as shown in Figure 97) performs the welding procedure (including the 1002 root pass weld procedure, the 1004 hot pass weld procedure and the fill and cap welding procedure 1006) at the 5136 interface region of outside tubes 1022a, 1022b.

[0922] In one embodiment, the 7001 purge and inspection system also provides internal clamps that are positioned internally within the tubes 1022a, 1022b to be welded. That is, in one embodiment, clamps 7050 and 7052 of purge and inspection system 7001 are configured to secure the inner surfaces 5130, 5132 (as shown in figure 33) of tubes 1022a, 1022b to be welded.

[0923] In one embodiment, the 7001 purge and inspection system also provides inspection detector 7042 and/or inspection camera 7044 which are positioned internally within tubes 1022a, 1022b. In one embodiment, inspection detector 7042 and/or inspection chamber 7044 of purge and inspection system 7001 is positioned in purge gas chamber 7054 of purge and inspection system 7001. In one embodiment, one or more processors 7062 (as shown in figure 90) of purge and inspection system 7001 is configured to interface with inspection detector 7042 and/or inspection camera 7044 to scan the 5136 interface region between tubes 1022a, 1022b to determine the profile of the region interface 5136 between tubes 1022a, 1022b before, during and subsequent to the welding process, to generate pre-weld profile data, real-time weld profile data and post-weld profile data based on the digitized and to control the 7500 external welding system or its operation based on generated pre-weld profile data, real-time weld profile data, or post-weld profile data.

[0924] In one embodiment, the purge and inspection system 7001 can be used for the first segment of tube 1022a and second segment of tube 1022b having an outer diameter of 26 to 28 inches. In one embodiment, purge and inspection system 7001 can be used for first segment of tube 1022a and second segment of tube 1022b having an outside diameter of less than 24 inches.

[0925] In one modality, the 7001 purge and inspection system includes a forward section 7002, a center section 7004, and a drive section 7006. In one modality, the structure, configuration, components, and operation of the section further on, the center section and drive section of the 7001 purge and inspection system are similar to the later section, center section and drive section of the 5004 internal welding system described in detail above, and therefore the structure, configuration, components and operation of the later section, center section and actuation section of the 7001 purge and inspection system will not be described in detail in this document, except for the differences noted below.

[0926] Unlike the center section of the 5004 indoor welding system, the center section 7004 does not include the welding torch assembly mounted on its rotating hub. In one embodiment, center section 7004 of purge and inspection system 7001 includes inspection detector 7042 mounted on its rotating hub 7012. In one embodiment, center section 7004 of purge and inspection system 7001 includes inspection detector 7042 and the 7044 inspection camera mounted on its 7012 rotating hub. In one embodiment, the 7004 center section of the 7001 purge and inspection system includes the 7044 inspection camera mounted on its 7012 rotating hub.

[0927] In one embodiment, the frontmost section 7002 houses all purge support components. In one embodiment, the center section 7004 is the part of the 7001 purge and inspection system that lines up the pipe, seals the purge area, and inspects the weld. In one embodiment, the 7006 drive section houses the batteries, compressed air, and purge gas that the rest of the 7001 purge and inspection system needs to operate.

[0928] FIG. 87 shows a detailed view of the previous 7002 section of the 7001 purge and inspection system and FIG. 88 shows a detailed view of a furthest section 7002 purge assembly. In one embodiment, the furthest section 7002 of the 7001 purge and inspection system includes a trailer hitch, a furthest electronics module, an inspection ring. front slide, a front clamp control valve, a front position sensor, adjustable ramps, a forward section frame, guide wheels, a front rotation motor and a 7104 front rotation coupling, and the frame and the Functions of each of these components are similar in the forward section of the 5004 internal welding system.

[0929] In one embodiment, the forward section 7002 of the 7001 purge and inspection system does not include a wired feed assembly. Instead, the front 7002 section of the 7001 purge and inspection system includes the 7014 purge assembly.

[0930] In one embodiment, the bleed assembly 7014 is rotatably connected to the rotating hub 7012 of the center section 7004 such that when the rotating hub 7012 is rotated by the first and second rotation motors, the bleed assembly, connected to rotating hub 7012, also rotates with rotating hub 7012.

[0931] In one embodiment, purge assembly 7014 is configured for house valves, sensors, and regulators to control the flow of purge gas in purge gas chamber 7054. In one embodiment, purge assembly 7014 is also configured to house electronics to operate all components in the purge assembly and the 7012 rotating hub.

[0932] In one embodiment, referring to FIG. 88, purge assembly 7014 includes a lower purge valve 7016, a primary lower purge regulator 7018, a secondary lower purge regulator 7020, an upper purge valve 7022, an upper purge regulator 7024, an oxygen sensor 7026 , a 7028 pump, a 7030 purge assembly frame, and a 7032 electronic purge module.

[0933] In one embodiment, the lower purge valve 7016 is configured to control the flow of purge gas in the purge gas chamber 7054. In one embodiment, the lower purge is generally referred to as a purge when the purge system is inspection 7001 is maintaining the inert atmosphere within purge gas chamber 7054. In one embodiment, the outlet of the lower purge valve 7016 passes to the lower primary purge regulator 7018. In one embodiment, the lower purge valve 7016 is always open (or on) except when seals 7046 and 7048 (as shown in figure 89) are not inflated and there is no purge in the 7001 purge and inspection system.

[0934] In one embodiment, the 7018 lower primary purge regulator is configured to reduce the purge gas pressure from a pressure of 5 psi to a pressure of 0.5 psi. In one modality, the output of the 7018 lower purge primary regulator passes to the 7020 lower purge secondary regulator. In one modality, the 7018 lower purge primary regulator is configured to be manually configured.

[0935] In one embodiment, the 7020 lower purge secondary regulator is an electronic device that is configured to control the pressure (between 0.1 and 0.5 psi) of the purge gas flowing to the 7054 purge gas chamber through closed-loop feedback. In one embodiment, the output of secondary purge regulator 7020 goes to purge gas chamber 7054.

[0936] In one embodiment, the upper purge valve 7022 is configured to control the flow of purge gas in the purge gas chamber 7054. In one embodiment, the upper purge is generally referred to as a purge when the purge system is inspection 7001 is establishing the inert atmosphere within purge gas chamber 7054. In one embodiment, the outlet from the upper purge valve 7022 goes to the upper purge regulator 7024. In one embodiment, the upper purge valve 7022 is set to turn off when oxygen (measured by oxygen sensor 7026) in purge gas chamber 7054 is below a predetermined oxygen content value.

[0937] In one embodiment, the 7024 upper purge regulator is configured to reduce the purge gas pressure from the supply pressure (up to 75 psi) to the maximum desired maximum purge pressure (typically 5-20 psi). In one embodiment, the output from upper purge regulator 7024 goes to purge gas chamber 7054. In one embodiment, upper purge regulator 7024 is configured to be manually configured. In one embodiment, upper purge regulator 7024 is configured to be open or operational until the oxygen (measured by oxygen sensor 7026) in purge gas chamber 7054 is below a predetermined oxygen content value.

[0938] In one embodiment, oxygen sensor input 7026 is connected to an output port of purge gas chamber 7054. In one embodiment, oxygen sensor 7026 is operatively linked to 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 the oxygen content of the gas in the purge chamber 7054 and to send oxygen content data, which is indicative of the oxygen content of the gas in purge chamber 7054, to one or more processors 7062. In one embodiment, oxygen sensor 7026 is configured to measure the oxygen level present in the gas leaving the purge gas chamber 7054 and send the oxygen content data to the purge electronics module 7032.

[0939] In one embodiment, one or more 7062 processors are configured to allow the welding operation after the amount of oxygen between the first seal and second seal 7046 and 7048 is below a predetermined threshold level or oxygen content value . In one embodiment, one or more 7062 processors 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 data oxygen content values are greater than the predetermined oxygen content value. In one embodiment, based on the excess oxygen gas signal, the 7100 purge and clamp system can be configured to open the upper purge regulator 7024 to allow purge gas (from the 7070 purge gas source/tank ) flow into purge chamber 7054 until the measured oxygen content drops below the predetermined oxygen content value. In one embodiment, based on excess oxygen gas signal, one or more 7062 processors of the 7100 purge and clamp system can send communication signals to the 7500 external welding system to stop the welding process.

[0940] In one modality, the predetermined value of oxygen content is 500 parts per million (ppm). In one embodiment, the oxygen content value can be within a predetermined range of 50 to 100 ppm.

[0941] In one modality, during bottom purge, the low pressure in purge gas chamber 7054 does not generate sufficient flow through oxygen sensor 7026. In one modality, pump 7028 is used to extract gas through the oxygen sensor. oxygen 7026 from purge gas chamber 7054. In one embodiment, pump 7028 can be used continuously or intermittently. In one embodiment, pump 7028 is used for the bottom purge operation.

[0942] In one embodiment, purge electronics module 7032 is configured to pass upstream communications through front slip ring 7034 to forward section electronics module 7036. In one embodiment, purge electronics module 7032 is configured to pass downstream communications through the 7038 rear slip ring to the 7040 center section electronics module.

[0943] In one embodiment, the electronic purge module 7032 is configured to control all sensors and valves attached to the rotating hub 7012 of the center section 7004. For example, in one embodiment, the electronic purge module 7032 is configured to control the oxygen sensor 7026, pump 7028, lower purge valve 7016, upper purge valve 7022, and secondary lower purge regulator 7020. In one embodiment, the electronic purge module 7032 is configured to communicate with and control a or more 7042 inspection detectors and the 7044 camera.

[0944] 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 in the center section of the inner welding system 5004. FIG. 91 shows a detailed view of purge seal 7046 or 7048 and FIG. 92 shows a detailed view of the rotating hub 7012.

[0945] In one embodiment, as discussed above, the forward section frame 7002 is connected to the front bracket 7050 (as shown in figure 95) of the center section 7004, and the purge assembly 7014 is rotatably connected to the rotating hub 7012 .

[0946] In one embodiment, center section 7004 of purge and inspection system 7001 includes front clamp 7050, first and second pipe engagement structures 7050 and 7052, inspection detector 7042, inspection chamber 7044 (such as shown in Figure 92), a rear clamp 7052, a rear clamp control valve 7058, a center section electronic module 7040, underside wheels, a center section frame, adjustable ramps, the rear swivel joint 7072, the rear rotation motor, a rear position sensor, rotation module 7012, purge seals 7046 and 7048, and rear slip ring 7038.

[0947] In one embodiment, bleed seals 7046 and 7048 are configured to inflate at the same time clamps 7050 and 7052 are actuated. When both vent seals 7046 and 7048 are inflated, they are constructed and arranged to engage with inner surfaces 5130, 5132 of tubes 1022a, 1022b, respectively forming chamber 7054 therebetween. In one embodiment, purge seals 7046 and 7048, when inflated, engage opposite sides of interface region 5136. In one embodiment, chamber 7054 is a closed volume that may be referred to as a purge gas chamber 7054. In one embodiment, chamber 7054 is constructed and arranged to receive a purge gas (or an insertion gas) therein.

[0948] In one embodiment, the front clamp control valve 7056 and the rear clamp control valve 7058 are continuous 4-way directional valves (eg with four hydraulic connections, corresponding to the inlet (P), ports of actuator (A and B) and return port (T) and a physical signal port connection (S)). For example, in one embodiment, one of the A or B actuator ports are used to extend its corresponding 7050 or 7052 clamps and inflate the respective corresponding 7046 or 7048 seal and the other one of the A or B actuator openings is used to retract the respective corresponding calipers 7050 or 7052 and deflate the corresponding seal 7046 or 7048.

[0949] FIG. 93 shows a detailed side view of actuation section 7006 of purge and inspection system 7001. In one embodiment, actuation section 7006 of purge and inspection system 7001 includes 7070 shielding gas tanks, batteries, electronic section module 7064 drive motors, pneumatic valves, sprockets, 7068 drive motors, brakes and compressed air tank, and the structure and operation of each of these components are similar in the drive section of the 5004 internal welding system.

[0950] FIG. 94 shows a schematic diagram showing the flow of purge gas through the 7001 purge and inspection system, where some components of the 7001 purge and inspection system are not shown for clarity and to better illustrate the other components and/or features of the purge and inspection system 7001.

[0951] In one embodiment, an inert/purge gas supply line is configured to communicate the inert/purge 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 gas source/purge 7070 is directed to the region 7054 between the first seal and the second seal 7046 and 7048 to reduce oxidation during a welding operation.

[0952] Referring to FIG. 94, 7070 purge gas tanks are shown in actuation section 7006 of purge and inspection system 7001. In one embodiment, a high pressure regulator 7074 can be positioned in actuation section 7006 of purge and inspection system 7001. In one embodiment, high pressure regulator 7074 may be positioned in center section 7004 of purge and inspection system 7001. In one embodiment, rear swivel 707, swivel hub 7012, purge gas chamber 7054, clamps front and rear 7050 and 7052, and front and rear seals 7046 and 7048 are shown in the 7004 center section of the 7001 purge and inspection system. The 7016 lower purge valve, the 7018 lower purge primary regulator, the secondary purge regulator The lower 7020, upper purge valve 7022, upper purge regulator 7024, oxygen sensor 7026, and pump 7028 are shown in the front 7002 section of the 7001 purge and inspection system.

[0953] In one embodiment, the 7070 purge gas tanks 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 swivel joint 7072. In one embodiment, the purge gas tanks 7070 are in fluid communication with the rear swivel joint 7072 through a 7071 valve and the 7074 high pressure regulator. In one embodiment, the 7074 high pressure regulator is configured to automatically shut off the purge gas flow at a pressure of 75 psi. That is, the 7074 high pressure regulator is typically configured to reduce the pressure in the 7070 purge gas tanks to about 75 psi in the fluid communication line downstream of the 7074 high pressure regulator and the 7072 rear rotary union to the lower bleed valve 7016 and the upper bleed valve 7022.

[0954] In one embodiment, the rear rotary union 7072 is in fluid communication through fluid communication lines with the lower purge valve 7016 and the upper purge valve 7022. In one embodiment, the purge gas is stored in the tanks of purge gas 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 lower purge valve 7016 and the high purge valve 7022.

[0955] In one embodiment, the top purge regulator 7024 is connected to an outlet of the top purge valve 7022. That is, the top purge regulator 7024 is positioned downstream of the top purge valve 7022. In one embodiment, the 7024 upper bleed regulator is adjusted to reduce the pressure output through the 7022 upper bleed valve to typically between 30 and 5 psi in the fluid communication line downstream of the 7024 upper bleed regulator and between the 7024 upper bleed regulator and the purge gas chamber 7054.

[0956] In one embodiment, a fluid communication line extends from the lower bleed valve 7016 to the lower bleed primary regulator 7018. In one embodiment, the 7018 lower bleed primary regulator is connected to an outlet of the bleed valve. lower bleed 7016. That is, the primary lower bleed regulator 7018 is positioned downstream of the lower bleed valve 7016.

[0957] In one embodiment, the 7018 lower bleed primary regulator is typically configured to reduce the pressure output through the 7016 lower bleed valve to about 0.5 to 5 psi in the fluid communication line downstream of the primary bleed regulator. 7018 lower bleed and between the 7018 low primary bleed regulator and the 7020 lower bleed secondary regulator.

[0958] In one embodiment, a fluid communication line extends from the 7018 lower bleed primary regulator to the 7020 lower bleed secondary regulator. In one embodiment, the 7020 lower bleed secondary regulator is positioned downstream of the primary regulator of lower purge 7018.

[0959] In one embodiment, the 7020 lower purge secondary regulator is adjusted to reduce the pressure output by the 7018 lower purge primary regulator to typically between 0.1 and 0.5 psi in the fluid communication line downstream of the regulator lower purge secondary 7020 and between the lower secondary purge regulator 7020 and the purge gas chamber 7054.

[0960] In one embodiment, the welding procedure is initiated at a pressure of about 0.5 psi and, during the welding process, when the purge gas leakage through the weld joint decreases as a result of welding (by For example, based on how much space between the pipe ends are welded together), the 7020 lower secondary purge regulator can then be throttled back to 0.1 psi.

[0961] In one embodiment, the pump 7028 is in fluid communication (through fluid communication lines) with the outlet/release port of the purge gas chamber 7054 on one side and is in fluid communication (through fluid communication lines) with the 7026 oxygen sensor on the other side. In one embodiment, pump 7028 is in fluid communication with the outlet of purge gas chamber 7054 such that pump 7028 is configured to operate (continuously or intermittently) to withdraw a sample of gas from the chamber. of purge gas 7054.

[0962] In one embodiment, the purge gas from the purge gas tanks 7070 is used only to fill and hold the purge gas in the purge gas chamber 7054. In one embodiment, compressed air is used to inflate the seals 7046 and 7048 and to expand clamps 7050 and 7052. In one embodiment, actuation section 7006 of purge and inspection system 7001 may include both purge gas tanks 7070 as well as compressed air gas tanks.

[0963] FIG. 95 shows a schematic diagram showing the flow of compressed air through the 7001 purge and inspection system, where some components of the 7001 purge and inspection system are not shown for clarity and to better illustrate the other components and/or features of the purge and inspection system 7001.

[0964] The compressed air flow through the 7001 purge and inspection system in FIG. 95 is similar to the flow of compressed air through the internal welding system 5004 in FIG. 70, except for the differences noted below.

[0965] 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 seal rear 7046 and is configured to supply compressed air to expand the rear seal 7046 of the rear clamps 7052. In one embodiment, one outlet of valve 7076 is configured to supply compressed air to expand the rear clamps 7052 and the other outlet of valve 7076 is configured to supply compressed air to inflate the 7046 rear seal.

[0966] 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 seal front 7046 and is configured to supply compressed air to expand front clamps 7050 and front seal 7046. In one embodiment, one outlet of valve 7082 is configured to supply compressed air to expand front clamps 7050 and the other outlet of valve 7082 is configured to supply compressed air to inflate the 7046 front seal.

[0967] FIG. 96 shows a schematic diagram showing the flow of purge gas through the 7001 purge and inspection system, where some components of the 7001 purge and inspection system are not shown for clarity and to better illustrate the other components and/or features of purge and inspection system 7001. For example, in one embodiment, in smaller purge and inspection systems 7001, purge gas is used not only to fill and hold the purge gas in purge gas chamber 7054, but also to inflate seals 7046 and 7048 and to expand clamps 7050 and 7052.

[0968] The purge gas flow through the 7001 purge and inspection system in FIG. 96 is similar to the purge gas flow through the 7001 purge and inspection system in FIG. 94, except for the differences noted below.

[0969] In one embodiment, the rear swivel joint 7072 is in fluid communication through fluid communication lines with the lower bleed valve 7016, the upper bleed valve 7022, and the front swivel 7104. In one embodiment, the Purge gas stored in 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 lower 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 swivel 7072 to the front swivel 7104. The front swivel has essentially the same components and operates essentially in the same way as the front swivel joint 5032 shown in FIG. 25 and is therefore not illustrated in the same detail as the front swivel joint 5032.

[0970] In one embodiment, purge gas is sent through the fluid communication lines from the rear swivel joint 7072 to the rear clamp control valve 7058. In one embodiment, the purge gas from the rear clamp control valve 7058 is provided through fluid communication line 7088 to expand rear clamps 7052 and is provided through fluid communication line 7090 to inflate rear seal 7048. In one embodiment, a 7092 pressure regulator is positioned in the communication line of fluid 7090 and is configured to automatically shut off the purge gas flow to seal 7048 at a predetermined pressure. In one embodiment, purge gas from the rear clamps 7052 is received by the rear clamp control valve 7058 through fluid communication line 7094 to retract the rear clamps 7052.

[0971] In one embodiment, 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 provided through fluid communication line 7098 to expand front clamps 7050 and is provided through fluid communication line 7100 to inflate front seal 7046. In one embodiment, a pressure regulator 7102 is positioned in the communication line of fluid 7100 and is configured to automatically shut off the flow of purge gas to seal 7046 at a predetermined pressure. In one embodiment, purge gas from the front clamps 7050 is received by the front clamp control valve 7056 through fluid communication line 7096 to retract the front clamps 7050.

[0972] FIG. 97 shows a partial view of purge and inspection system 7001 where inspection detector 7042 and camera 7044 are configured to carry out inspection from inside the tubes while an external welding torch 7502 of external welding system 7500 is configured. to perform external welding to tubes 1022a, 1022b. In one embodiment, the externally positioned welding torch 7502 may be mounted to an outer surface of one of the first tube and the second tube 1022a, 1022b.

[0973] For example, in FIG. 97, an ideal alignment of the welding torch 7502 to a bevel 7106 (along the longitudinal axis AA of tubes 1022a, 1022b) is shown. FIG. 98 shows a close-up view of welding torch 7502 being perfectly aligned with bezel 7106. Tubes 1022a, 1022b shown in FIGS. 97 and 98 are perfectly aligned and have no Hi-Lo.

[0974] FIGs. 99 and 100 show close-up views of the external welding torch of the external welding system used in a prior art system and the 7001 inspection and purge system, respectively, where the tubes have a radial displacement clearance and alignment (Hi-Lo ). For example, as shown in FIGS. 99 and 100, tubes 1022a, 1022b have a spacing of 1 millimeter and radial displacement (Hi-Lo).

[0975] As shown in FIG. 99, in the prior art system, the raised edge of the pipe protects the right side of the weld groove, causing reduced weld penetration. As shown in FIG. 100, the 7500 external welding system used with the 7001 inspection and purge system is configured to receive weld profile data (for example, before, during and subsequent to the welding procedure) from the 7001 inspection and purge system and is configured, based on the received weld profile data, to offset the external welding torch 7502 and/or to tilt the external welding torch 7502 to obtain full weld penetration. Thus, the weld profile data from the 7001 inspection and purge system can be used by the 7500 external welding system to make a better weld.

[0976] The operation of the 7001 purge and inspection system is now described. In one modality, the 7001 purge and inspection system is configured to be operated through a repeated operating cycle.

[0977] After it is determined that a weld has been completed on the current weld joint, one or more 7062 processors (from a 7060 computer system) are configured to send communication signals to the 7032 purge electronics module for control (via control signals) the 7016 low purge valve, 7022 upper purge valve, and 7020 lower purge regulator to empty the 7046 and 7048 purge seals. The one or more 7062 processors are also configured to send communication signals to the forward section electronic module 7036 to control/switch off (via control signals) the front clamp control valve 7056 to retract the first coupling frame 7050 to its original and retracted position and/or to deflate the purge seal 7046. One or more processors 7062 are also configured to send communication signals to the center section electronics module 7040 for control/off (via control signals) the 7058 rear clamp control valve to retract the 7052 second hitch frame to its original retracted position and/or to empty the 7048 purge seals. The 7001 purge and inspection system (including the purge seals 7046 and 7048 and clamps 7050 and 7052) has to be moved to the next solder joint.

[0978] In one embodiment, one or more 7062 processors are configured to send communication signals to the unit section electronic module 7064 to control (via control signals) the 7068 drive motors to accelerate the purge and inspection system 7001 to travel at a predetermined speed and then decelerate and stop at the next weld. In one mode, the predetermined speed at which the 7001 purge and inspection system accelerates can be 6 ft/second.

[0979] When the second 7052 mating frame is positioned on the next weld joint, the unit section electronics module 7064 sends communication signals to the purge electronics module 7032 to verify alignment with the pipe end. In one embodiment, the electronic purge module 7032 is configured to operate (turn on) one or more inspection detectors 7042 to measure where the second engagement structure 7052 is relative to the end of the tube. In one embodiment, rotating hub 7012 may not be operated when one or more inspection detectors 7042 are measuring where second engagement structure 7052 is relative to the end of the tube.

[0980] In one mode, the purge electronic module 7032 is configured, sends the measured distance information to the drive section electronic module 7064. In one mode, the steering section electronic module 7064 is configured to control (via of control signals) drive motors 7068 to move the second hitch frame 7052 by the measured distance information.

[0981] In one embodiment, when the second coupling structure 7052 is properly aligned and positioned relative to the end of the tube, the drive section electronic module 7064 is configured to send communication signals to the center section electronic module 7040 in the sense that the 7001 purge and inspection system is in position at the next weld joint. In one embodiment, center section electronics module 7040 controls (opens via control signals) rear clamp control valve 7058 to elevate second hitch frame 7052 and secure 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.

[0982] The next/new segment of pipe 1002a is then brought in and slid over the frontmost section 7002 of purge and inspection system 7001 into the work crew position. At this time, one or more processors 7062 are configured to send communication signals to purge electronics module 7032 to operate one or more inspection detectors 7042 to verify tube alignment. In one embodiment, one or more processors 7062 can rotate rotating hub 7012 to perform measurements at multiple locations.

[0983] If tube alignment data is within a predetermined tolerance, purge electronics module 7032 sends communication signals to forward electronics module 7036 to actuate and operate front clamp 7050. In one mode, the module forward electronic 7036 controls/opens (via control signals) the 7056 front clamp control valve to raise the first 7052 hitch frame and secure the new 1002a pipe segment. In one embodiment, the forward electronic module 7036 controls/opens (via control signals) the front clamp control valve 7056 to inflate the front seal 7046 at the same time.

[0984] If the tube alignment data is not within the predetermined tolerance, the purge electronics module 7032 sends communication signals (a message) to one or more processors 7062 that identify the misalignment between the tubes 1022a, 1022b. In one embodiment, this information can be transmitted to a crane operator via traditional crane operator hand signals or by an electronic signal to a computer screen terminal in the crane cab.

[0985] After tube clamping, one or more 7062 processors are configured to send communication signals to the 7032 purge electronics module to operate one or more 7042 inspection detectors to measure distance and radial displacement (Hi-Lo) at a plurality of points along the circumference of the weld joint. In one embodiment, this data is communicated to one or more 7062 processors and compared to allowable tolerances.

[0986] If the gasket fits (ie the space and radial displacement (Hi-Lo)) is within a predetermined tolerance, either one or more 7062 processors or the 7032 purge electronics module send communication signals to the operator , indicating that welding can begin.

[0987] If the joint fit (ie, the space and radial offset (Hi-Lo)) is not within the predetermined tolerance, an alert is sent to the operator, who can restart the tightening sequence or override the alert.

[0988] In one embodiment, the 7032 purge electronics module is configured to send control signals to the 7022 upper purge valve to open and the 7024 upper purge regulator to operate. In one embodiment, the purge electronic module 7032 is configured to continuously monitor the oxygen content level reading in the purge gas chamber 7054 of the oxygen sensor 7026. When the measurement data of the oxygen sensor 7026 is below a predetermined value of oxygen content (eg, 500 parts per million (ppm)), the 7032 electronic purge module is configured to send control signals to the 7022 elevated purge valve to close and the 7016 lower purge valve to open. In one modality, the measurement data from the 7026 oxygen sensor must be within a predetermined range (eg, 50 to 100 ppm).

[0989] In one embodiment, although the top purge valve 7022 is open, the purge electronics module 7032 along with the forward section electronics module 7036 and the center section electronics module 7040 are configured to use one or more detectors. inspection 7042 to measure the gap and Hi-Lo of the solder joint at a plurality of points along the circumference of the solder joint. Scan/scan results are communicated to one or more 7062 processors to pre-program the 7500 external welding system.

[0990] In one embodiment, after the lower purge valve 7016 is closed, the lower secondary purge regulator 7020 is configured to maintain a constant, determined pressure in the purge gas chamber 7054. In one embodiment, the secondary purge regulator lower 7020 is set to maintain pressure between 0.1 and 0.5 psi and is set to stop operation when pressure is above 0.5 psi.

[0991] In one modality, the pressure starts at a relatively high value (eg, 5 psi) and gets progressively lower values as the weld proceeds. In one embodiment, the lower purge secondary regulator 7020 may include a pressure sensor that is configured to communicate with one or more processors 7062. In one embodiment, the pressure sensor is configured to measure the pressure of the purge gas in the chamber. vent 7054 and sending a pressure information, which is indicative of the pressure of the purge gas in the bleed chamber 7054, to one or more processors 7062. In one embodiment, one or more processors 7062 are configured to receive the pressure data, compare the received pressure data with its predetermined pressure value and generate an overpressure signal if the pressure information 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 pressure in purge chamber 7054 until the measured pressure drops below a predetermined pressure value. In one embodiment, based on the overpressure signal, the 7100 purge and inspection system can be configured to send communication signals to the external welding system to stop the welding process.

[0992] In one modality, communication signals are sent to the umbilical in the sense that the correct purge gas level has been reached and the soldering procedure can begin. In one modality, the operator issues commands to the 7500 external welding system to start the welding process. In one modality, commands are automatically sent from one or more 7062 processors to the 7500 external welding system to start the welding process.

[0993] In one embodiment, the purge electronics module 7032, in conjunction with the forward section electronics module 7036 and the center section electronics module 7040, are configured to use one or more inspection detectors 7042 to measure the gap and Hi-Lo weld joint a short distance ahead of where the 7500 external welding system is currently welding. In one embodiment, inspection data from inspection detector 7042 can be communicated in real time to one or more processors 7062 that use inspection data to send updated weld parameters to external welding system 7500.

[0994] In one embodiment, the 7500 external welding system is configured to communicate its position to one or more 7062 processors that transmit the information to the 7032 purge electronics module so that the 7032 purge electronics module can maintain the chamber pressure. purge gas and control the position of inspection detector 7042 accordingly.

[0995] In one modality, the soldering procedure can be performed in several different ways.

[0996] In one embodiment, the soldering procedure can be performed from top to bottom on one side of the tubes and then from top to bottom on the other side of the tubes. In one modality, the first weld is completed before the second weld starts. In this situation, inspection detector 7042 scans the front of the weld in real time.

[0997] In one embodiment, the weld procedure can be performed from top to bottom on each side of the tube with the second weld starting before the finish of the first weld. In one embodiment, inspection detector 7042 scans a distance ahead of a weld faster than the welder is traveling, and then quickly shifts position to the other weld to scan faster than it travels. In one embodiment, inspection detector 7042 can alternate between the two weld locations until the first weld ends.

[0998] In one embodiment, the weld procedure can be performed all the way around the pipelines in a single pass with inspection detector 7042 scanning a short distance ahead of the weld.

[0999] In one embodiment, after the weld is complete, rotating hub 7012 continues to rotate while purge electronics module 7032 uses inspection detector 7042 and camera 7044 to inspect the weld. In one embodiment, weld inspection data is communicated to one or more 7062 processors.

[01000] In one embodiment, if one or more weld defects are detected in the weld inspection data, the weld defects can be repaired while clamps 7050 and 7052 are still in position and purge gas chamber 7054 is still filled with inert gas.

[01001] In one mode, once the inspection and any repairs are completed and verified by the operator, the operator sends a command to the forward section electronic module 7036 and the center section electronic module 7040 to turn off the valves front and rear clamp control buttons 7056 and 7058, lower/retract clamp shoes 7050 and 7052, and deflate seals 7046 and 7048.

[01002] In one embodiment, one or more 7062 processors of the 7100 purge and inspection system can be operatively connected to the most advanced electronics module of the 7100 purge and inspection system, the 7032 purge electronics module, the central section electronics module of the 7100 purge and inspection system, and the 7064 drive section electronics module.

[01003] In one embodiment, the field system of the present application may include one or more splitters/cubes/routers that are configured to transmit data, control signals and communication signals between one or more 5140 or 7062 processors and a or more electronic modules described in this order.

[01004] During pipeline formation procedures (for example, for offshore or terrestrial (onshore) applications, one section of pipe 1022a or 1022b is connected to another section of pipe 1022b or 1022a in a socket weld (the location on which the two pipe sections are welded together) aligning the two facing ends of the pipe sections and forming the solder joint 1026. Such a solder joint 1026 connects the two pipe sections 1022a, 1022b at their facing ends, so that the 1026 solder joint produces a hermetic seal and thus a continuous fluid passage between the two joined pipe sections. Each pipe section 1022a, 1022b can be considerably long (eg hundreds or thousands of feet or up to 1 mile), which makes internal cooling difficult within the pipe sections 1022a, 1022b at or near the socket weld location after the weld joint 1026 has been formed. In particular, the placement of a cooling structure as well how removing such a structure internally within pipe sections 1022a, 1022b for cooling in solder joint 1026 could be a challenge.

[01005] The internal cooling system of the present application provides internal cooling within the tube sections 1022a, 1022b after the tube sections have been clamped together through the solder joint 1026. In one embodiment, the internal cooling system can be a Internal heat exchanger which may be referred to as "IHEX". In one embodiment, the internal cooling system includes a cooling section to provide direct cooling to inner surface portions of tube sections 1022a, 1022b and a control or controller section that is configured to control components of the cooling section, and beyond further configured to facilitate the mobility of the internal cooling system within the tube sections 1022a, 1022b. In one embodiment, the cooling section utilizes a cooler to provide cooling internally in tube sections 1022a, 1022b. In one embodiment, the internal cooling system may further include a cooler supply section that includes a 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 application includes a mechanism configured to internally cool the tube sections 1022a, 1022b after they are welded together, as well as a mechanism for placing the internal cooling system internally and recovering the internal cooling system from the pipe sections 1022a, 1022b during the pipe forming process, which results in a reduction in the time needed to cool the pipe sections after heating and also an ongoing acceleration through the stations required for manufacturing.

[01006] FIG. 104 shows an exemplary 2010 internal cooling system of the present application. In one embodiment, the internal cooling system 2010 includes a suitably rigid frame housing components of the internal cooling system, the frame comprising a plurality of longitudinally extending rods 2019, 2021 constructed of one or more suitable materials (by example, a metal such as steel or other suitably rigid and durable materials) and has a suitable configuration to allow insertion of the frame into pipe sections to facilitate internal cooling within pipe sections 1022a, 1022b.

[01007] A 2011 first section of the frame includes a 2012 coolant supply source composed of one or more tanks (a single tank is shown in Fig. 104) protected within the 2011 first section. coolant may include any suitable coolant, 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 frame location adjacent to the first section 2011 and communicates with the coolant supply source 2012 through a suitable 2014 valve structure (eg shown in figure 104 as an or plus valves, regulators, piping, etc.) which facilitates the delivery of coolant from the 2012 coolant supply source to the 2007 coolant section outlet ports 2016 at one or more appropriate pressures and/or flow rates.

[01008] A third section 2018 of the frame is disposed adjacent to the cooling section 2016 and comprises a plurality of rods 2021 that form a caged housing around a controller 2020. A pneumatic and/or electronic drive system 2022 may also be by the least partially disposed within the 2018 third section and may include one or more rollers controlled by the 2025 engine and/or any other suitable locomotive structure(s) configured to engage the inner surface portions of pipe sections when the 2010 internal cooling system is disposed within such sections of pipe to control the movement of the 2010 internal cooling system in forward and reverse directions within sections of pipe during procedures as described in this document. In one embodiment, the 2022 drive system may be in communication (e.g., wired or wireless communication) with the 2020 controller to facilitate the control, through the 2020 controller, of forward and backward movements of the internal cooling system 2010 during procedures (eg control of a 2022 drive system motor by the 2020 controller controls the rotation of the roller(s) and therefore the forward or backward movement of the 2010 internal cooling system). In one embodiment, drive system 2022 can be substantially encompassed within and/or as part of the frame of internal cooling system 2010. In one embodiment, drive system 2022 can include a frame that extends beyond the frame. In one embodiment, the 2022 drive system 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/reverse movement of the 2010 internal cooling system within piping sections (eg via a winch frame provided within the internal cooling system frame and/or at an anchored location outside the piping sections. tubes and in connection with the cable structure). In one embodiment, rollers can also be provided at one end of the internal cooling system 2010 (eg rollers 2023 provided at the end end of the 2011 first frame section, as shown in figure 104) to increase the mobility of the cooling system internal 2010 inside tube sections 1022a, 1022b.

[01009] In one embodiment, the 2020 controller may include at least one suitable processor that controls the operations of the 2010 internal cooling system through suitable control process logic instructions stored within a controller memory as well as provided electronic signals remotely via another user-controlled device arranged at a suitable distance from the internal cooling system. In one embodiment, the 2020 controller can be configured to communicate with a user-operable remote control device (eg, a computer, handheld control device, or any other appropriate electronic device) via electronic signals, where the Electronic signals are communicated via a wireless or hardwire network link between the 2020 controller and the remote control device. In one embodiment, the remote control device is shown in FIG. 104 as a 2030 computer (eg laptop, notepad, personal digital assistant, smart phone, etc.) that communicates with the 2020 controller via a wireless communication link (shown as the dashed line in figure 104). Electronic signal communications may include bi-directional communications between the 2020 controller and the remote control device such that the 2020 controller is configured to provide information to the remote control device (such as measured internal temperature information and/or other types of conditions measurements inside the pipe sections) as well as control information received to perform remote control operations of the 2010 internal cooling system.

[01010] In one embodiment, one or more 2017 electronic sensors may be provided in one or more suitable locations within the structure of the internal cooling system and may be in communication (via hardwired or wireless link) with the 2020 controller to provide information about conditions within the tube sections during procedures. For example, in one modality, one or more 2017 electronic sensors comprise one or more temperature sensors (eg IR temperature sensors, RTD temperature sensors, thermocouples, etc.) may be provided in one or more different locations in the first 2011 section, the 2016 cooling section and/or the 2018 third section of the 2010 internal cooling system, where the temperature sensors are configured to measure temperature and provide this measured temperature information to the 2020 controller during procedures. In one embodiment, one or more 2017 electronic sensors comprising pressure and/or flow rate sensors may be provided at one or more suitable locations within the 2012 coolant source 2012 tank(s) within the structure valve 2014 and/or near the 2007 outlet ports of the 2016 cooling section, where the measured pressure and/or flow information is provided by these sensors to the 2020 controller during the procedures. It should be appreciated that 2017 sensors can also comprise a combination of temperature and pressure sensors. In one embodiment, one or more cameras 2027, controlled by the 2020 controller (and remotely controlled by the remote control device), may also be provided in one or more suitable locations to facilitate a display within the piping sections (for example, to determine a suitable location to position the 2010 internal cooling system within pipe sections 1022a, 1022b during procedures). Examples of pressure/temperature sensors and/or cameras are shown generically at positions 2017 and 2027 in FIG. 104.

[01011] In one embodiment, the 2010 internal cooling system may include a suitable power supply to provide electrical power to the 2020 controller, the 2022 drive system, the electronic sensors, the 2014 valve structure (for example, to electronically control one or more valves and thereby control the 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 structure of the internal cooling system (for example, one or more batteries disposed in a battery provided within the third section 2018 or at any other suitable location within the structure of the system. internal cooling system). In one embodiment, the power supply source can be located outside the pipe sections, where an electrical cable connects the power supply with the 2010 indoor cooling system to supply electrical power to the various components of the indoor cooling system.

[01012] In one embodiment, the 2016 cooling section can include any suitable structure that facilitates cooling by exchanging heat with the inner solder portion as well as other inner wall portions of the pipe sections. In one embodiment, coolant from coolant supply source 2012 is supplied through valve section 2014 to coolant section 2016. In one embodiment, coolant section 2016 includes a plurality of 2007 nozzles arranged around from an outer periphery of the 2016 cooling section to facilitate a coolant flow at a suitable flow rate (as controlled by the 2014 valve section and 2007 cooling section nozzle design) from the 2016 cooling section towards the surfaces internals in the solder joint and other internal portions of the two joined tube sections.

[01013] The operation of the 2010 internal cooling system in relation to pipe welding procedures is now described with reference to FIGS. 105-107. In preparation for welding an open end of the first tube section 1022a to a forward open end of the second tube section 1022b, the two tube sections 1022a, 1022b are axially aligned in position with each other. In one embodiment, the two sections of pipe 1022a, 1022b can be held in such alignment with a snap-on clamp (not shown in Figures 105-107). A suitable mating clamp (e.g., clamps 5302 (positioned externally to the tube) as described elsewhere in this application) can be attached externally to the facing ends of the tube sections 1022a, 1022b to hold the sections 1022a, 1022b in place in relation each other during the welding process. In one embodiment, an internally mating clamp (eg, inner clamps 5142, 5144 (positioned within the tube) as described elsewhere in this application) can be used to hold the facing ends in place during the welding process. Both types of connection clamps (external and internal) are known in the tube welding art and therefore are not described in more detail in this document. After the socket clamp is applied to hold the ends of the pipe sections 1022a, 1022b in place with respect to each other, the weld joint 1026 is formed in the socket weld position (i.e., at the two open ends facing the first and second section of tubes). The solder joint 1026 is formed in the manner described in detail above and may include the root pass solder layer, the hot run solder layer, the filler pass solder layer(s) and the cover pass solder layer to ensure a properly formed solder joint. In one embodiment, formation of the solder joint 1026 may involve preheating the facing ends of the first and second tube sections 1022a, 1022b to a minimum temperature of about 150°C. The remainder of the soldering procedure can cause a temperature rise around the solder joint as high as about 300°C. After the formation of the 1026 solder joint, the 1026 solder joint is typically AUT (ultrasonic tested) and/or with X-ray inspection, as described elsewhere in this order, to confirm the quality/integrity of the solder joint. 1026. In one modality, AUT weld inspection cannot be conducted above temperatures of about 50°C to about 75°C (Tmaximum), where Tmaximum is the highest temperature at which inspection can be effectively performed. In addition, the AUT weld inspection procedure of the tube fabrication procedure must be stopped until tube temperatures near the 1026 weld joint are reduced to a temperature around such inspection temperature range. The internal cooling system of the present order is configured to remove heat from the weld area so as to reduce the temperature of the tube weld area to at least the acceptable AUT inspection temperature (Tmaximum).

[01014] In one embodiment, after the weld inspection procedure, field joint coating (FJC) is also applied to external areas of the 1022a, 1022b pipe sections that surround the 1026 weld joint to provide an insulation barrier to prevent or minimize corrosion in weld areas. Such insulation will generally only be effectively applied when the pipe temperature is above a minimum pipe temperature Tmin. Heat is therefore added to the weld area until the pipe temperature in the weld area to be insulated rises back to about 220 to 240 °C (Tmin), where Tmin is the lowest temperature at which the insulation can be effectively applied to the isolation area.

[01015] After the coating/insulation application procedure, the pipe can be coiled for field installation. However, at temperatures around Tmin, the winding procedure cannot be carried out effectively, maintaining the integrity of the weld. Therefore, the tube manufacturing procedure can again be halted as the tube temperature is gradually allowed to drop naturally (relative to ambient temperature) from Tmin to an acceptable coil temperature (Tmax), where Tmax is the maximum/plus temperature high on which the tube can be effectively coiled. In one embodiment, the internal cooling system of the present application is configured to again remove heat from the solder area so as to reduce the temperature to a maximum temperature of about 50 to about 75°C (Tmax) acceptable for the winding effective (by winding the tube onto a spool). Therefore, the internal cooling system of this order is configured to reduce the temperature before the weld inspection procedure and/or reduce the temperature before the winding procedure, in order to minimize the time required to weld, inspect, insulate and wind a length of pipe segments.

[01016] During the operational period when pipe sections 1022a, 1022b are being welded together (with subsequent application of coating/insulation), the 2010 internal cooling system is loaded within an open end of pipe section 1022a as shown in FIG. 105. In one embodiment, one or both tube sections 1022a, 1022b may comprise a single tube unit. In another embodiment, one of the tube sections 1022a, 1022b may comprise a plurality of tube units welded together. In one embodiment, when one of the tube sections 1022a or 1022b comprises a plurality of tube units already welded together, it may be desirable to load the internal cooling system 2010 into the tube section 1022a or 1022b comprising a single tube unit (or the tube section with the shortest length) in order to reduce the time required for the 2010 internal cooling system to travel within the tube section to reach the socket weld location. Thus, in one embodiment, pipe section 1022a may comprise a single pipe unit that is being connected with a longer pipe section represented by pipe section 1022b (e.g., two or more pipe units connected through joints soldering).

[01017] In one embodiment, the internal cooling system 2010 is loaded at the open end of pipe section 1022a (i.e., the end that opposes the open end facing the open end of pipe section 1022b that defines the location of socket weld) such that the first section 2011 of the internal cooling system frame serves as the front end and thus first enters into the pipe section 1022a. In one embodiment, internal cooling system 2010 is moved (leading with first section 2011) within pipe section 1022a to a suitable position close to the socket weld location, as shown in FIG. 106. In one embodiment, controller 2020 (which can be remotely controlled by a user) is configured to control the operation of the 2022 drive system (for example, controlling one or more motors that move the 2025 rollers in contact with wall portions internals of tube section 1022a) to facilitate advancement of the internal cooling system 2010 into tube section 1022a and towards the socket weld location. Upon reaching a suitable location close to the socket weld location (for example, an internal cooling system location as shown in Figure 106), controller 2020 can control drive system 2022 so as to stop further movement of the cooling system. 2010 internal cooling until cooling procedures are initiated. For example, a 2027 camera mounted in a suitable location in the first section 2011 and which is controlled by the 2020 controller can provide video images to the remote control device so that a user can determine the proximity of the internal cooling system to the gasket. weld 1026. In one embodiment, in combination with video images provided by the camera 2027, one or more 2017 temperature sensors are suitably located in the 2010 internal cooling system structure that measure internal temperatures within the tube section 1022a and provide such temperature information to the 2020 controller. When one or more measured temperatures reach a threshold value (eg, around 100 °C or greater), this can provide an indication that the 2010 internal cooling system has reached a location close to the gas joint. 1026 weld. Any other suitable mechanism may also be used to provide an adequate indication of the location of the welding system. internal coolant 2010 within the tube section 1022a as it moves towards the socket weld location.

[01018] Upon reaching the desired location that is close to or near the socket weld location, a cooling procedure can be performed after the 1026 weld joint is formed and prior to AUT/X-ray inspection (if necessary). In one embodiment, the cooling procedure can be performed after the tube is reheated to apply an outer coat, and an FJC has been applied (if necessary). In one embodiment, when internal cooling system 2010 reaches a suitable location within the tube section 1022a that is close to the socket weld location and prior to completion of the welding procedure, internal cooling system 2010 is held in position and is ready to be used for cooling once the soldering or reheating procedure is completed. The cooling procedure is carried out by first positioning the cooling section 2016 in a suitable location (for example, in relation to the 1026 solder joint, as shown in figure 107). This can be achieved by advancing the 2010 internal cooling system from its position in FIG. 106 to its position in FIG. 107 via the 2020 controller (which is user controlled via the remote control device) controlling the 2022 drive system until the 2010 internal cooling system is in the desirable position. Movement to such a location (e.g. as shown in Fig. 107) can be achieved based on video images within the tube sections 1022a, 1022b being provided to the remote control device, temperature sensor information being provided to the device. remote control and/or via any other suitable mechanism.

[01019] Upon reaching a desired location within the pipe sections 1022a, 1022b (for example, where the cooling section 2016 is arranged next to the weld joint 1026 as shown in figure 107), the controller 2020 (which can be controlled by the user through the remote control device) controls the operation of the 2014 valve structure (for example, through the control of one or more electronic valves) to facilitate a coolant flow from the coolant supply source 2012 to a pressure and/or flow rate suitable for the 2016 coolant section, where coolant flows from the 2007 nozzles arranged in the 2016 coolant section and suitably oriented to direct the coolant flow away from the 2016 coolant section and towards the inner wall surface portions within the tube sections 1022a, 1022b. The temperature sensor(s) monitor the internal temperature in the 2010 internal cooling system within the 1022a, 1022b pipe sections and provide measured temperature information to the 2020 controller. Upon reaching a sufficient temperature within the 1022a pipe sections , 1022b (measured by the temperature sensor(s), eg a temperature of Tmax °C or lower), the 2020 controller can control the 2014 valve frame to stop the flow of coolant to the cooling section 2016.

[01020] In one embodiment, the 2010 internal cooling system can be moved in forward or backward directions by controlling the 2022 drive system by the 2020 controller to provide additional cooling procedures (as desired and based on temperatures inner tube measurements) at other locations along inner wall surface portions of tube section 1022a and/or tube section 1022b. When it has been determined that sufficient cooling has been achieved, the internal cooling system 2010 can be removed from the connected pipe sections 1022a, 1022b. For example, internal cooling system 2010 can be moved in reverse, controlling drive system 2022 through controller 2020, to move towards the free and open end of pipe section 1022a so that third section 2018 first emerged from the tube section 1022a. Another section of pipe can then be aligned (the internal cooling system may remain within section 1022a as the new section is adjusted to 1022a) with the free and open end of pipe section 1022a (now connected through the gasket of weld 1026 with the tube section 1022b) to form a socket weld location, and the process is then repeated in which the internal cooling system 2010 enters through the free and open end of the additional tube section and is advanced towards the Socket weld location to perform cooling procedures on the weld joint to be formed between the pipe sections.

[01021] While the drive system 2022 shown in the mode of FIGS. 104-107 comprises the 2025 rollers operable by an engine system which is controlled by the 2020 controller, the 2022 drive system for the internal cooling system can also implement any suitable mechanism capable of providing user-controlled movements of the internal cooling system within of the tube sections. For example, one or more cable/winch systems can be implemented, in which one or more winches can 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 (on the internal cooling system or a connection point external to the piping sections) in order to facilitate placement of the internal cooling system in there and/or removal of the system from internal cooling of tube sections during procedures.

[01022] Note that the procedures described above in relation to the internal cooling system can be performed for any type of socket welding applications between sections of pipe in a piping system. For example, the internal cooling system can be used to create pipelines for marine, underwater, as well as mainline applications. In one embodiment, the 2010 internal cooling system can be used for the coil base socket weld sequence (as shown in description in relation to Figure 6) and the barge weld sequence (as shown in description in relation to Figure 6). figure 7).

[01023] In a mainline application, pipe sections from 40 feet (12 meters) to 80 feet (24 meters) are welded together to form long "connecting" sections. In scenarios where an umbilical cord may be required to control the movement and/or other procedures of the internal cooling system, the umbilical cord may be at least 240 feet (72 meters) long. The procedure of loading the internal cooling system within a section of pipe and moving the internal cooling system into position for cooling after a welding procedure (with optional inspection of AUT welding/X-ray and application of coating/insulation/ FJC) occurs similarly to that described above with respect to FIGS. 104 - 107.

[01024] FIG. 108 shows an internal cooling system 2010-1 according to another embodiment of the present patent application. The 2010-1 internal cooling system is similar to the modalities described above, except for the differences, as noted below. In one embodiment, the 2010-1 internal cooling system is configured to connect to an internal snap-on clamp 2060 at an end section 2024 of the third frame section 2018 of the 2010-1 internal cooling system. In one embodiment, the inner snap-in clamp 2060 includes a frame 2062 of a suitable configuration that allows insertion of the snap-in clamp 2060 into 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 the pipe sections 1022a, 1022b in place in the mating weld position (e.g., expanding to form a frictional engagement with the inner wall surface portions of the pipe sections in their ends facing when fitting clamp 2060 is properly positioned within pipe sections 1022a and 1022b). In one embodiment, section 2064 and clamp 60 correspond to sections in inner welding system 5004 that have first tube clamp 5142 and second tube clamp 5144. In one embodiment, a connecting member 2080 (e.g., a rod or spring member) is configured to connect one end 2066 of the 2060 snap-on clamp with the 2024 end section of the 2010-1 internal cooling system frame.

[01025] In one embodiment, the 2010-1 internal cooling system can be a towing member for the 2060 snap-on clamp. For example, the 2060 snap-on clamp, with the 2010-1 internal cooling system attached to it ( through connecting member 2080), can be inserted into its end 2065 (i.e., one end of the frame that opposes the end of the frame 2066 that connects to the internal cooling system 2010-1 through the connecting member 2080) at a pipe section, where movement of the 2060 snap-in clamp within the pipe section also results in the corresponding movement of the 2010-1 internal cooling system within the pipe section. In one embodiment, the 2010-1 internal cooling system can be inserted through its 2011 first frame section into the pipe section and then moved into position so as to also place the 2060 snap-on clamp in proper alignment with the socket weld location between the two aligned pipe sections. In one embodiment, the 2010-1 internal cooling system 2022 drive system can be used to move the 2060 snap-on clamp/2010-1 internal cooling system combined structure to a suitable location within the pipe sections or alternatively , any other suitable drive mechanism can also be used to move this structure within the piping sections (eg one or more cable/winch systems).

[01026] In one embodiment, the socket clamp 2060 holds the ends of the pipe sections 1022a, 1022b together until the solder joint 1026 is formed. In one embodiment, section 2064 and clamp 60 correspond to sections in internal welding system 5004 that have first tube clamp 5142 and second tube clamp 5144. , as required), the 2060 snap-on clamp can be disengaged from the inner wall surface portions of the pipe sections to facilitate movement of the 2010-1 internal cooling system to a suitable location (eg so that the pipe section coolant 2016 is aligned with the solder joint) to initiate internal cooling within pipe sections 1022a, 1022b.

[01027] FIG. 109 describes another embodiment for connecting the internal cooling system to an internal snap-in clamp, in which a longer connecting member 2082 (e.g., an elongated rod) is provided for connecting the internal cooling system 2010-1 with the clamp. socket 2060. In one embodiment, link member 2082 has a greater longitudinal dimension than link member 2080 (shown in Figure 108), which minimizes heating of internal cooling system 2010-1 during welding procedures ( due to a greater separation distance between the internal cooling system and snap-on clamp).

[01028] In one embodiment, the procedure includes loading the 2060 fitting clamp with the 2010-1 internal cooling system into one of the pipe sections and aligned so that the 2060 fitting clamp holds the two opposite ends of the pipe sections. tube in place at the socket weld location. After certain welding procedures have been performed (for example, the root and hot pass welding procedures), the 2060 Plug-in Clamp with the 2010-1 Internal Cooling System can be moved together and away from the Socket-weld location to Avoid exposure to more heat from the ongoing soldering process necessary to complete the solder joint. In one embodiment, if the connecting member is of sufficient length (e.g., connecting member 2082 of Figure 109), the snap-in bracket 2060 with the internal cooling system 2010-1 can be displaced so that the snap-in bracket 2060 can be moved. fitting is attached on one side, while the internal cooling system is on the other side of the fitting solder location (with only link member 2082 being placed directly or close to it in relation to the fitting solder location). Upon completion of welding and AUT/X-Ray inspection (if necessary), and after any coating/insulation/FJC has been applied, the 2060 Fitting Clamp with the 2010-1 internal cooling system can be moved to the its position such that the 2016 cooling section of the internal cooling system is in close proximity to the solder joint and cooling procedures can be performed (for example, in a manner similar to that described above with respect to the embodiment of Figures 104 to 107 ).

[01029] In one embodiment, the cooling section of the internal cooling system can be implemented with any type of cooling structure to quickly and/or efficiently cool the pipe sections in 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 (eg, 2122 fans shown and described below) that force air through portions. internal surface of pipe sections and/or through heat exchange fins or other cooling members of the cooling section of the internal cooling system, discharge of liquid and/or gaseous fluids (eg, cryogenic fluids, liquids, air ) at suitable pressures and temperatures from the 2007 or 2318 nozzles of the 2016 or 2316 cooling section towards inner surface portions of the pipe sections, using coolants in a closed loop recirculation cycle (eg 2212 pump, manifold 220 and fin members 2218 as shown in Figures 111A and 111b) and through the heat exchange structure of the cooling section using cooling thermoelectric (eg through Peltier devices in direct contact with the inner wall surface portions of the pipe sections) etc.

[01030] FIGS. 110A and 110B show an internal cooling system 2110 in accordance with another embodiment of the present application. The 2110 internal cooling system is similar to the modalities described above, with the exception of differences, as noted below. In one embodiment, cooling section 2116 of internal cooling system 2110 comprises a heat sink that includes a plurality of fin members 2118 disposed about the periphery and extending radially outwardly from a central support member 2120 of the cooling section 2116 and include curved outer surface portions corresponding to the curved inner surface portions of the tube 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 outwardly toward a curved end wall section of the member. of fin 2118. In one embodiment, the fin members 2118 are constructed of a material with a suitable thermal conductivity (e.g., copper, aluminum, etc.) to facilitate a high rate of heat transfer from the inner wall surface portions from the tube sections 1022a, 1022b to the cooling section heat sink 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 longitudinal direction. through the fin members. In one embodiment, electric fans 2122 may be mounted on central support member 2123 and located in close proximity to the ends of the fin members 2118 and in alignment with the fin channels 2120. In one embodiment, the electric fans 2122 provide an air flows through the fin channels 2120 to cool the fin members 2118 and thus force heat through 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 cable or wireless communication link) with the 2020 controller to facilitate selective operation of the 2122 fans during cooling procedures. In one embodiment, each fan 2122 can be implemented with a variable speed of operation to selectively control the fan speed and corresponding airflow rate through the fin members 2118 differently and as needed during the cooling procedure.

[01031] The internal cooling system 2110 procedure of FIGS. 110A and 110B is similar to that described above for the embodiment of FIGS. 104- 107 regarding the placement of the internal cooling system during the welding process and positioning for cooling after completion of the welding procedures. During cooling, fans 2122 can be activated to provide a flow of cooling air at one or more desired flow rates through channels 2120 of fin members 2118. In one embodiment, fin members 2118 draw heat from the fin portions. inner wall surface of tube sections 1022a, 1022b (including weld joint 1026) towards center support member 2123 of cooling section 2116 and forced air currents provided by fans 2122 remove heat from fin members 2118 , thus achieving a cooling of the tube sections 1022a, 1022b at the location of the cooling section 2116. As described in previous embodiments, the temperature sensors of the internal cooling system can provide measured temperature information to the controller 2020 and such temperature information Measures can be used to control the operation of the 2122 fans (including changing the fans). fan speeds of one or more fans 2122) during the cooling procedure. When a desired temperature is reached within the tube sections 1022a, 1022b, the fans 2122 can be turned off via the controller 2020. In one embodiment, the internal cooling system 2110 can further be moved to different positions as needed within the tube sections. 1022a, 1022b for cooling in different locations.

[01032] FIGS. 111A and 111B show an internal cooling system 2210 in accordance with another embodiment of the present application. The 2210 internal cooling system is similar to the modalities described above, except for the differences, as noted below. In one embodiment, internal cooling system 2210 includes a cooling section 2216 that includes a series of fin members 2218 disposed along a periphery and extending radially outwardly from a central support member 2223 of the section. cooling 2216, wherein fin members 2218 have an outer shape or profile similar to fin members 2118 of the embodiment of FIGS. 110A and 110B. In one embodiment, fin members 2218 may also be constructed of a material with a suitable thermal conductivity (eg, aluminum or copper). However, each fin member 2218 may have a hollow, sealed interior to facilitate a flow of coolant through member member 2218. In one embodiment, each fin member 2218 includes an inlet at one end and an outlet at the other. end, and a 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 fin member. 2212 pump. Any suitable type of coolant (eg water, a cryogenic fluid such as liquid nitrogen or liquid argon, etc.) may be used.

[01033] In one embodiment, the pump 2212 (shown in figure 111A) can be positioned externally from the tube sections 1022a, 1022b, with supply and return flow ducts 2214 extending between the pump 2212 and a manifold structure 2220 (shown in Figure 111B). In one embodiment, the manifold structure 2220 includes a plurality of tube connections that connect to the inlets and outlets of the fin members 2218. Thus, the cooling section 2216 facilitates heat exchange between the circulating fluid flow. cooling within fin members 2218 and the inner wall surface portions of tube sections 1022a, 1022b (eg, at or near solder joint 1026) during cooling procedures.

[01034] In one embodiment, the 2212 pump can be controlled (via a wired connection or suitable wireless connection) via the 2210 internal cooling system controller. Alternatively, the 2212 pump can be controlled externally (as it is easily accessible to the user). The flow of coolant through pump 2212 can be controlled based on measured temperature information provided by one or more temperature sensors in internal cooling system 2210. Once a desired temperature is achieved within pipe sections 1022a, 1022b, the pump can be turned off or off to cease the recirculating flow of coolant and facilitate movement of internal cooling system 2210 within pipe sections 1022a, 1022b.

[01035] FIGS. 112A and 112B show an internal cooling system 2310 in accordance with another embodiment of the present application. The 2310 internal cooling system is similar to the modalities described above, with the exception of differences, as will be noted below. In one embodiment, internal cooling system 2310 includes a cooling section 2316 having a plurality of spray nozzles 2318 positioned around a central support member 2323 of cooling section 2316. In one embodiment, spray nozzles 2318 are positioned in generally linear lines extending longitudinally along the center support member 2323. A suitable piping frame is provided at each end of each linear line of spray nozzles 2318, where the piping frame connects to a manifold 2320 The manifold 2320 connects through a 2314 fluid duct to a 2312 cooling pump supplied externally or outside the pipe sections. In one embodiment, operating coolant pump 2312 provides a flow of coolant (eg, water, a cryogenic fluid such as liquid nitrogen or liquid argon, etc.) from a source of coolant through the manifold 2320 and out of spray nozzles 2318 and toward the inner surface portions of tube sections 1022a, 1022b (including weld joint 1026). While the embodiment of FIGs. 112A and 112B show pump 2312 located outside pipe sections 1022a, 1022b, it is noted that cooling section 2316 with alignment of spray nozzles 318 can also be easily implemented for the embodiment of FIGS. 104-107 (ie where the manifold 2320 and spray nozzles 2318 receive coolant from the coolant source 2012). The cooling procedures of the internal cooling system 2310 can be carried out in a manner similar to that described for the previous embodiments, where the pump 2312 can be controlled through the internal cooling system controller 2310 and/or externally and where the flow of Coolant can be implemented based on measured temperature information provided by temperature sensors arranged in the internal cooling system 2310.

[01036] Thus, the internal cooling system of the present patent application is configured to provide improvements to the pipe welding procedures, including increasing the cooling of the pipe sections connected after the formation of weld joints, providing a controlled cooling internally within the pipe sections and reducing production time (since cooling can occur more quickly and efficiently, increasing the number of solder joints between pipe sections that can occur in a given period of time). Furthermore, the number of workstations associated with welding procedures and also the resources associated with such welding procedures can be reduced. For example, the workspace required to weld tube sections together can be reduced, and this can become particularly beneficial in scenarios where workspace is limited (eg on barges or other watercraft).

[01037] In one embodiment, a method is provided to weld a pair of insulated tubes (eg tubes 1022a, 1022b as shown in Figure 113). As shown in FIG. 113, each tube 1022a, 1022b includes the interior of metal tube 5244, surrounded by insulating material 5246. In one embodiment, end portions 5248, 5250 of tubes 1022a, 1022b to be welded have the interior of metal tube 5244 exposed. .

[01038] In one embodiment, referring to FIGS. 113-134, the method includes aligning the exposed metal tube ends 5248, 5250 that will be welded, welding the exposed metal tube ends 5248, 5250 together, heating the exposed end portions 5248, 5250 of the weld tube 1022a, 1022b, apply an insulator 5246 to the heated exposed end portions 5248, 5250 of the welded tubes so that the insulator 5246A (as shown in Figure 118) is adhered to the outer surface 5254 of the inner metal tube 5244, thereby insulating the end portions previously exposed 5248, 5250 of tubes 1022a, 1022b, and applying cooling energy from tubes 1022a, 1022b to an interior surface 5130a, 5130b of metal tubes 1022a, 1022b.

[01039] In one embodiment, the application of cooling energy from the tubes to the inner surface of the metal tubes is carried out after applying the insulator. In one embodiment, the method also includes performing a piping procedure. In one embodiment, the application of cooling energy reduces a wait time between application of the insulator and carrying out the piping procedure. In one embodiment, the plumbing procedure is a winding procedure. In one modality, the plumbing procedure is an S-lay procedure.

[01040] In one embodiment, the pipe development procedure is a pipe lowering procedure. In one embodiment, the tube implantation procedure is described in relation to FIG. 1B of the present application.

[01041] In one embodiment, bases 5330 (as shown in Figures 10A and 10B) or bases 6010A and 6010B (as shown in Figure 73) are used to transport and move tubes 1022a and 1022b and to provide the metal tube end exposed 5248 of inlet tube 1022a at the exposed metal tube end 5250 of tube 1022b. That is, the 5330 or 6010A/6010B bases are used to align the ends of exposed metal tubes 5248, 5250 to be welded.

[01042] In one embodiment, adjustment of the relative positioning of tubes 1022a, 1022b (based on pre-weld profile data) can be performed automatically by the 5140 processors that control the externally positioned rollers 5332 (as shown in Figures 10A and 10B ) or performed by an operator using a crane and clamps (internal and/or external). In one embodiment, after aligning tubes 1022a, 1022b, tubes 1022a, 1022b may be tightened using outer clamps 5302 (as shown in Figures 7A and 7B) and/or inner clamps 5142 or 5144. In one embodiment, as described in this application, one or more external or internal clamps may be used when aligning the ends of exposed metal tubes 5248, 5250 (to be welded). That is, one or more external or internal clamps can be used independently and/or in combination with the bases. In one embodiment, the operation of one or more external or internal clamps and bases may be controlled by one or more 5140 processors.

[01043] In one embodiment, one or more 5140 processors are configured to operate bases 5330 (or 6010A and 6010B) to adjust the relative placement of tubes 1022a, 1022b based on pre-weld profile data. In one embodiment, pre-weld profile data can be obtained for one or more inspection detectors that are operatively connected to one or more processors 5140. In one embodiment, adjusting the relative positioning of tubes 1022a, 1022b (based in the pre-weld profile data) may include a fit along the longitudinal axis of tubes 1022a, 1022b and/or an fit along the radial axis of tubes 1022a, 1022b. In one embodiment, after fitting tubes 1022a, 1022b, tubes 1022a, 1022b are tightened back using external and/or internal clamps. Fig. 113 shows tubes 1022a, 1022b with their exposed metal tube ends 5248, 5250 correctly aligned and ready for the welding process.

[01044] FIG. 114 shows tubes 1022a, 1022b with solder joint 1026 formed between their exposed metal tube ends 5248, 5250. In one embodiment, an internally positioned welding torch 5502 (e.g., within tube 1022a, 1022b) may be configured to weld the exposed 5248, 5250 metal tube ends together. In one embodiment, an externally positioned welding torch 7502 (e.g. external/external tubes 1022a, 1022b) can be configured to weld the ends of exposed metal tubes 5248, 5250 together. In one embodiment, a combination of the internally positioned welding torch 5502 and the externally positioned welding torch 7502 can be used to weld the exposed metal tube ends 5248, 5250 together. In one embodiment, the externally positioned 7502 welding torch and/or internally positioned 5502 welding torch are operatively linked to one or more 5140 processors.

[01045] In one embodiment, referring to FIGS. 115A and 115B, a heater 5304 may be configured to heat the exposed end portions 5248, 5250 of welded tubes 1022a, 1022b. In one embodiment, heater 5304 may be an induction heating system used to heat exposed end portions 5248, 5250 of welded tubes 1022a, 1022b of tubing 1024 in preparation for application of the liner or insulator materials. In one embodiment, heater 5304 may include ultra high frequency (UHF) induction coils that are configured to rapidly heat exposed end portions 5248, 5250 of welded tubes 1022a, 1022b of tube 1024 to the required coating temperature. In one embodiment, the 5304 heater can use two induction coils. In one embodiment, heater 5304 may be an electrical heating system. In one embodiment, heater 5304 may be a radiant heating system. In one embodiment, induction coils 5307 of heater 5304 are shown in FIG. 115A.

[01046] As shown in FIGS. 115A and 115B, heater 5304 is configured to circumferentially surround exposed end portions 5248, 5250 of welded tubes 1022a, 1022b of tubing 1024. In one embodiment, heater 5304 may include two half-round annular heater members 5304a and 5304b. In one embodiment, the two half-round annular heating members 5304a and 5304b are pivotally connected to each other by a gasket 5305 at the top and are releasably connected to each other through one or more connector members (not shown) in the lower part.

[01047] In one embodiment, heater 5304 is also configured to regulate the temperature of exposed end portions 5248, 5250 of welded tubes 1022a, 1022b of tubing 1024 to maintain a suitable coating application temperature. In one embodiment, heater 5304 may also include a heating feedback system configured to allow heater 5304 to obtain and maintain the required coating temperature and a temperature sensor operatively coupled to the heater feedback system. In one modality, the temperature sensor can be a contact or a non-contact temperature sensor. In one embodiment, the heater feedback system may include other sensors that are configured to detect other parameters of the heating procedure, eg, heating time, etc. In one embodiment, through feedback signals from one or more sensors, the heater's 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 can be operatively linked to one or more processors 5140. In one embodiment, one or more processors 5140 can be configured to control the operation of the heater 5304 and its feedback system.

[01048] In one embodiment, referring to FIG. 116A, 116B, 117A and 117B, a supply of insulator 5306 configured to apply insulator material 5312 to heated exposed end portions 5248, 5250 of welded tubes 1022a, 1022b so that insulator 5246A (as shown in Figure 118) is adhered to the outer surface 5254 of the metal tube interior 5244, thereby isolating the previously exposed end portions 5248, 5250 from the welded tubes 1022a, 1022b. In one embodiment, the insulator supply 5306 comprising a container 5310 configured to contain the insulating material 5312 and an outlet nozzle 5308 configured to spray the insulating material 5312 onto the exposed end portions 5248, 5250 of the welded tubes 1022a, 1022b. In one embodiment, container 5310 configured to contain insulating material 5312 may be pressurized.

[01049] In one embodiment, the 5306 isolator supply may include a feedback system configured to allow the 5306 isolator supply to achieve the desired coatings on the 1024 pipe and one or more sensors operatively connected to the feedback system. In one modality, one or more sensors can be configured to detect the following insulator application procedure parameters - insulator material temperature, insulator material volume, etc.

[01050] In one embodiment, referring to FIGS. 116A and 116B, insulator supply 5306 is an automated system and includes a casing frame 5393 that is configured to be positioned in the area of solder joint 1026. In one embodiment, casing structure 5393 of insulator supply 5306 is configured to be preprogrammed to rotate around the solder joint area 1026 so as to achieve the desired dry film thickness of the insulating material. That is, casing structure 5393 is constructed and arranged to move uniformly around the weld joint area 1026. In one embodiment, the spray head (including container 5310 and outlet nozzle 5308) is mounted to the structure. of casing 5393 in a specific position (eg, perpendicular to heated exposed end portions 5248, 5250 of welded tubes 1022a, 1022b).

[01051] In one embodiment, the provision of isolator 5306, shown in FIGS. 116A and 116B, is configured to apply the Fusion Bond epoxy insulator material to the heated exposed end portions 5248, 5250 of the welded tubes 1022a, 1022b such that the Fusion Bonded epoxy insulator 5246A (as shown in Figure 118) is adhered to the exterior surface 5254 of the interior of metal tube 5244, thereby isolating previously exposed end portions 5248, 5250 from welded tubes 1022a, 1022b.

[01052] In one embodiment, the provision of isolator 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 welded tubes 1022a, 1022b so that the injection molded polypropylene insulator 5246 is adhered to the outer surface 5254 of the interior of metal tube 5244. In one embodiment, the insulator supply 5306 of FIGS. 117A and 117B can be used to apply injection molded polyurethane insulator material to the heated exposed end portions 5248, 5250 of welded tubes 1022a, 1022b so that the injection molded polyurethane insulator 5246 is adhered to the outer surface 5254 of the interior of the 5244 metal tube.

[01053] Referring to FIGS. 117A and 117B, in one embodiment, insulator supply 5306 is an automated system and includes a mold 5381 that is configured to circumferentially surround the area of weld seam 1026 and to create an annular space 5383 for the injection molded insulating material 5246 to filling purposes. In one embodiment, a hydraulically operated valve (not shown) is configured to supply/inject molten insulating material 5385 into annular space 5383. The supplied/injected molten insulating material 5385 enters mold 5381 (and annular space 5383) surrounding the area of weld seam 1026 and forming the inner/inner profile of mold 5381. In one embodiment, ice water may be supplied to the mold to cool the outer profile of the insulating material such that the injection molded polyurethane insulator 5246 is adhered to the outer surface 5254 of the interior metal tube 5244, thus isolating the previously exposed end portions 5248, 5250 from the welded tubes 1022a, 1022b.

[01054] In one embodiment, the provision of isolator 5306 shown and described above with respect to FIGS. 116A and 116B can be used for terrestrial plumbing applications. In one embodiment, the provision of insulator 5306 shown and described above in relation to FIGS. 117A and/or 117B can be used for marine plumbing applications.

[01055] In one embodiment, the provision of isolator 5306 shown and described above with respect to FIGS. 116A, 116B, 117A and/or 117B can also be used to apply other insulated materials described elsewhere in this application and/or other insulated materials as would be appreciated by one skilled in the art for heated exposed end portions 5248, 5250 of welded tubes 1022a, 1022b.

[01056] In one embodiment, the 5306 isolator supply and its corresponding feedback system may be operatively linked to one or more 5140 processors. In one embodiment, the one or more 5140 processors may be configured to control the operation of the source of 5306 isolator and its corresponding feedback system.

[01057] In one embodiment, FIG. 118 shows tubing 1024 in which insulating material is applied to heated exposed end portions 5248, 5250 of welded tubes 1022a, 1022b such that insulator 5246A is adhered to outer surface 5254 of metal tube interior 5244, thereby insulating the previously exposed end portions of tubes 1022a, 1022b.

[01058] In one embodiment, referring to FIGS. 119 and 120, a cooling system 6500 is configured to be positioned within tubes 1022a, 1022b. In one embodiment, the 6500 cooling system includes a frame, a plurality of rollers 6530, a drive motor 6532, and a brake system. In one embodiment, a forward frame 6618, a center frame 6634 and a rear frame 6522 of the cooling system 6500 may be collectively referred to as the frame of the cooling system 6500.

[01059] For example, the frame is configured to be placed inside welded tubes 1022a, 1022b, the plurality of rollers 6530 is configured to rotatably support the frame, drive motor 6532 drives rollers 6530 to move the frame within the tubes 1022a, 1022b and the brake system protect the frame from movement at the desired location within tubes 1022a, 1022b. The structure, configuration and operation of the plurality of rollers, drive motor and brake system of the 6500 cooling system are similar to the plurality of rollers, drive motor and brake system of the internal welding systems described in this application, and, therefore, will not be described in detail in this document. For example, in one embodiment, the brake system of cooling system 6500 may include one or more clamps that secure circumferentially spaced positions on the interior surface 5130, 5132 of welded tubes 1022a, 1022b. In another embodiment, the brake system of cooling system 6500 may include a wheel lock that prevents rotation of rollers 6530.

[01060] In one embodiment, the cooling system 6500 includes a frame carried cooler and applies cooling energy to the interior surface 5130a, 5132a of the metal tubes 1022a, 1022b to facilitate the cooling of the welded metal tubes 1022a, 1022b. In one embodiment, the cooling device includes a heat exchanger 6502 that carries coolant therein and has a tube contact surface 6572 that contacts the inner surface 5130a, 5132a of tube 1022a, 1022b to facilitate cooling of the welded tubes. 1022a, 1022b. In one embodiment, cooling system 6500 includes a heat exchanger motor 6552 configured to move heat exchanger 6502 radially outward so that tube contact surface 6572 can be moved outwardly to engage interior surface 5130a , 5132a of welded tubes 1022a, 1022b after the frame is positioned in the desired location within tubes 1022a, 1022b.

[01061] In one modality, the 6500 cooling system includes one or more processors that are operatively connected with the 6532 drive motor, the brake system, and the 6502 cooler. In one modality, one or more processors are configured to operate the cooler 6502 to reduce the temperature of welded tubes 1022a, 1022b to a predetermined level. For example, in one embodiment, the cooling system includes one or more 2017a temperature sensors that are operatively communicated (wired or wireless) with one or more processors to determine the temperature of the tubes. In one embodiment, cooling power may continue until a predetermined threshold temperature is detected.

[01062] In one embodiment, one or more processors are communicatively connected to the brake system, the 6532 drive motor or the 6502 cooler through one or more wired or wireless links. Wireless connections can include, for example, a Wi-Fi connection, a Bluetooth connection, an NFC connection, a cellular connection, or another wireless connection.

[01063] In one modality, one or more processors, which receive tube temperature information from the 2017a temperature sensor, are communicatively connected to a remote computer system and configured to transmit tube cooler data to the computer system remote. 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 the change in tube temperature over time. In one embodiment, the remote computer system contains cooler data from other welding systems and calculates the expected time until the temperature of the welded tubes falls below a threshold. In one modality, the expected time is sent to one or more processors.

[01064] In one embodiment, the 6500 cooling system may include a user interface, and wherein the time temperature and/or expected temperature is sent to the user interface by the one or more processors. The user interface can be a computer, for example, with a display.

[01065] In one embodiment, the expected time for the tube (at least the portion of the tube in question) being cooled to a certain threshold temperature is calculated, at least in part, based on the size (eg the circumference, thickness, temperature, mass, or any combination thereof) of the welded tube. In another modality, the calculation is still based on a cooling energy output from the cooler. For example, this cooler power output can be based on the volume of water or gas directed to the surface of the tube, the initial temperature of the tube or gas, etc. As another example, the cooler energy for a closed fluid system heat exchanger can be known in advance, or calculated based on its operating parameters (fluid velocity, fluid temperature, heat transfer efficiency, etc.).

[01066] In another embodiment, the cooling power output of the cooling system and/or the expected cooling time is based on information received from the remote cloud-based computer system that contains a large central database of information obtained from various remotely operated cooler systems. In one embodiment, the cooling power output is predetermined. In one embodiment, one or more processors are communicatively connected to a remote computer system and configured to transmit coolant consumption data (eg, the amount of water used to cool the pipe of a known size needed to reach the temperature of the threshold.)

[01067] In one modality, the 6500 cooling system can be totally unpowered. Specifically, the 6500 cooler system does not need to include the reach rod or umbilical and all communications to and from the 6500 cooler system are completely wireless. In one embodiment, the 6500 cooling system may include a transmitter that is configured to transmit all communication signals fully wirelessly from the 6500 cooling system to the remote uLog processing system and a receiver that is configured to receive all the fully wireless communication signals from the remote uLog processing system. In one embodiment, one or more processors and/or all electronic modules of the 6500 cooler are configured to fully wirelessly communicate with the remote uLog processing system. In one modality, all sensors, all motors, all valves and/or other components/members of the 6500 cooling system are configured to fully wirelessly communicate with the remote uLog processing system.

[01068] In one modality, any information of the 6500 cooler system can be communicated wirelessly with systems outside the tube by Wi-Fi, Bluetooth, NFC, by radio frequency, or through cell transmissions, just for example. In some embodiments, where appropriate, information is communicated through the use of repeaters or extenders, where the transmission signal must travel long distances or through curved areas.

[01069] In one embodiment, one or more processors and one or more sensors of the 6500 cooling system are configured to monitor the load levels of the onboard cooler power supply, onboard travel power supply, and other power supplies on board. For example, the voltage output of these power sources can be (continuously or at regular intervals) monitored. In one embodiment, the 6500 cooling system transmitter transmits the monitored charge/battery level information entirely wirelessly to the uLog remote processing system for further processing. For example, the monitored charge level information from onboard power supplies can be used to determine the estimated remaining operating time of the 6500 cooling system. In one modality, one or more processors of the 6500 cooling system can be configured to determine locally the estimated remaining operating time of the 6500 cooling system on the 6500 cooling system. In one modality, the remote uLog processing system can be configured to determine the estimated remaining operating time of the 6500 cooling system based on information from charge/charge battery transmitted wirelessly. In one modality, the remote uLog processing system can be configured to transmit the estimated remaining operating time of the 6500 cooling system to one or more processors of the 6500 cooling system. In one modality, the remote uLog processing system can also be configured to transmit (fully wireless to the 6500 cooler system) additional instructions on the operation of the 6500 cooling system based on the estimated remaining operating time of the 6500 cooling system.

[01070] In one embodiment, one or more processors and one or more sensors of the 6500 cooling system are configured to monitor the levels of the onboard coolant supply/tank. For example, the pressure and/volume of the coolant supply tanks can be (continuously or at regular intervals) monitored. In one embodiment, the 6500 cooling system transmitter transmits fully monitored coolant consumption data wirelessly to the remote uLog processing system for further processing.

[01071] For example, the monitored coolant consumption data can be used to determine the estimated remaining operating time of the 6500 coolant system before coolant recharge/recharge. In one modality, one or more 6500 cooling system processors can be configured to determine the estimated remaining runtime of the 6500 coolant system (eg, before coolant refill) locally on the 6500 cooling system. , the remote uLog processing system can be configured to determine the estimated remaining operating time of the 6500 cooler (for example, before the next coolant recharge) based on the wirelessly transmitted coolant consumption data. In one embodiment, the remote uLog processing system can be configured to transmit the estimated remaining operating time of the 6500 cooler system (for example, before coolant recharge) to one or more processors of the 6500 cooler system. In this modality, the remote uLog processing system can also be configured to transmit (fully wireless to the 6500 cooler system) additional instructions on the operation of the 6500 cooler system based on the estimated operating time of the 6500 cooler system (eg before coolant refill).

[01072] In one embodiment, the remote uLog processing system receives battery charge data from multiple cooler systems in different locations (eg different locations across the country or across the world) and establishes a database about them . This database is used by the uLog processing system to determine, based on a large dataset, battery lifetimes based on different operating parameters of the cooling system. This can be utilized by uLog and/or one or more processors of the 6500 Cooler System to anticipate battery lifetimes for various components based on the current operating conditions of those components. This information can be used by one or more processors to reduce or regulate the power consumption of one or more components by modifying one or more operating parameters. For example, the cooling rate, voltage and/or current can be regulated (eg, lowered) to conserve battery power if one or more processors determines that such operating conditions can be modified without negatively affecting the associated operation being performed.

[01073] In one modality, battery life, voltage output, coolant levels and any of the operating parameters are wirelessly sent to a user interface such as a computer monitor with computer display , so they can be monitored by a user.

[01074] In one embodiment, such as the 6500 cooler system, all other cooler systems (eg 2010, 2110, 2210, 2310) described in the application are configured to communicate wirelessly with the remote uLog processing system.

[01075] In one embodiment, referring to FIG. 120, cooler system 6500 is configured to apply cooling energy to the interior surface 5130a, 5132a of metal tubes 1022a, 1022b to facilitate cooling of metal tubes 1022a, 1022b after insulating material 5312 is applied. In one embodiment, the cooler system 6500 comprises a heat exchanger or cooler 6502 configured to transport a moving fluid therethrough. That is, cooling energy is applied by the moving fluid disposed within heat exchanger 6502. In one embodiment, the moving fluid can be a gas or liquid.

[01076] For example, in an embodiment as shown in FIGS. 119-122, heat exchanger 6502 may have liquid passage lines 6593 therein which transport mobile liquid therethrough and cooling energy is applied by the mobile liquid disposed within fluid passage lines 6593 of heat exchanger 6502 In one embodiment, as shown in FIGS. 124-125, heat exchanger 6502 may have air channels 6576 which transport mobile air therethrough and cooling energy is applied by the mobile air disposed within air channels 6576 of heat exchanger 6502.

[01077] In one embodiment, a contact surface 6572 of heat exchanger 6502 is configured to be positioned in contact with the interior surface 5130a, 5132a of welded tubes 1022a, 1022b to remove heat from welded tubes 1022a, 1022b.

[01078] 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 heat exchanger 6502 is constructed and molded to closely conform to the interior surfaces of welded tubes 1022a, 1022b to remove heat from welded tubes 1022a, 1022b. In one embodiment, the contact surface 6572 of heat exchanger 6502 is constructed and arranged to be thermally conductive.

[01079] In one embodiment, cooling energy is applied by a fluid released within tubes 1022a, 1022b so that the fluid directly contacts the interior surface 5130a, 5132a of tubes 1022a, 1022b. In one embodiment, the fluid includes a liquid. In one embodiment, the fluid includes a gas. For example, in one embodiment, fluid nozzles 6562 (as shown in Fig. 123) are configured to apply (or spray) a coolant (directly) to the interior surface 5130a, 5132a of welded tubes 1022a, 1022b to remove heat of welded tubes 1022a, 1022b. In one embodiment, the vent 6505 (as shown in Figure 133) is configured to apply (or blow) a cooling gas (directly) to the interior surface 5130a, 5132a of welded tubes 1022a, 1022b to remove heat from welded tubes 1022a, 1022b.

[01080] In one embodiment, the contact surface 6572 of the heat exchanger 6502 is configured to be positioned in contact with the inner surface 5130a, 5132a of the welded tubes 1022a, 1022b to remove heat from the welded tubes 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 inner surface 5130a, 5132a of the welded tubes 1022a , 1022b to remove heat from welded tubes 1022a, 1022b.

[01081] Referring to FIGS. 119-122, heat exchanger 6502 of cooling system 6500 may include a plurality of heat exchanger members or fins 6580 positioned at circumferentially spaced locations on a center frame 6634. In one embodiment, each heat exchanger element 6580 may have one or more lines of 6593 coolant therethrough. In one embodiment, each heat exchanger member 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 between the contact surfaces 6572 of the heat exchanger elements 6580 and the inner surfaces 5130a, 5132a of the tubes 1022a, 1022b when the heat exchanger elements 6580 are in their retracted positions.

[01082] In one embodiment, the 6582 actuator mechanism 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 the 6580 heat exchanger element being used.

[01083] In one embodiment, there may be two actuator mechanisms, in which one actuator mechanism is positioned (axially along the tube axis) on one side of the 6580 heat exchange element and the other actuator mechanism is positioned (axially along the tube axis) on the other side of the 6580 heat exchange element. In one embodiment, the two actuator mechanisms may operate simultaneously to move the 6580 heat exchange elements between their extended and retracted positions. In one embodiment, there can 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).

[01084] In one embodiment, each second member 6590 is constructed and arranged to be connected to heat exchanger element 6580 at one end and to first element 6588 at the other end. In one embodiment, each first member 6588 is constructed and arranged to be attached to the second member 6590 at one end and to a portion of position 6586 (or a member movable by piston 6586) at the other end.

[01085] In one embodiment, the second member 6590 is constructed and arranged to be positioned in a radially extending opening 6592 in a (fixed) frame member 6594 such that the radially extending opening 6592 facilitates radial movement (e.g., radial upward and downward movement) of the second member 6590.

[01086] In one embodiment, piston 6586 is configured to be axially movable in cylinder 6584. In one embodiment, first members 6588 moved axially by reciprocating piston 6586, for example, are actuated by fluid pressure (hydraulic or pneumatic) within of cylinder 6584.

[01087] The heat exchanger elements 6580 are displaced from their retracted positions (as shown in figure 122) where the contact surfaces 6572 of the heat exchanger members 6580 are not in contact with the inner surfaces 5130a, 5132a of the tubes 1022a, 1022b to their extended positions (as shown in FIGS. 120 and 121) in which the contact surfaces 6572 of the heat exchanger elements 6580 are configured to be in contact with the inner surfaces 5130a, 5132a of the tubes 1022a, 1022b, activating the cylinder 6584 such that piston 6586 is moved axially in cylinder 6584. Compressed air entering an inlet 6503 pushes piston 6586 to move heat exchanger elements 6580 to their extended positions.

[01088] In one embodiment, the axial movement of piston 6586 is translated to radial movements of second members 6590 through first members 6588. Thus, radial contact forces are generated by the fluid pressure of compressed air acting on piston 6586. Piston 6586 drives first members 6588 which convert axial movement of piston 6586 to radial movements of second members 6590. As each heat exchanger element 6580 is operatively connected to second members 6590, radial movements of second members 6590 cause the radial movement of the heat exchanger element 6580 between its extended and retracted positions.

[01089] In one embodiment, the cylinder size, applied fluid pressure and sizes of various components of the 6582 actuator mechanism can be changed to control the extension and retraction of the  6580 heat exchanger elements.

[01090] In one embodiment as shown in FIG. 123, cooler system 6500 may include a fluid nozzle 6562 configured to apply a coolant to the interior surface 5130a, 5130b of welded tubes 1022a, 1022b to remove heat from welded tubes 1022a, 1022b. In one embodiment, fluid nozzle 6562 is a water nozzle that blows/sprays water onto the inner surface 5130a, 5132a of tube 1022a, 1022b to facilitate cooling of welded tubes 1022a, 1022b.

[01091] In one embodiment, heat exchanger 6502 may include a plurality of fluid nozzles 6562 that are positioned circumferentially and axially spaced apart (along the axis of the tube). In one embodiment, each fluid nozzle 6562 is configured to receive coolant from a coolant source 6564 through a coolant supply line 6566 and through one or more valves. In one embodiment, the coolant is a gas or liquid. In one embodiment, received coolant is sprayed from fluid nozzles 6562 to the interior surface 5130a, 5132a of welded tubes 1022a, 1022b to remove heat from welded tubes 1022a, 1022b.

[01092] FIGs. 124 and 125 show a heat exchanger element or fin 6574 that is configured to be extensible, for example, using actuator mechanism 6582 shown and described in accordance with 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 the extended position, is configured to be positioned in contact with the inner surface 5130a, 5132a of the welded tubes. 1022a, 1022b to remove heat from welded tubes 1022a, 1022b. In one embodiment, the heat exchanger may include a plurality of such heat exchanger element or fin 6574 positioned at circumferentially spaced locations and which may be extended and retracted by an actuating mechanism (e.g., a tire or otherwise). In one embodiment, the heat exchanger element or fin 6574 may include a plurality of fluid (air) channels 6576 that are configured to allow fluid to pass therethrough. In one embodiment, channels 6576 may be radially extended and circumferentially spaced.

[01093] Referring to FIGS. 126-128, in one embodiment, the 6500 cooling system can include a 6602 drive system. In one embodiment, the 6602 drive system can include a 6604 cable structure extending from the 6500 internal cooling system and through from one or more pipes 1022a, 1022b to an open end 6606 of a pipe 1022a. In one embodiment, cable structure 6604 is used to facilitate forward movement of internal cooling system 6500 within tubes 1022a, 1022b.

[01094] In one embodiment, one or more 6608 and 6604 cable/winch systems may be implemented, in which one or more 6608 winches may be provided as part of the 6500 internal cooling system and/or located at one or more points of anchors (eg 6610) that are external to tubes 1022a, 1022b. In one embodiment, a winch frame may be provided within the frame of the 6500 intercooler system.

[01095] For example, in one embodiment, a 6608 winch frame is provided in an anchored position 6610 external to tubes 1022a, 1022b and attached to cable frame 6604. That is, with reference to figures 127 and 128, an end 6612 of cable frame 6604 is connected to winch frame 6608 and the other end 6614 of cable frame 6604 is connected to a member 6616 of a forward frame 6618 of cooler system 6500. 6608 winch facilitates forward movement of the 6500 intercooler system within the 1022a, 1022b pipes.

[01096] In one embodiment, another cable structure may be attached to a member 6620 of a rear frame 6622 (as shown in Figure 119) of the 6500 cooling system to facilitate reverse movement of the 6500 internal cooling system within the 1022a tubes, 1022b. This cable structure can be operated by another winch structure (e.g. provided in a back and outer anchored position for tubes 1022a, 1022b) to facilitate a 6500 reverse movement internal cooling system within tube sections 1022a, 1022b.

[01097] Thus, the 6604 cable structure extends between the 6608 winch and a connection point (either in the internal cooling system 6500 or in an external connection point to the pipes 1022a, 1022b) to facilitate the placement of the cooling system internal 6500 inside and/or withdrawing the 6500 internal cooling system from tubes 1022a, 1022b during procedures.

[01098] In an embodiment as shown in FIG. 129, cooling system 6500 may include a plurality of rollers 6530 configured to engage the inner surface 5130, 5132 of one or more of tubes 1022a, 1022b and a drive motor 6532 configured to drive rollers 6530 to move an assembly. of frame 6503 (including front frame 6618, center frame 6634 and drive frame 6622) of cooler system 6500.

[01099] In one embodiment, the 6528 electronic cooling module is configured to control the operation of the 6602 drive system (for example, controlling one or more 6532 motors (which move the 6530 rollers in contact with the inner wall portions of the tube). )) to facilitate the advancement of the 2010 internal cooling system into the tube 1022a and towards the weld location. In one embodiment, the electronic cooling module 6528 of the internal cooling system 6500 is configured to communicate with one or more processors 5140 and one or more other processors or electronic modules (e.g., operatively connected with the different welding systems, operatively connected with bases, clamps or other pipe alignment systems and/or positioned remotely from such systems) as described in this order.

[01100] In the illustrated embodiment, each roller 6530 of the 6500 cooling system is operatively connected to 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 two rollers 6530 which are directly connected to the drive motors 6532.

[01101] In one embodiment, as shown in FIGS. 130 and 131, the 6500 cooling system may include a power supply 6526 for providing electrical power to the electronic cooling module 6528 of the 6500 cooling system, the 6602 drive system, the electronic sensors, the valve structure (by for example, to electronically control one or more valves 6522 and thereby control the flow of coolant from coolant supply source 6524 to heat exchanger 6502). In one embodiment, power source 6526 is carried by the frame assembly of cooling system 6500. In one embodiment, power source 6526 includes a plurality of battery cells or battery packs that are carried by the frame. rear 6622 of the 6500 cooling system. In one mode, seven batteries are shown. In one modality, the number of batteries can vary. In one embodiment, the number of batteries may depend on the type of heat exchanger being used and/or other power requirements of the 6500 cooler system. In the illustrated embodiment, power source 6526 is shown in a cooling system which has a thermoelectric heat exchanger. However, it is contemplated that power supply 6526 may be used with cooling systems having any type of heat exchanger as described in this application.

[01102] In one embodiment, the one or more battery cells carried by the 6500 cooling system frame are configured to power the 6532 drive motor and the brake system of the 6500 cooling system. In one embodiment, the one or more battery cells carried by the 6500 cooling system frame are configured to power the 6502 cooler of the 6500 cooling system.

[01103] In one embodiment, as shown in FIGS. 130 and 132, the heat exchanger 6502 of cooling system 6500 may be a thermal heat exchanger 6502. For example, the thermoelectric heat exchanger may be a Peltier device.

[01104] In one embodiment, the thermoelectric heat exchanger 6502 may have a plurality of frame members 6538 positioned at circumferentially spaced locations on an axis member 6542 of the cooling system 6500. In the illustrated embodiment, six frame members 6538 are shown In one mode, the number of members of the 6538 frame can vary. In one embodiment, each frame member 6538 may have a plurality of thermoelectric heat transfer elements 6544 positioned thereon. In the illustrated embodiment, six thermoelectric heat transfer elements 6544 are positioned on each frame member 6538. In one embodiment, the number of thermoelectric heat transfer elements 6544 positioned on each frame member 6538 can vary.

[01105] In one embodiment, frame members 6538 may be supported on shaft element 6542 of cooling system 6500 via support members 6540 (e.g. two). In one embodiment, support members 6540 can be extended and retracted by an actuation mechanism. In one embodiment, the actuation mechanism is configured to extend support members 6540 such that frame members 6538 and thermoelectric members 6544 positioned thereon are positioned in contact with the inner surface 5130a, 5132a of the welded tubes to remove heat from welded tubes 1022a, 1022b. In one embodiment, the drive mechanism may be pneumatically controlled or it may be controlled in any other way as would be appreciated by one of skill in the art.

[01106] In an embodiment as shown in FIG. 133, heat exchanger 6502 of cooling system 6500 may be a vent 6505 configured to blow a cooling gas onto the inner surface 5130a, 5132a of welded tubes 1022a, 1022b to remove heat from welded tubes 1022a, 1022b. In one embodiment, the fan blows air over the inner surface 5130a, 5132a of tube 1022a, 1022b to facilitate cooling of welded tubes 1022a, 1022b. In one embodiment, vent 6505 may include a frame member 6550 having a plurality of holes 6552 therein. In one embodiment, frame member 6550 is constructed and arranged to receive air from the outlet of a compressed (e.g., high pressure) air source 6554. In one embodiment, frame member 6550 is constructed and arranged to receive air from the output of a motor-driven fan. In one embodiment, holes 6552 formed in frame member 6550 are configured to function as outlets to supply incoming air to the interior surface 5130a, 5132a of welded tubes to remove heat from welded tubes 1022a, 1022b.

[01107] In one embodiment as shown in FIG. 134, a 6556 camera mounted at a CL location in the 6558 first section is controlled by the 6528 electronic cooler module can provide video images to a remote control device so that a user can determine the proximity of the 6500 internal cooling system to the weld. set 1026.

[01108] In one embodiment, as shown in FIGS. 135 and 136, cooling system 6500 includes a fan 6650 configured to make a cooling gas on the interior surface 5130a, 5132a of welded tubes 1022a, 1022b to remove heat from welded tubes 1022a, 1022b. In one embodiment, the 6505 fan includes a fan. In one embodiment, the structure, position and operation of fan 6505 may be similar to fan 2122 as described in detail elsewhere in this application.

[01109] In one embodiment, referring to FIGS. 135 and 136, heat exchanger elements 6580 are moved from their retracted positions (as shown in Figure 136) where contact surfaces 6572 of heat exchanger elements 6580 are not in contact with inner surfaces 5130a, 5132a of tubes 1022a, 1022b to its 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 tubes 1022a, 1022b, operating an actuation mechanism 6664.

[01110] In one embodiment, the 6664 actuator mechanism may be a linear actuator. In one embodiment, actuator mechanism 6664 may include a motor 6652, a link bolt 6654, a link nut 6656, a plurality of first members 6664, and a plurality of second members 6666. In one embodiment, the number of first and second members members may depend on the number of heat exchanger element 6580 being used. In one embodiment, each second element 6666 is constructed and arranged to be connected to heat exchange element 6580 at one end and to first element 6664 at the other end. In one embodiment, each first element 6664 is constructed and arranged to be connected to second element 6666 at one end and to a member 6662 movable by motor 6652 at the other end.

[01111] In one mode, the 6652 motor is configured (eg, mechanically linked) to turn connecting screw 6654. In one mode, the 6652 motor is configured to rotate clockwise or counterclockwise so as to cause raising or lowering heat transfer elements 6580 substantially perpendicular to the tube axis of tubes 1022a, 1022b. In one embodiment, the 6652 motor is configured to be connected directly to turn connecting bolt 6654. In another embodiment, the 6652 motor is configured to be indirectly connected, for example, through a series of gears or a gearbox, to turn the connection screw 6654.

[01112] In one embodiment, connecting bolt 6654 includes wires machined on its outer surface and extending along its length. In one embodiment, connector nut 6656 is constructed and arranged to be threaded onto connector bolt 5514 and includes complementary wires machined into its interior surface.

[01113] In one embodiment, the link nut 6656 is configured to interlock with a portion of a member 6662 such that the rotation of the link nut 6656 is prevented along with the link bolt 6654. 6656 is prevented from rotating along with tie bolt 6654, therefore, tie nut 6656 is configured to move tie bolt 6654 up and down. In one embodiment, tie nut 6656 is interlocked and positioned on a member opening 6662. In one embodiment, link bolt 5514 is configured to pass through an opening of interlocking link nut 5516.

[01114] The operation of the 6664 actuator mechanism is discussed in detail below. When connecting bolt 6654 is rotated by motor 6652, connecting nut 6656 is driven along the threads. In one embodiment, the direction of movement of link nut 6656 depends on the direction of rotation of link bolt 6654 by motor 6652. As link nut 6656 is interlocked into the opening of member 6662, member 6662 is configured to displace link bolt 6654 along with link nut 6656. That is, member 6662 translates linearly (right to left or left to right) as motor 6652 rotates. Furthermore, as member 6662 is connected to first members 6658, movement of member 6662 causes movement of first members 6658. As second members 6660 are connected to first members 6658, movement of first members 6658 causes movement radial (up or down) of second members 6660. That is, the linear translation of member 6662 is converted to radial (up or down) movement of second members 6660 through first members 6658.

[01115] As heat exchanger element 6580 is connected to second members 6660, radial movement (up or down) of second members 6660 causes radial movement (up or down) in heat exchanger element 6580. the motor 6652 is configured to move the contact surfaces 6572 of the heat exchanger elements 6580 outwardly into engagement with the inner surface 5130a, 5132a of the metal tubes 1022a, 1022b.

[01116] In one embodiment, the time it takes the cooling system to cool the tubes (for example, after the coating procedure and before the winding procedure) can be in the range between 90 and 150 minutes.

[01117] As the cooling system can be used to apply cooling energy to an inner surface of the metal tubes, inside the tubes, the cooling time of the metal tubes can be reduced (for example, compared to what allows the natural cooling of the metal tubes or compared to the application of a coolant on top of the insulating material). This, for example, can facilitate the cooling of metal tubes after the insulating material is applied to a welded tube, which must be preheated before applying the weld material. As a result, the welded tube can be put into service or further processed more quickly. Specifically, after the welded pipe has been heated to apply the applied insulating and insulating material, it should not be subjected to the high stresses that can occur in a deployment process. For example, in some embodiments, welded tube and its insulation (that insulation is applied only after the temperature of the welded tube is heated to a temperature of at least 160°C) to be wound onto a coil in a winding operation . This winding operation is ideally conducted only after the welded and insulated metal tube has been cooled below a threshold level (eg below 50°C). The use of the internal cooler can accelerate the achievement of metal tube cooling below the threshold level. In another application of the internal cooling system, after the tubes are welded (and before the insulator is applied).

[01118] The winding operation is one of several deployment procedures that can ideally be performed only after the welded tube is below a threshold temperature (eg by running the internal cooler). Other deployment procedures may include an S-lay procedure and/or a J-lay procedure on a pipe barge. The welded tube must be below a threshold temperature before the tube is submerged in water (eg sea or ocean).

[01119] Also, 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 work ideally below a threshold temperature (eg below 80°C), which can be achieved more quickly (after the tube is heated as a result of the welding operation) by using the system cooler. Thus, in a system, the cooler can be used before an operation of the ultrasound inspection system, which would be performed after welding and before reheating the tube to apply the insulation material.

[01120] In one embodiment, referring to FIG. 136A, an ultrasound inspection station 6801 is provided which is configured to inspect the weld between welded metal tubes 1022a, 1022b. In one embodiment, the cooling system 6500 is configured to facilitate cooling of the metal tubes 1022a, 1022b after the tubes 1022a, 1022b are welded and prior to inspection of the weld by the ultrasound inspection station 6801.

[01121] In one embodiment, a temperature sensor (eg 2017a as shown in FIGS. 104-109) can be used to determine the temperature of tube 1022a, 1022b in the vicinity of weld 1026. For example, referring to the FIG. 107, the 2017a temperature sensor is configured to be positioned in the internal cooling system and in proximity to the 1026 weld. In one embodiment, the 2017a temperature sensor can be positioned near the heat transfer elements or fins of the internal cooling system to measure the temperature of the inner surfaces 5130, 5132 of tube 1022a, 1022b. In another embodiment, the temperature sensor can be positioned on the 6801 ultrasound inspection station. In one embodiment, the temperature sensor can be a contact or a non-contact temperature sensor.

[01122] In one embodiment, the 2017a temperature sensor that detects a temperature of tubes 1022a, 1022b may be operatively communicating with one or more processors. In one embodiment, one or more processors send operating instructions to the 6502 cooler based on signals received from the 2017a temperature sensor. In one modality, one or more processors operate the cooler until sensor 2017a and the processor determines that the temperature of tubes 1022a, 1022b is below a threshold temperature.

[01123] In one embodiment, one or more processors can be configured to determine that the temperature of tube 1022a, 1022b in the vicinity of weld 1026 is below a predetermined temperature threshold. In one embodiment, the temperature sensor can be configured to detect if the temperature of tube 1022a, 1022b in the vicinity of weld 1026 is below a predetermined temperature threshold.

[01124] In one embodiment, inspection by ultrasound inspection station 6801 begins after temperature sensor 2017a detects that the temperature of tube 1022a, 1022b in the vicinity of weld 1026 is below a predetermined temperature threshold.

[01125] FIG. 136B shows a method for laying the pipeline. FIGS. 136C and 136D show schematic views of the S-lay tube deployment system and the J-lay tube deployment system. FIG. 136E shows the S-lay and J-lay release barges.

[01126] In one embodiment, tubes 1022a, 1022b (eg, about 40 feet or 80 feet long) are manufactured during the 6902 tube fabrication process. In one embodiment, the fabricated tubes are stored in the tube storage 6904 before shipping the tubes for further processing, for example, to a 6942 S-lay barge (as shown in figure 136C), a winding base/coil, or a 6944 J-lay barge (as shown in figure 136D ). In one embodiment, the tube storage can include a plurality of storage racks.

[01127] In one embodiment, in coil base procedure 6914, fabricated tube sections are received by the coil base, these tube sections are joined, at the coil base, to form long tube sections, and these tube sections are joined together at the coil base. Long tubes are then glued together and loaded onto a vessel, ship or barge. In one embodiment, the coil base may include semi-automatic or automatic welding systems, field joint coating systems, non-destructive inspection and testing systems, storage racks, roller systems and/or other pipe handling equipment for fabrication, coiling and loading of rigid piping prior to installation.

[01128] In one embodiment, the pipe stalks are towed in large coils on barges (as shown in figure 136E) and not placed when the barge arrives at the job site. In one embodiment, the coiled tube stalks are not placed on the vessel, ship or barge in procedure 6916 and the tube sections are then deployed in procedure 6918. In one embodiment, the vessel, ship or barge is "unwinding" they can be a J-lay barge or an S-lay barge. FIG. 136E shows the S¬lay and J-lay release barges.

[01129] In one embodiment, the 6942 S-lay barge receives the stored tube sections from the tube storage. In one embodiment, in procedure 6906, the S-lay 6942 barge utilizes its onboard systems to produce long tube sections. In one embodiment, in procedure 6906, automatic welding systems, tube lining systems, back-up clamps, bleed clamps and/or other support equipment are used on the 6942 S-lay barge to produce long tube sections. In one embodiment, the S-lay piping procedure is used for marine piping applications. In one modality, the tube implantation procedure is used in shallow and intermediate waters. In one embodiment, the S-lay tube deployment procedure allows the tube to leave the vessel in a horizontal position. In one embodiment, the S-lay tube laying procedure provides high production rates. As shown in FIG. 136C, the 6942 S-lay barge is constructed and arranged to lay the tube sections in an S-shaped tube configuration.

[01130] In one embodiment, the 6944 J-lay barge receives the stored tube sections from the tube storage. In one embodiment, in procedure 6908, the 6944 J-lay barge utilizes its onboard systems to produce long tube sections. In one embodiment, in procedure 6908, automatic welding systems, tube coating systems, J-lay clamps and/or other support equipment are used on the 6944 J-lay barge to produce long tube sections. In one embodiment, the J-lay piping procedure is used for marine piping applications. In one embodiment, the J-lay tube implant procedure is used for deep water work. In one embodiment, the J-lay tube deployment procedure allows the tube to leave the lay system in a position very close to vertical. This means that a pipeline is installed with very low stresses in the pipe. As shown in FIG. 136D, the 6944 J-lay barge is constructed and arranged to lay the tube sections in a J-shaped tube configuration.

[01131] The control, positioning and communication with the internal welding system, the plug-in welding system and/or the tube cooling systems, when located within a tube, can be carried out in several ways, as described in this document. In yet another embodiment, the position of the system within the tube may be detected by a low frequency electromagnetic signal transmission from a coil placed in close proximity parallel to the outer surface of the tube. This signal is detected by a pair of orthogonal receive coils mounted in the system on the tube, in proximity to the inner surface of the tube. The phases of the received signals in relation to the transmitted signal and the amplitude ratio of the two received signals are used to estimate the relative position of the transmitter and receivers. Control of the system within the pipe (ie, internal welder, plug-in welder or cooling system, etc.) together with the transmission of information can also be accomplished through a high frequency direct sequence spread spectrum radio link between one or more processors (for example, inside a computer console) outside the tube and one or more system-mounted processors in the tube. Details of this implementation can be appreciated from US Patent 6,092,406, incorporated herein by reference in its entirety.

[01132] In one embodiment, the internal welding system 5004, 3001 may include a welding material consuming device. In one embodiment, the external welding system 7500 may include a welding material consuming device. In one embodiment, the soldering material consuming device may be a part of the wire feed assembly 5020 of the internal soldering system 5004.

[01133] In one embodiment, the solder consumption device may have similar structure and operation to the device(s) as shown and described in relation to 161A-165 of this application. For example, in one embodiment, the structure, configuration and operation of coil 5272 (as shown in FIG. 22A) used internal soldering system 5004 may be similar to coil 14480 as shown and described in relation to FIG. 161A. In one embodiment, the structure, configuration, and operation of the motors of wire feed assembly 5020 of inner welding system 5004 may be similar to motor 14490 as shown and described in accordance with FIGS. 162, 164A and 164B. Additionally, in one embodiment, the wire feed assembly 5020 of indoor welding system 5004 may include a weight sensor that is configured to detect depletion of the consumable material. The structure, configuration, and operation of the internal welding system weight sensor 5004 may be similar to the weight sensor 14484 as shown and described in relation to FIG. 161C. In one embodiment, internal welding system 5004 may include other sensors (eg, shown at 161B) to determine an amount of consumable weld material used by internal welding system 5004 over a given period of time.

[01134] In one embodiment, one or more 5140 processors operatively associated with the 5004 internal welding system may be configured to determine the wire feed speed from the speed of the motors of the 5020 wire feed assembly as described elsewhere herein. application. In one embodiment, one or more 5140 processors operatively associated with internal welding system 5004 may be configured to determine an amount of consumable welding material used by internal welding system 5004 over a given period of time and generate material consumption data. solder based on it. In one embodiment, a transmitter of the 5004 indoor welding system can transmit the weld material consumption data completely wirelessly to the remote uLog processing system for further processing. In one modality, the remote uLog processing system can also be configured to transmit (fully wireless to the internal welding system, external welding system and/or internal plug-in welding system) additional instructions on the operation of the internal welding system, external welding system and/or internal plug-in welding system based on the processed welding material consumption data. For example, instructions may include correcting a slippage of wired power assembly motors by increasing the internal welding system wired power assembly motor speed, external welding system and/or internal welding system plug-in. In one embodiment, one or more processors 5140 of internal soldering system 5004 may use the procedures shown and described in accordance with FIGS. 163 and 165 to determine the welding material consumption data, the processed welding material consumption data, etc.

[01135] In one embodiment, the structure and operation of the solder consumption device are described above in relation to the internal welding system 5004. In one embodiment, the external welding system 7500 and the internal welding system 3001 lashing may include a solder consumption device with similar structure and operation. That is, in one modality, the cube, electronics, software and images being sent by the solder material consuming devices of the internal soldering system and the external soldering system are generic for both devices. However, the shape and size of the welding material consuming devices of the 5004, 3001 and 7500 external welding system can change. In one embodiment, the welding material consuming devices of the inner welding system 5004, 3001 and the outer welding system 7500 may have different shape configurations and/or different geometries. In one embodiment, the solder material consuming device may be configured to detect the unauthorized wire spool used in the indoor welding system 5004, 3001 or the external welding system 7500.

[01136] Field System Tests and Operations

[01137] FIG. 137A shows a 13700 system to facilitate testing the field system or its operations according to one or more modalities. As shown in FIG. 137, system 13700 may comprise one or more field systems 13702 (or field systems 13702a-13702n), one or more remote computer systems 13704, and one or more networks 150 through which components of system 13700 can communicate with one another. the others. A 13702 field system may comprise one or more field devices 13712, one or more control devices 13714, one or more field computer systems 13716, or other components. A remote computer system 13704 may comprise one or more processors 13730 configured to run one or more subsystems, such as object profile subsystem 13732, operation management subsystem 13734, operation protocol subsystem 13736, operation management subsystem 13736, operation monitoring 13738, operation trigger subsystem 13740, presentation subsystem 13742, or other components. As described below, in one or more embodiments, operations of the respective components of remote computer system 13704 may be performed by one or more processors of remote computer system 13704. It should be noted that while one or more operations are described in this document as being performed by components of remote computer system 13704, such operations may, in some embodiments, be performed by components of field system 13702 (e.g., field computer system 13716) or other components of system 13700.

[01138] In one embodiment, field system 13702 may be field system 5000. In one embodiment, if computer system 5138 is local to field system 5000, field computer system 13716 may be system of local computer system 5138 and field computer system processors 13718 may be local computer system processors 5140. If computer system 5138 is located remotely from field system 5000, remote computer system 13704 may be the remote computer system 5138 and the remote computer system processors 13730 may be the remote computer system processors 5140.

[01139] FIG. 137B shows communication links between remote computer system 13730, field computer system 13716 of field system 13702 and other components of field system 13702, in accordance with one or more embodiments. In one embodiment, remote computer system 13704 (or its processors 13730) may communicate with one or more other components of field system 13702 through field computer system 13716 (and one or more wired or wireless communication links. wires between field computer system 13716 and remote computer system 13704). For example, the processors of the 13718 field computer system may receive inspection data, input parameters, operation observation data, or other data from one or more of the other systems of the 13702 field system (or their respective 13720 processors), such as 3001 welding system (eg 3001 connection internal welding system), 5004 welding system (eg 5004 internal welding system), 6500 cooling system (eg 6500 internal cooling system), system purge and inspection system 7001, welding system 7500 (eg 7500 welding system) or other 13724 systems of the 13702 field system (eg cradles or other pipe alignment systems, other inspection systems, etc.). Field computer system processors 13718 may transmit (via a transmitter) inspection data, input parameters, operating observation data, or other data to remote computer system 13704 and, in response, receive a response. comprising profile data (eg, pre-validated profile data, voting profile data, post-weld profile data, etc.), instructions for performing operations on an object, alerts (eg indicating a defect if there is a malfunction, an indication to start or stop an operation, etc.) or other data from the remote computer system 13704. In a use case, if the response includes profile data, the field computer system processors 13718 may use profile data to generate alerts (eg indicating a defect if a defect exists, an indication to start or stop an operation, etc.) get instructions to perform an operation on an object, etc. In another use case, if the response includes instructions to perform an operation on an object, the field computer system processors 13718 can transmit the instructions to the appropriate 13702 field system system to cause that system to perform the operation of according to transmission instructions.

[01140] In one embodiment, it may be beneficial to use one or more wireless communication links to enable one or more components of remote computer system 13704, field computer system 13716, solder system 3001, solder system 5004, 6500 cooling system, 7001 purge and inspection system, or 7500 welding system to communicate with each other to reduce the number of communication cables in the various 13702 field system systems to reduce the potential entanglement of cables that can delay the operations or damage other components of these systems. For example, reducing the number of communication cables in welding system 3001, welding system 5004, purging and inspection system 7001, or welding system 7500 in some embodiments can reduce potential cable entanglement during rotation of an inspection device. (eg inspection laser, inspection camera or other inspection device), a welding torch or other component of these systems.

[01141] FIG. 137C shows communication links between remote computer system 13730 and components of field system 13702 without field computer system 13716, in accordance with one or more embodiments. In one embodiment, remote computer system 13704 (or its processors 13730) may communicate with one or more other components of field system 13702 through one or more wired or wireless communication links between the various systems of field system 13702 and remote computer system 13704 (e.g., without the need for a separate field computer system 13716). For example, remote computer system processors 13730 may receive inspection data, input parameters, operation observation data, or other data from one or more systems of the 13702 field system (or its respective electronic modules) such as the system. welding system 3001 (eg connection internal welding system 3001), welding system 5004 (eg internal welding system 5004), cooling system 6500 (eg internal cooling system 6500), purge system and inspection 7001, 7500 welding system (eg, external welding system 7500), or other 13724 systems of the 13702 field system (eg, indoor cooler. In response, the respective 13702 field system systems receive one or more responses that comprise profile data (eg pre-weld profile data, flight profile data, post-weld profile data, etc.), instructions for performing operations on an object, alerts (eg indicating u a defect if there is a defect, an indication to start or stop an operation, etc.), or other data from the remote computer system 13704. In a use case, for example, if one of the systems of the 13702 field system receives a response comprising instructions to perform an operation on an object, that system can perform the operation in accordance with the transmitted instructions.

[01142] As another example, one or more of electronic modules 5014, 5046, 5064, 5118 or other components of welding system 5004 may comprise one or more processors configured to communicate with field computer system 13716 (or its processors 13718), the remote computer system (or its processors 13730), or other components of the soldering system 5004 via one or more wired or wireless communication links. In one scenario, for example, one or more of the electronic modules 5014, 5046, 5064, 5118 can receive data from one or more sensors or inspection devices of the 5004 welding system, process the sensor or inspection data, transmit the sensor or inspecting data for the field of computer system processors 13718 or for remote computer system processors 13730, generating signals to control one or more motors or other mechanisms of welding system 5004 to perform one or more operations, etc.

[01143] As another example, one or more of the electronic modules 3126, 13722 or other components of welding system 3001 may comprise one or more processors configured to communicate with field computer system 13716 (or its processors 13718), or remote computer system (or its processors 13730), or other components of welding system 3001 via one or more wired or wireless communication links. In one scenario, for example, one or more of the electronic modules 3126, 13722 may receive data from one or more sensors or inspection devices of the 5004 welding system, process the sensor or inspection data, transmit the sensor or inspection data to the field of computer system processors 13718 or for remote computer system processors 13730, generating signals to control one or more motors or other mechanisms of welding system 3001 to perform one or more operations, etc.

[01144] As another example, one or more of electronic modules 6528, 13722 or other components of the 6500 cooling system may comprise one or more processors configured to communicate with field computer system 13716 (or its processors 13718), or remote control computer system (or its 13730) processors, or other components of the 6500 cooling system via one or more wired or wireless communication links. In one scenario, for example, one or more of the 6528, 13722 electronic modules can receive data from one or more sensors or inspection devices of the 6500 refrigeration system, process the sensor or inspection data, transmit the sensor or inspection data to the field of computer system processors 13718 or for remote computer system processors 13730, generating signals to control one or more motors or other mechanisms of cooling system 6500 to perform one or more operations, etc.

[01145] As another example, one or more of electronic modules 7032, 7036, 7040, 7064 or other components of purge and inspection system 7001 may comprise one or more processors configured to communicate with field computer system 13716 (or its 13718) processors, the remote computer system (or its 13730) processors, or other components of the 7001 purge and inspection system via one or more wired or wireless communication links. In one scenario, for example, one or more of the electronic modules 7032,7036, 7040, 7064 can receive data from one or more sensors or inspection devices of the 7001 purge and inspection system, process the sensor or inspection data, transmit the sensor or inspection data for the field of computer system processors 13718 or for remote computer system processors 13730, generate signals to control one or more motors or other mechanisms of the purge and inspection system to perform one or more operations, etc. .

[01146] As another example, one or more of the electronic modules 3126, 13722 or other components of welding system 3001 may comprise one or more processors configured to communicate with field computer system 13716 (or its processors 13718), or remote computer system (or its processors 13730), or other components of welding system 3001 via one or more wired or wireless communication links. In one scenario, for example, one or more of the electronic modules 3126, 13722 may receive data from one or more sensors or inspection devices of the 5004 welding system, process the sensor or inspection data, transmit the sensor or inspection data to the field of computer system processors 13718 or for remote computer system processors 13730, generating signals to control one or more motors or other mechanisms of welding system 3001 to perform one or more operations, etc.

[01147] In one embodiment, a field system (eg, 5000 field system, 13702 field system, etc.) can work with one or more remote computer systems (eg, the 5138 computer system that is located remotely from field system 5000, remote computer 13704, etc.) to facilitate field testing or physical operations based thereon. The field system can comprise one or more components that can be communicatively connected to each other and/or one or more components of the remote computer systems. In one embodiment, one or more field devices (eg, field devices 13712) of the field system can be made to perform one or more operations based on inspections of one or more objects. As an example, an inspection device (for example, inspection device 13714) of the field system can inspect an object. One or more processors of the field system (e.g., processors 13718 of field computer system 13716) may receive, from the inspection device, inspection data associated with inspection of the object. Based on inspection data, processors can cause a field device in the field system to perform an operation that physically affects the object. The inspection devices may comprise an inspection camera, an X-ray radiography inspection device, a gamma ray inspection device, an ultrasonic inspection device, a magnetic particle inspection device, a current inspection device, a temperature monitor or other inspection device. Inspection data can comprise laser inspection data, camera inspection data, X-ray inspection data, gamma ray inspection data, ultrasonic inspection data, magnetic particle inspection data, inspection data. Foucault, temperature inspection data or other inspection data.

[01148] In one embodiment, field system processors (for example, 13718 field computer system processors 13716) can process inspection data to generate data related to performing the operation that physically affects the object and causes the field device to perform the operation based on the data related to the operation. In one embodiment, field system processors can transmit (via a transmitter) inspection data to a remote computer system. By transmitting inspection data, processors can receive, from the remote computer system, data related to carrying out an operation that physically affects the object. As an example, operation-related data can be generated on the remote computer system based on inspection data. Upon receipt of the operation-related data, the processors can have the field device perform the operation based on the operation-related data. Processors can make the field device perform the operation by transmitting the operation-related data to the field device (for example, in a format that the field device can interpret and use to perform the operation), use the related data the operation to control the field device to perform the operation, monitoring and providing in-flight updates to perform the operation (eg, monitoring the object during the performance of the operation) or other techniques.

[01149] In an embodiment, inspection data can be processed to automatically determine whether the object has one or more defects, whether the object is ready for the next stage of operations, or other information. As an example, if one or more defects are detected based on inspection data, the generated operation-related data can relate to performing an operation to resolve the detected defects. As another example, if it is determined that the object is ready for the next stage of operations, the operation-related data generated may be related to performing an operation associated with the next stage of operations.

[01150] The field device (for example, the field device 13712) may comprise a welding device, a coating device, an alignment device, a heating device, a cooling device, a protection device, a control device or other device. Operation-related data may include solder-related instructions, coating-related instructions, change-related instructions, alignment-related instructions, or other instructions or data. Welding-related instructions can include instructions related to welding an interface region between a first object and a second object (for example, an interface region between tubes or other objects), instructions related to wire feed speed, consumption of wire, oscillation width, oscillation waveform, oscillation amplitude, weld time, gas flow rate, welding arc power levels, welding current, welding voltage, welding impedance, welding speed. welding coil, position of the welding torch welding tip along the tube axis, angular positioning of the welding torch tip welding in relation to its rotational plane, the distance of the welding torch welding tip to the internal surfaces of the pipes to be soldered, etc., for soldering or other soldering-related instructions. Instructions related to coating may include instructions for coating an object (for example, coating a pipe or other object), instructions related to preheat temperature, coating thickness, or other instructions related to coating. Change-related instructions may include instructions relating to enlarging at least a portion of an object, instructions relating to reducing at least a portion of an object, instructions relating to resizing at least a portion of an object (for example, radial resizing, proportional resizing, etc.), modifying a shape of at least a portion of an object, or other instructions related to the alteration. Instructions relating to alignment may include instructions relating to aligning at least a portion of an object with at least a portion of another object or other instructions relating to alignment.

[01151] In one embodiment, based on inspection data associated with an inspection of an interface region between a first object and a second object, one or more processors of a field system (for example, processors 13718 of the field system 13716) field computer can obtain data related to the performance of a welding operation in the interface region. For example, processors can transmit (via a transmitter) inspection data to a remote computer system (eg, remote computer system 13704) and, in response, processors can obtain instructions related to soldering the interface region. from the remote computer system. Processors can cause a field device to solder the interface region based on soldering-related instructions.

[01152] In a use case, if it is determined based on inspection data that a first weld pass layer has a defect (but nevertheless modifiable via a second weld pass), the instructions related to soldering may include instructions for the second solder pass, so that the second solder pass is to compensate for the defect of the first layer of solder pass. For example, if the first layer of solder pass is determined to be insufficiently thick, the soldering-related instructions may include instructions for longer soldering time or use of solder wire (than if the first layer of solder pass was sufficiently thick) for the second soldering pass. As such, the resulting second solder pass layer may be thicker (than it would otherwise be) to compensate for the insufficiently thick first solder pass layer. As another example, if the first layer of solder pass is too thick, soldering-related instructions may include instructions for less soldering time or use of soldering wire (than if the first layer of solder pass were appropriately thick) for the second soldering pass. In this way, the resulting second solder pass layer can be thinner (than it would otherwise be) to compensate for the extra thickness of the first solder pass layer.

[01153] In another use case, if a defect is detected in a first layer of solder pass, the soldering-related instructions may not necessarily include instructions to repair or compensate for the detected defect. For example, a fix may not be recommended for a defect based on a defect size that does not satisfy a predefined defect size threshold (for example, a minimum repairable defect size to recommend a fix). The predefined defect size limit can, for example, correspond to a defect size that would not have a significant negative effect on weld quality. As such, in this use case, if the defect size in the first weld pass layer is less than the predefined defect size limit, the weld-related instructions can simply include instructions for the next weld pass layer as if the defect was not detected.

[01154] In one embodiment, based on inspection data associated with an inspection of an object, one or more processors of a field system (for example, processors 13718 of field computer system 13716) can obtain data related to the coating the object. For example, processors can transmit (via a transmitter) inspection data to a remote computer system (eg, remote computer system 13704) and, in response, processors can obtain instructions related to coating the system object. remote computer. Processors can have a field device apply one or more layers of coating to the object based on instructions related to coating. In a use case, if it is determined based on inspection data that the object weld is complete and the completed weld is within specification, the remote computer system can transmit instructions to begin coating the object to system processors of field.

[01155] In an embodiment, based on inspection data associated with an inspection of an object, one or more processors of a field system (for example, processors 13718 of field computer system 13716) can obtain data related to change an object's size, shape, or other aspect. For example, processors can transmit (via a transmitter) inspection data to a remote computer system (eg, remote computer system 13704) and, in response, processors can obtain instructions related to changing the system object. remote computer. Processors can cause a field device to enlarge at least a portion of the object, reduce at least a portion of the object, radially resize at least a portion of the object, change a shape of at least a portion of the object (eg, machining a new bevel on the end of a tube or performing shape shifts), or perform other changes to the object based on instructions related to the change.

[01156] In one embodiment, based on inspection data associated with an inspection of an object, one or more processors of a field system (for example, processors 13718 of field computer system 13716) can obtain data related to the object alignment. For example, processors can transmit (via a transmitter) inspection data to a remote computer system (eg, remote computer system 13704) and, in response, processors can obtain instructions related to system object alignment. remote computer. Processors can make a field device align at least a portion of the object with at least a portion of another object based on instructions related to alignment. In a use case, for example, where the objects are tubes, and the remote computer system's analysis of the inspection data indicates an alignment error, the alignment-related instructions received from the remote computer system may include instructions to change the position of at least one of the tubes that would fix the alignment error (for example, angular error that caused a gap between the tubes, position error that caused Hi-Lo problems, etc.).

[01157] In one modality, one or more operations can be performed on one or more objects based on inspections of multiple objects. In this way, for example, inspection data from inspections of multiple objects can be used to perform analyzes on objects as a whole. In some scenarios, such analysis may be incomplete if it is isolated from inspection data for a single object. For example, although the individual tubes of a pipeline may be within specification, the pipeline or a portion of the pipeline (which includes multiple individual pipelines) as a whole may be out of specification. As another example, although the individual pipes of the pipeline may be ready for the next stage of operations, the pipeline or portion of the pipeline as a whole may not be ready for the next stage of operations. By using inspection data from inspections of each of the pipes in the pipe or portion of the pipe, a more complete analysis can be performed on the pipe or part of the pipe as a whole.

[01158] In one embodiment, one or more processors of a field system (for example, processors 13718 of field computer system 13716) may receive (via a receiver) first inspection data associated with an inspection of a first object and second inspection data associated with an inspection of a second object. Based on the first inspection data and the second inspection data, processors can cause a field device in the field system to perform an operation that physically affects one or more objects. The first inspection data and the second inspection data can each comprise at least one of the laser inspection data, X-ray inspection data, gamma-ray inspection data, ultrasonic inspection data, data particle inspection data, eddy inspection data, temperature inspection data, or other inspection data. Inspection of the first object and inspection of the second object can be performed by the same inspection device or by different inspection devices.

[01159] In one embodiment, field system processors (for example, 13718 field computer system processors 13716) can process the first inspection data and the second inspection data to generate data related to performing an operation that physically affect an object and cause the field device to perform the operation based on data related to the operation. In one embodiment, field system processors may transmit the first inspection data and the second inspection data to a remote computer system (eg, remote computer system 13704). Responsible for transmitting the first inspection data and the second inspection data, the processors can receive, from the remote computer system, data related to the performance of the operation that physically affects the object. As an example, data related to the operation can be generated in the remote computer system based on the first inspection data and the second inspection data. Upon receipt of the operation-related data, the field system processors can cause the field device to perform the operation based on the operation-related data.

[01160] In one modality, the data related to the operation (on which the performance of an operation on an object is based) can, additionally or alternatively, be based on one or more input parameters of one or more operations performed on one or more objects (eg the object, another object, etc.). As an example, a field device of a field system can perform operations before an inspection of the object. Input parameters of previously performed operations, inspection data associated with inspection of the object or other data can be transmitted to a remote computer system. After receiving the transmitted data, the remote computer system can generate the data related to the operation based on the input parameters, inspection data or other data. If, for example, a defect is detected based on inspection data, the input parameters can be analyzed in connection with the detected detection to determine the cause of the defect (for example, the actual output does not match the theoretical output of the parameters. input) and the operation-related data can be generated so that the operation-related data can be used to perform an operation consisting of repairing or compensating for the detected defect or the cause of the defect.

[01161] In a use case, if a first weld layer resulting from a weld operation is determined to be insufficiently thick (based on inspection data associated with an inspection of the first weld pass layer), the input parameters for the soldering operation can be taken into account to determine the cause of insufficient thickness of the first layer of solder pass. For example, if insufficient solder time or solder wire is determined by insufficient thickness, solder-related instructions for a second solder pass can be generated to understand calibrated input parameters to compensate for insufficient thickness of the first layer of soldering pass or the determined cause (eg longer soldering time, increased wire usage, etc.). Processing data from a field system

[01162] In one embodiment, a computer system (eg computer system 5138, remote computer system 13704, field computer system 13716, etc.) may work with one or more field systems (eg computer system field 5000, field system 13702) to facilitate field testing or physical operations based thereon. The computer system may comprise one or more processors or other components that may be communicatively connected to one another and/or one or more components of one or more field systems. The computer system may be a local computer system in relation to at least one of the field systems or a remote computer system in relation to at least one of the field system. In one embodiment, computer system processors may receive, from a field system, inspection data associated with an inspection of an object. Processors can process inspection data to generate data related to performing an operation that physically affects the object. Processors can transmit operation-related data to the field system to make the field system perform the operation that physically affects the object. As an example, the field system can perform the operation based on data related to the operation. As described in this document, data related to operation may include instructions related to soldering, instructions related to coating, instructions related to alteration, instructions related to alignment, or other instructions or data.

[01163] In one embodiment, the computer system processors can receive inspection data (via a receiver) associated with inspections of multiple objects from one or more field systems and generate, based on the inspection data, data related to the performing an operation that physically affects an object from at least one of the field systems. Processors can transmit operation-related data to the field system to make the field system perform the operation that physically affects the object. The inspection data associated with inspections of each object may comprise at least one of the laser inspection data, X-ray inspection data, gamma-ray inspection data, ultrasonic inspection data, particle inspection data magnetic data, eddy inspection data, temperature inspection data, or other inspection data. Inspections of multiple objects can be performed by the same inspection device or by different inspection devices.

[01164] In an embodiment, the data related to the operation (on which the performance of an operation on an object is based) can additionally or alternatively be based on one or more input parameters of one or more operations performed on the object. As an example, a field device (eg, field device 13712) of a field system may perform operations prior to an inspection of the object. Computer system processors may obtain input parameters from previously performed operations, inspection data associated with inspection of the object, or other data from the field system or other sources. Computer system processors can generate transaction-related data based on the data obtained. For example, if a defect is detected based on inspection data, the input parameters can be analyzed in connection with the detected detection to determine the cause of the defect (eg the actual output does not match the theoretical output of the input parameters ) and the operation-related data can be generated so that the operation-related data can be used to carry out an operation that consists of repairing or compensating for the detected defect or the cause of the defect.

[01165] In one modality, the data related to the operation (on which the performance of an operation on an object is based) can additionally or alternatively be based on observations of one or more operations performed on one or more other objects. In one embodiment, computer system processors can monitor one or more operations on one or more objects. For example, processors can monitor operations through one or more inspection devices, such as one or any combination of an inspection laser, an inspection camera, an X-ray radiography inspection device, an inspection device. gamma rays, an ultrasonic inspection device, a magnetic particle inspection device, a current inspection device, a temperature monitor or other inspection device. During this monitoring, processors can obtain data related to observations of operations, such as observations of one or more field devices during the performance of operations, observations of objects during the performance of operations, observations of environmental conditions during the performance of operations, or other observations. Processors can compare observations to determine circumstances that are likely causes of defects and can generate operation-related data for subsequent operations to avoid or mitigate such defects. In one embodiment, computer system processors may 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 elsewhere in this document). In one embodiment, the determination of such circumstances can be stored and used (for example, in conjunction with the determination of such circumstances occurring in other field systems) to (i) generate and select one or more operating protocols for subsequent operations ( as described in this document ) to prevent or reduce defects, (ii) enable the detection of defects earlier in the process (eg as described in this document through active monitoring how operations are performed, in-flight inspection during an operation, etc.) , or (iii) provide other advantages to create better products for current and future customers.

[01166] As an example, analysis of inspection data for multiple welds and operation observation data for these welds may reveal that lack of fusion defects is significantly more likely when the weld voltage drops by more than 0.5V below a welding voltage input parameter while the torch is welding between the 2 o'clock and the 4 o'clock positions on a tube. In contrast, the welding voltage can drop 1.2V below the welding voltage input at other positions in the tube without causing a lack of fusion defect. Based on these observations, the computer system processors can generate and send new welding input parameters that tell the welding devices to increase the welding voltage by 0.7V when the torch is between the 2 o'clock and the 4 o'clock positions. As another example, if the analysis reveals that the welding voltage drop circumstance causes lack of fusion defects while the torch is welding downhill (but not during climb), the new generated welding input parameters may indicate that the welding devices implement welding voltage increase only when the torch is welding downhill. As another example, if the analysis reveals that the welding voltage drop circumstance causes lack of fusion defects for external welds (but not internal welds), the new generated weld input parameters may indicate external welding devices to implement the increase in welding voltage.

[01167] In one embodiment, computer system processors can obtain inspection data associated with inspections of one or more objects and compare the inspection data with a predefined quality profile for the objects. Based on the comparison, processors can determine whether the object has one or more defects, whether the object is ready for the next stage of operations, or other information. As an example, if one or more defects are detected based on inspection data, the generated operation-related data can relate to performing an operation to resolve the detected defects. As another example, if it is determined that the object is ready for the next stage of operations, the operation-related data generated may be related to performing an operation associated with the next stage of operations.

[01168] As an example, the predefined quality profile may include one or more size criteria, shape criteria, consistency criteria, alignment criteria, temperature criteria, color criteria, or other criteria. In a use case, a predefined quality profile for a pipe in a pipe may comprise one or more acceptable ranges for the inner diameter of the pipe, the outer diameter of the pipe, the thickness of the pipe, the size of the interface region between the pipe. tube and other tube to which the tube is or is to be welded, the height of the weld inside the tube, the height of the weld outside the tube, the temperature of the weld material or the tube (for example, during a welding operation welding), the color of the weld material or tube during a welding operation (for example, which may indicate the temperature of the weld material or tube) or other criteria. The predefined quality profile can correspond to a specific quality level, such as a "gold" quality standard (eg a high quality level), a minimum required quality level, etc.

[01169] In one embodiment, computer system processors may provide inspection data associated with inspections of one or more objects, one or more analytical results of an inspection data analysis, or other data for presentation to a user (for example, operator, inspector, manager or other user). In one embodiment, processors may receive user input from the user indicating a defect related to at least one of the objects. As an example, the user can specify where and what the defect is in an object. Based on the specified defect, processors can generate operation-related data that can be used to cause a field system to perform an operation to repair or compensate for the object-related defect.

[01170] In an embodiment, one or more operation triggers may be provided to address circumstances that result in one or more defects (eg, in an object, a group of objects, a design, etc.). For example, despite using the same input parameters for a specific operation, field devices that use those input parameters to perform the operation might perform the operation differently from each other, which might cause an object (operated by a field device) to have a defect while another object (operated by another field device) can be defect-free. These differences in results can be caused by one or more of the actual inputs to the field devices being different from the expected inputs, one or more of the actual outputs from the field devices being different from the expected outputs, one or more imperfections in objects where the field devices are operating, one or more actual operating conditions being different from acceptable operating conditions (eg, environmental conditions, misalignment of objects or displacements, etc.) or other circumstances.

[01171] In one embodiment, computer system processors may monitor one or more operations on one or more objects. During this monitoring, processors can obtain data related to observations of operations, such as observations of one or more field devices during the performance of operations, observations of objects during the performance of operations, observations of environmental conditions during the performance of operations, or other observations. Processors can compare observations against each other to generate one or more operation triggers. After implementing these triggers, one or more field systems can cause one or more operations to be performed by responding to one or more subsequent observations that satisfy the respective triggers. Triggers can include one or more triggers that cause operations to prevent or reduce defects or other triggers.

[01172] In one modality, based on data related to the observations of operations, the computer system processors can compare a first set of observations of an operation performed on an object determined to have a defect (after the execution of the operation) against a or more other sets of observations of the same operation performed on one or more other objects without the defect. After the comparison, processors can determine one or more differences between the first set of observations and the other sets of observations. Based on the differences, processors can generate one or more triggers associated with one or more operations (for example, a defect prevent operation or other operation). As an example, if there are common differences between the first set of observations and each of the other sets of observations, it may be likely that the observed circumstances corresponding to the common differences caused the defect. As such, if these circumstances are observed during a subsequent operation, one or more operations to address those circumstances can be carried out to prevent the defect from occurring (for example, stopping the subsequent operation until the circumstances no longer occur, modifying the parameters of input to the subsequent operation to compensate for the circumstances, generating an alert indicating the circumstances, etc.).

[01173] In one modality, based on data related to the observations of the operations, the computer system processors can compare a second set of observations of the same operation performed on another object determined to have a defect (after the performance of the operation) against the other sets of observations (of the same operation performed on the other objects without the defect). After the comparison, processors can determine one or more differences between the second set of observations and the other sets of observations. For example, processors can compare (i) the common differences between the first set of observations and each of the other sets of observations with (ii) the common differences between the second set of observations and each of the other sets of observations to determine the differences shared by the first and second sets of observations (for example, the similarities between the first and second set of observations share with each other that they are common differences with other sets of observations for other objects without the defect). Based on the common differences for both the first and second sets, processors can generate one or more triggers associated with one or more operations (for example, an operation to prevent the defect or another operation).

[01174] In a use case, comparing one or more sets of observations from a welding operation to a root pass (for one or more pipe-to-tube interface regions), the computer system's processors can determine common differences that by less one set of observations of the weld operation (which produced a defect in its root pass) has with other sets of observations of the weld operation that produced a root pass without the defect. As an example, if the common differences comprise a certain deviation between one or more measured inputs and the input parameters used for the welding operation, processors can generate one or more triggers that activate one or more operations to address the deviation when that deviation is detected. For example, subsequent weld operations for a root pass can be monitored and, if the deviation from the input parameters used by a welding device for the root pass weld operation, the generated triggers can cause the operations to associated are taken to address the deviation (for example, modifying the input parameters to make the actual inputs to the weld operation fall within the expected input ranges associated with the unmodified input parameters, generating an alert provided to an operator or to another individual or system, interrupting the welding operation, etc.). In other use cases, one or more types of similar activators can be generated to face circumstances during a coating operation, a preheat operation, a cooling operation, an alignment operation, a shielding operation, a shielding operation. inspection or other operation, respectively.

[01175] In another use case, when monitoring a subsequent operation on an object, a circumstance corresponding to observations common to defective objects can be detected. In response, an operation trigger for the circumstance can cause an operation associated with the operation trigger to be performed on the object. As an example, computer system processors may modify one or more input parameters for the subsequent operation or other operation to be performed after the subsequent operation. Processors can, for example, modify the input parameters for the subsequent operation during the subsequent operation, modify the input parameters for the next other operation before the next next operation, or perform other modifying operations associated with the operation trigger. Input parameters that are modified can include one or more weld parameters, coating parameters, alignment parameters, change parameters, or other parameters. As another example, processors can stop the subsequent operation (for example, stop the subsequent operation until further notice), generate an alert during the subsequent operation indicating the circumstances (for example, generating and transmitting the alert to a field system running the subsequent operation, providing the alert to a manager, field operator or other personnel, etc.), or perform other operations associated with the trigger of the operation. In this way, for example, previous operation triggers and/or active monitoring can enable the detection of defects earlier in the process and prevent or reduce defects to provide more effective and efficient operations and provide current and future customers with better products. Operation Protocols and Based Operations

[01176] In an embodiment, one or more operation protocols to perform one or more operations can be generated based on inspections of one or more objects. For example, computer system processors (e.g., computer system 5138, remote computer system 13704, field computer system 13716, etc.) may receive from a field system (e.g., field system 5000, 13702 field system, etc.), inspection data associated with an inspection of an object (for example, an inspection before performing one or more operations that physically affect the object, an inspection during the performance of operations, an subsequent inspection of the performance of operations, etc.). Processors can generate an operation protocol (associated with at least one operation type of operations) based on inspection data and one or more input parameters used to perform the operations. The operating protocol can, for example, include a soldering protocol, a coating protocol, an alignment protocol, a change protocol, or other protocol. One or more parameters of the operating protocol may comprise one or more welding parameters, coating parameters, alignment parameters, changing parameters or other parameters.

[01177] In one modality, the computer system processors can select the operation protocol to perform a subsequent operation similar to at least one of the operations (which physically affected the object). Processors can generate, based on at least one input parameter of the operation protocol, data related to the performance of the subsequent operation. Processors can transmit operation-related data to the field system to make the field system perform the subsequent operation. As an example, the field system can perform the subsequent operation based on the data related to the operation.

[01178] In one modality, based on the inspection data, the computer system processors can detect a defect related to the object. In response to defect detection, processors may generate the operating protocol such that the operating protocol comprises a set of input parameters that have at least one input parameter different from a set of input parameters used to perform the operations. . As an example, a predefined operation protocol can be used to perform an operation on the object. If a defect with the object is detected based on an inspection of the object, the predefined operation protocol can be modified to avoid similar defects when the predefined operation protocol is used for one or more subsequent operations similar to the operation that likely caused the defect detected with the object. The modified operation protocol can be stored as a new predefined operation protocol, replace the previous version of the predefined operation protocol, etc.

[01179] In a use case, a predefined weld operation protocol can be used to perform a weld operation to weld two tubes together, where the predefined weld operation protocol can comprise input parameters related to feed speed wire consumption, wire consumption, oscillation width, oscillation waveform, oscillation amplitude, weld time, gas flow rate, welding arc power levels, welding current, welding voltage, welding impedance , welding torque running speed, position of the welding torch welding tip along the tube axis, the angular positioning of the welding torch welding tip relative to its plane of rotation, the welding tip distance from the welding torch to the inner surfaces of the tubes to be welded or other parameters. If, for example, it is determined that the welding operation produced a weld pass layer of insufficient thickness, the preset welding operation protocol can be modified to allow for longer welding time, more wire usage (eg increased welding). wire feed speed) or other switches to the preset welding operation protocol input parameters. As such, when the modified operating protocol is subsequently used to perform a similar operation on two similar tubes, modifying the input parameters can obviate the issue of thickness insufficiency.

[01180] In one modality, based on the inspection data, the computer system processors can determine whether the quality of one or more aspects of the object resulting from the operations (which physically affected the object) meets or exceeds a quality standard indicated by a predefined quality profile. For example, processors can generate the operation protocol so that the operation protocol comprises one or more input parameters (used to perform the operations) that respond to the quality of the aspects of the object that meet or exceed the quality standard indicated by predefined quality profile. The predefined quality profile can correspond to a specific quality level, such as a "gold" quality standard (eg a high quality level), a minimum required quality level, etc. If the quality of the object's aspects meets or exceeds the quality standard indicated by the predefined quality profile, the input parameters (used to perform the operations that produce these results) can be used to generate the operation protocol (for example, the operating protocol comprises some or all of the input parameters). In this way, for example, the operation protocol can be used to perform one or more subsequent operations similar to the operation that produced such results so that the subsequent operations produce a similar quality.

[01181] As another example, if the quality of the object's aspects does not meet the quality standard (indicated by the predefined quality profile), processors can generate the operation protocol so that the operation protocol does not include one or more parameters input (used to perform the operations that resulted in the inspected state of the object). In a use case, if a predefined operation protocol (which includes the input parameters used to perform the operations) was selected to perform at least one of the operations and the quality of the resulting object aspects failed to satisfy a required minimum level of quality, one or more input parameters of the predefined operation protocol can be modified to avoid unsatisfactory subsequent results when the predefined operation protocol is used to perform subsequent operations.

[01182] In one embodiment, computer system processors can obtain inspection data associated with inspections of one or more objects and compare the inspection data with a predefined quality profile for the objects to determine whether the quality of one or more aspects objects meets or exceeds a quality standard indicated by the predefined quality profile. As an example, based on the comparison, processors can determine whether the object has one or more defects, whether the object is ready for the next stage of operations, or other information. As another example, responsive to the quality of aspects of an object that exceeds the quality standard indicated by the predefined qualified profile, processors can generate a new quality profile based on inspection data, where the new quality profile indicates a new standard which is based on inspection data. The new quality profile can, for example, be stored in a database for use in analyzing one or more aspects resulting from one or more subsequent operations.

[01183] In one embodiment, computer system processors may provide inspection data associated with inspections of one or more objects, one or more analytical results of an inspection data analysis, or other data for presentation to a user (for example, operator, inspector, manager or other user). In one modality, processors can receive user input from the user indicating a quality level of one or more aspects of an object resulting from one or more operations (eg, a low quality level, a high quality level, etc. .). In response to user input, processors can generate a new quality profile associated with the indicated quality level, where the new quality profile indicates a new quality standard based on the inspection data. The new quality profile can, for example, be stored in a database for use in analyzing one or more aspects resulting from one or more subsequent operations.

[01184] In one modality, the computer system processors can generate one or more operation protocols based on data related to the input parameters used to perform one or more operations, data related to the observation of operations, inspection data associated with a inspection of objects on which operations are performed (for example, before, during or after an operation) or other data. As an example, processors can analyze inspection data to determine if and which objects are defective. Processors can 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 elsewhere in this document). Based on the comparison, processors can generate the operation protocols so that the operation protocols avoid or otherwise meet the circumstances (probably caused the defect) when the operation protocols are used for one or more subsequent operations (for example , subsequent operations that are the same or similar to the operation performed and observed).

[01185] As another example, if it is observed that the input parameters used to perform the operation on one or more objects are different from the input parameters used to perform the operation on one or more other objects, processors can compare these observations with each other to determine whether differences in input parameters are likely to cause the defect. For example, observations can be compared to determine common differences between input parameters used to perform the operation on objects with a resulting defect and input parameters used to perform operations on objects without the defect. Based on the common differences, processors can generate the operating protocols so that the operating protocols avoid including the input parameters that are likely to cause the defect. The generated operation protocols can be stored so that the operation protocols can be used in one or more subsequent operations (for example, subsequent operations that are the same or similar to the operation performed and observed). For example, in a use case regarding welding protocols, analysis of the inspection data for multiple welds and the operation observation data for those welds can reveal that the lack of fusion defects is significantly more likely when the stress welding voltage drops more than 0.5V below a welding voltage input parameter while the torch is welding between the 2 o'clock and the 4 o'clock positions on a tube. In contrast, the welding voltage can drop 1.2V below the welding voltage input at other positions in the tube without causing a lack of fusion defect. Based on these observations, computer system processors can generate welding protocols that comprise new welding input parameters that indicate the need to increase the welding voltage by 0.7V when the torch is between the 2 o'clock and 4 o'clock positions . Other Sample Flowcharts

[01186] FIG. 138 shows a flowchart of a method 13800 for facilitating, by a field system (e.g., one of the field systems 13702), field trials and physical operations based thereon, according to one or more modalities. The processing operations of the method presented below are intended to be illustrative and not limiting. In some embodiments, for example, the method can be performed with one or more additional operations not described, and/or without one or more of the operations discussed. Furthermore, the order in which method processing operations are illustrated (and described below) is not intended to be limiting. In some embodiments, the method can be implemented by at least one or more processing devices (eg, 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 electronic information processing). Processing devices may include one or more devices that perform some or all of the method's operations in response to instructions stored electronically in an electronic storage medium. Processing devices may include one or more devices configured through hardware, firmware and/or software to be specifically designed to perform one or more of the method's operations.

[01187] In one modality, an object can be scanned (13802). As an example, the object can be checked before, during, or after an operation that physically affects the object being performed on the object to obtain inspection data. Operation 13802 can be performed by an inspection device that is the same or similar to inspection device 13714, according to one or more modalities. As an example, the inspection devices may comprise an inspection camera, an X-ray radiography inspection device, a gamma ray inspection device, an ultrasonic inspection device, a magnetic particle inspection device, an inspection device. current inspection, a temperature monitor or other inspection device. Inspection data can comprise laser inspection data, camera inspection data, X-ray inspection data, gamma ray inspection data, ultrasonic inspection data, magnetic particle inspection data, inspection data. Foucault, temperature inspection data or other inspection data.

[01188] In one modality, inspection data associated with the object scan (13804) can be obtained. Operation 13804 may be performed by a field computer system that is the same or similar to field computer system 13716, according to one or more embodiments.

[01189] In one embodiment, inspection data may be transmitted to a remote computer system (eg, remote computer system 13720) (13806). Operation 13806 may be performed by a field computer system that is the same or similar to field computer system 13716, in accordance with one or more embodiments.

[01190] In one embodiment, data related to performing an operation that physically affects the object can be obtained from the remote computer system responsive to the transmission of inspection data (13808). As an example, operation-related data can be derived from inspection data. As another example, operation-related data can be obtained by the remote computer system from inspection data, other inspection data associated with a scan of another object, input parameters used to perform operations on the respective objects before the scans, or other data. Operation 13808 may be performed by a field computer system that is the same or similar to field computer system 13716, in accordance with one or more embodiments.

[01191] In one modality, based on data related to the operation, a field device of the field system can be made to perform the operation that physically affects the object (13810). Operation 13810 may be performed by a field computer system that is the same or similar to field computer system 13716, in accordance with one or more embodiments.

[01192] In one embodiment, with respect to FIG. 138, data related to operation may include instructions related to soldering, such as instructions related to wire feed speed, wire consumption, oscillation width, oscillation waveform, oscillation amplitude, weld time, flow rate of gas, welding arc power levels, welding current, welding voltage, welding impedance, welding torch travel speed, welding torch welding tip position along tube axis, tip angular positioning distance of the welding torch with respect to its plane of rotation, distance from the welding tip of the welding torch to the inner surfaces of the tubes to be welded, or other instructions. Based on the instructions related to welding, a field device of the field system can be made to perform a welding operation on a first object and a second object (for example, welding two tubes together, welding two other objects together, etc. ).

[01193] In one embodiment, with respect to FIG. 138, data related to operation may include instructions related to coating, such as instructions related to preheat temperature, coating thickness, or other instructions. Based on the instructions related to coating, a field device in the field system may be required to apply one or more layers of coating to an object.

[01194] In one embodiment, with respect to FIG. 138, data related to operation may include instructions related to alignment. Based on the instructions related to alignment, a field device of the field system can be made to align an object (eg aligning two tubes for welding, aligning other objects with each other, etc.).

[01195] In one embodiment, with respect to FIG. 138, the data related to the operation may include instructions related to the change. Based on the instructions related to the change, a field system field device can be caused to change an object, such as increasing at least a part of the object, reducing at least a part of the object, resizing at least a part of the object , modifying a shape of at least a part of the object, or other changes.

[01196] FIG. 139 shows a flowchart of a method 13900 for facilitating, by a computer system, field trials and physical operations based thereon, according to one or more modalities. The processing operations of the method presented below are intended to be illustrative and not limiting. In some embodiments, for example, the method can be performed with one or more additional operations not described, and/or without one or more of the operations discussed. Furthermore, the order in which method processing operations are illustrated (and described below) is not intended to be limiting. In some embodiments, the method can be implemented by at least one or more processing devices (eg, 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 electronic information processing). Processing devices may include one or more devices that perform some or all of the method's operations in response to instructions stored electronically in an electronic storage medium. Processing devices may include one or more devices configured through hardware, firmware and/or software to be specifically designed to perform one or more of the method's operations.

[01197] In one embodiment, inspection data associated with a scan of an object can be obtained from a field system (13902). Operation 13902 may be performed by an object profile subsystem that is the same or similar to object profile subsystem 13732, according to one or more embodiments. As an example, inspection data can comprise laser inspection data, camera inspection data, X-ray inspection data, gamma-ray inspection data, ultrasonic inspection data, magnetic particle inspection data, eddy inspection data, temperature inspection data, or other inspection data.

[01198] In one modality, one or more input parameters of one or more operations performed on the object can be obtained (13904). As an example, operations performed on the object can be operations that physically affected the object and were performed on the object prior to the verification of the object (on which the inspection data is based). Input parameters can be input parameters used to perform operations on the object (for example, weld parameters, coating parameters, or other input parameters). Operation 13904 can be performed by an operation monitoring subsystem that is the same or similar to operation monitoring subsystem 13738, according to one or more modalities.

[01199] In one modality, inspection data and input parameters can be processed to generate related data to perform an operation that physically affects the object (13906). As an example, the operation-related data may comprise one or more of the types of operation-related data described above with respect to FIG. 138 (eg instructions related to soldering, instructions related to coating, etc.). Operation 13906 may be performed by an operation management subsystem that is the same or similar to operation management subsystem 13734, according to one or more modalities.

[01200] In one modality, data related to the operation can be transmitted to the field system to make the field system perform the operation, where the operation is performed based on the data related to the operation (13908). As an example, the operations that the field system can perform may comprise one or more of the types of operations (which a field device of the field system is caused to perform) described above with respect to FIG. 138. Operation 13908 may be performed by an operation management subsystem that is the same or similar to operation management subsystem 13734, according to one or more modalities.

[01201] FIG. 140 shows a flowchart of a method 14000 for facilitating, by a computer system, field trials and physical operations based thereon, according to one or more modalities. The processing operations of the method presented below are intended to be illustrative and not limiting. In some embodiments, for example, the method can be performed with one or more additional operations not described, and/or without one or more of the operations discussed. Furthermore, the order in which method processing operations are illustrated (and described below) is not intended to be limiting. In some embodiments, the method can be implemented by at least one or more processing devices (eg, 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 electronic information processing). Processing devices may include one or more devices that perform some or all of the method's operations in response to instructions stored electronically in an electronic storage medium. Processing devices may include one or more devices configured through hardware, firmware and/or software to be specifically designed to perform one or more of the method's operations.

[01202] In an embodiment, a defect related to an object can be detected based on inspection data associated with an object scan (14002). For example, scanning can be performed after an operation has been performed on the object using a first set of input parameters (eg weld parameters, coating parameters, or other input parameters). Inspection data can be received from the field system, where inspection data can comprise laser inspection data, camera inspection data, X-ray inspection data, gamma ray inspection data, laser inspection data. ultrasonic, magnetic particle inspection data, eddy inspection data, temperature inspection data, or other inspection data. Operation 14002 may be performed by an object profile subsystem that is the same or similar to object profile subsystem 13732, according to one or more embodiments.

[01203] In one modality, an operation protocol associated with an operation type of the operation (which was executed on the object using the first set of input parameters) can be generated (14004). As an example, the operation protocol can be generated such that the operation protocol comprises a second set of input parameters different from the first set of input parameters (for example, which was used to perform the operation that likely caused the failure ). In a use case, for example, the first set of input parameters and inspection data can be analyzed to determine which of the parameters likely caused the defect, and these parameters (determined as likely to have caused the defect) can be modified to generate the second set of input parameters for the operating protocol. After generation, the operation profile can be stored in a database (for example, an operation protocol database or other database) for use with subsequent operations. Operation 14004 may be performed by an operating protocol subsystem that is the same or similar to operating protocol subsystem 13736, according to one or more embodiments.

[01204] In one modality, the operation protocol can be selected to perform a subsequent operation similar to the operation (performed on the object using the first set of input parameters) (14006). For example, if the previous feature was a weld feature for a root pass, the subsequent feature could also be a weld feature for a root pass. As another example, if the previous operation was a welding operation for a hot pass, the subsequent operation could also be a welding operation for a hot pass. Operation 14006 may be performed by an operating protocol subsystem that is the same or similar to operating protocol subsystem 13736, according to one or more embodiments.

[01205] In one modality, data related to carrying out the subsequent operation can be generated based on at least one parameter of the operation protocol (14008). Operation 14008 may be performed by an operation management subsystem that is the same or similar to operation management subsystem 13734, according to one or more modalities.

[01206] In one modality, data related to the operation can be transmitted to the field system to cause the field system to perform the subsequent operation, where the subsequent operation is performed based on the data related to the operation (14010). Operation 14010 can be performed by an operation management subsystem that is the same or similar to operation management subsystem 13734, according to one or more modalities.

[01207] FIG. 141 shows a flowchart of a method 14100 for facilitating, by a computer system, field trials and physical operations based thereon, according to one or more modalities. The processing operations of the method presented below are intended to be illustrative and not limiting. In some embodiments, for example, the method can be performed with one or more additional operations not described, and/or without one or more of the operations discussed. Furthermore, the order in which method processing operations are illustrated (and described below) is not intended to be limiting. In some embodiments, the method can be implemented by at least one or more processing devices (eg, 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 electronic information processing). Processing devices may include one or more devices that perform some or all of the method's operations in response to instructions stored electronically in an electronic storage medium. Processing devices may include one or more devices configured through hardware, firmware and/or software to be specifically designed to perform one or more of the method's operations.

[01208] In an embodiment, a quality of one or more aspects of an object can be determined based on inspection data associated with an object scan (14102). For example, scanning can be performed after an operation has been performed on the object using a set of input parameters (for example, weld parameters, coating parameters, or other input parameters). Inspection data can be received from the field system, where inspection data can comprise laser inspection data, camera inspection data, X-ray inspection data, gamma ray inspection data, laser inspection data. ultrasonic, magnetic particle inspection data, eddy inspection data, temperature inspection data, or other inspection data. Operation 14102 may be performed by an object profile subsystem that is the same or similar to object profile subsystem 13732, according to one or more embodiments.

[01209] In a modality, responding to quality that exceeds a quality standard (indicated by a predefined quality profile), an operation protocol associated with an operation type of the operation (which was performed on the object using the set of parameters of input) can be generated (14104). As an example, the operation protocol can be generated in such a way that the operation protocol comprises one or more parameters from the set of input parameters (used to perform the operation). As another example, the operation protocol can be generated in such a way that the operation protocol comprises all parameters of the input parameter set. After generation, the operation profile can be stored in a database (for example, an operation protocol database or other database) for use with subsequent operations. Operation 14104 may be performed by an operating protocol subsystem that is the same or similar to operating protocol subsystem 13736, according to one or more embodiments.

[01210] In one modality, the operation protocol can be selected to perform a subsequent operation similar to the operation (performed on the object using the first set of input parameters) (14106). Operation 14106 may be performed by an operating protocol subsystem that is the same or similar to operating protocol subsystem 13736, according to one or more embodiments.

[01211] In one embodiment, data related to performing the subsequent operation can be generated based on at least one parameter of the operation protocol (14108). Operation 14108 may be performed by an operation management subsystem that is the same or similar to operation management subsystem 13734, according to one or more modalities.

[01212] In one embodiment, data related to the operation can be transmitted to the field system to cause the field system to perform the subsequent operation, where the subsequent operation is performed based on the data related to the operation (14110). Operation 14110 may be performed by an operation management subsystem that is the same or similar to operation management subsystem 13734, according to one or more modalities.

[01213] FIG. 142 shows a flowchart of a method 14200 for facilitating, by a computer system, field trials and physical operations based thereon, according to one or more modalities. The processing operations of the method presented below are intended to be illustrative and not limiting. In some embodiments, for example, the method can be performed with one or more additional operations not described, and/or without one or more of the operations discussed. Furthermore, the order in which method processing operations are illustrated (and described below) is not intended to be limiting. In some embodiments, the method can be implemented by at least one or more processing devices (eg, 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 electronic information processing). Processing devices may include one or more devices that perform some or all of the method's operations in response to instructions stored electronically in an electronic storage medium. Processing devices may include one or more devices configured through hardware, firmware and/or software to be specifically designed to perform one or more of the method's operations.

[01214] In a modality, one or more operations that are being performed on one or more objects can be monitored (14202). Operation 14202 may be performed by an operation monitoring subsystem that is the same or similar to operation monitoring subsystem 13738, according to one or more modalities.

[01215] In one modality, data related to observations of operations can be obtained based on monitoring (14204). As an example, observation-related data may include data related to observations of one or more field devices during the performance of operations, observations of objects during the performance of operations, observations of environmental conditions during the performance of operations, or other observations. Operation 14204 may be performed by an operation monitoring subsystem that is the same or similar to operation monitoring subsystem 13738, according to one or more modalities.

[01216] In one modality, one or more sets of observations of an operation (performed on one or more objects determined to have a defect) can be compared with one or more other sets of observations of the operation (performed on one or more operations without the defect) (14206). Operation 14206 may be performed by an operating protocol subsystem that is the same or similar to operating protocol subsystem 13736, according to one or more embodiments.

[01217] In an embodiment, one or more common differences of the sets of observations (corresponding to defective objects) with the other sets of observations (corresponding to objects without the defect) can be determined based on the comparison (14208). Operation 14208 may be performed by an operating protocol subsystem that is the same or similar to operating protocol subsystem 13736, in accordance with one or more embodiments.

[01218] In a modality, one or more operation triggers can be implemented based on common differences (14210). As an example, after implementing an operation trigger based on one of the common differences, the operation trigger can cause an associated operation to be performed when a circumstance corresponding to the common differences occurs in a subsequent operation. Operation 14210 may be performed by an operating protocol subsystem that is the same or similar to operating protocol subsystem 13740, in accordance with one or more embodiments.

[01219] In one modality, the universal cloud profiling system (here also as "uLog" or "uLog system" or "uCloud") is a system of software, hardware, equipment and telecommunications networks, which seamlessly gather data from welding to provide quality control and management, welding data profiling, project and task management, safety and inspection control and management, real-time welding activity monitoring and data communication and visualization. The uLog system may use wired systems and devices and/or wireless systems and devices and/or Bluetooth systems and devices and/or cloud-based systems and devices. The uLog system may use software technology, mobile device and desktop technology, telecommunications technology and other technologies in products, appliances, systems, processes and methods to achieve high quality welding, inspection, control, management and safety results. The uLog system can be used in, under construction conditions on land, at sea, ship based, platform based, structure based or other construction conditions. In one modality, uLog can process Bluetooth communications and data can be transmitted to uLog for processing via Bluetooth or any other wireless means.

[01220] In one modality, uLog has tools that perfectly collect weld data and/or weld data profiles. The uLog system can, in its multiple and varied modalities, use weld data and other piping constructions and related data to produce one or more of the following: analytical results, field reports, control data, quality control data, reports automatically generated administrative summaries, daily summaries, data files, weld logs, material usage data, quality control records, and project management records.

[01221] In one modality, uLog can be used to maintain and/or generate procedure qualification records (procedure qualification records, "PQR") and data related to them. The uLog functionality can also be used to record, develop, maintain and manage welding procedure specifications (WPS).

[01222] uLog can provide the functionality to view, record, track, measure and analyze profile data for a user about one or more welds and/or welding activities and/or pipeline construction and/or coating activities and /or inspection activities and/or management activities. By using uLog and its analytical features, a user can achieve improved weld quality and quantify the results of the welding process. In its many and varied modalities, uLog can have functionalities to process data in real time or based on historical data. This allows a user to make decisions in real time and/or based on historical data. In one modality, uLog can provide a real-time user dataset about any aspect of welding, coating, inspection, pipe handling, project management, pipeline construction and/or ongoing construction activities and achieves control over real-time quality welding and/or welding activities and/or other activities relating to piping construction. In another modality, uLog can also provide functionality regarding construction management, project management, accounting, inventory and materials management, as well as financial controls and financial and materials audits. uLog can also provide functionality in human resource management and timing, as well as payroll accounting and support.

[01223] Without limitation, various embodiments of the present invention can be, for example, embodied as a computer system, a method, a cloud-based service or a computer program product. Thus, various modalities can take the form of an all-hardware modality, an all-software modality (for example, one or more computer applications, such as an "App" (or "App") to be deployed on a mobile device and /or an application to be deployed to a desktop computer) or a modality that combines both software and hardware aspects. Furthermore, embodiments may take the form of a computer program product stored on a computer-readable storage medium having computer-readable instructions (e.g., software) embedded in the storage medium. Various modalities can take the form of computer software implemented over the web. Any suitable computer readable storage medium can be utilized, including, for example, hard disks, compact disks, DVDs, optical storage devices, solid state storage devices and/or magnetic storage devices.

[01224] Various embodiments are described below with reference to schematics, block diagrams, images and illustrations of method flowcharts, apparatus (eg systems) and computer program products. It is to be understood that each block of the block diagram and flowchart illustrations and combinations of blocks in the block diagrams and flowchart illustrations, respectively, can be implemented by a computer executing computer program instructions. These computer program instructions can be loaded into a general purpose computer, a special purpose computer or other programmable data processing apparatus to produce a machine such that the instructions that are executed in the computer or other data processing apparatus programmable data creates a means to implement the functions specified in the block or blocks of the flowchart.

[01225] These computer program instructions may also be stored in computer readable memory which can direct a computer or other programmable data processing apparatus to function in such a way that the instructions stored in computer readable memory produce an article of fabrication that can be configured to implement the function specified in the flowchart block or blocks. Computer program instructions can also be loaded into a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process so that the instructions run on the computer. computer or other programmable equipment provide the steps for performing the functions specified in the flowchart block or blocks.

[01226] Therefore, blocks in block diagrams and flowchart illustrations support combinations of mechanisms to perform the specified functions, combinations of steps to perform the specified functions, and program instructions to perform the specified functions. It should also be understood that each block in the block diagram and flowchart illustrations and combinations of blocks in the block diagrams and flowchart illustrations can be implemented by hardware-based computer systems for specific purposes, which perform the specified functions or steps or combinations of purpose-built hardware and other hardware that executes the appropriate computer instructions. Implementation can also be done by purpose-built software and equipment running the purpose-built software and/or applications. The entire system can be accessible from various computer platforms, including mobile devices.

[01227] FIG. 143 contains images of terrestrial pipelines. uLog can be used to manufacture any pipeline in any construction environment. Construction environments can be on land, at sea, on land and at sea, under water, under water, in an installation, on a ship, on a barge, on a platform, on a structure, in space or in any another construction environment. For example, uLog can be used in pipe welding control.

[01228] FIG. 144 shows a soldering station 14410, in accordance with an embodiment of the present disclosure. The uLog can be used in conjunction with the 14410 soldering station. The uLog can process data from the 14410 soldering station. The soldering station can include a 14412 soldering machine or soldering system, a 14414 welder, or a soldering system automated or robot. In one embodiment, the 14412 welding machine or welding system is an orbital welding machine. An example of a 14412 welding machine or welding system is described in US Patent No. 3,974,356 to Nelson et al., issued August 10, 1976, the entire contents of which are incorporated herein by reference. The soldering station 14410 can be controlled by a computer system 14416 to control the soldering process and also the acquisition of data about the soldering process. The uLog implemented in computer system 14416 can control welding station 14410 including welding machine 14412 and can also process data from a workpiece 14418 such as a tube and/or in relation to work or welding applied over the workpiece (eg tube) 14418.

[01229] FIG. 145 shows a plurality of pipeline weld stations 14410 (a pipeline weld spread 14420), in accordance with an embodiment of the present disclosure. uLog can be used in 14420 pipe weld propagation. uLog can process data from one or more 14410 weld stations in 14420 pipe weld propagation. In one modality, uLog can process data from one number or from many stations No. 14410 welding stations. There is no limitation on the locations of 14410 welding stations. 14418 lines can be very long and one or more stations can be in any location without any limitation. In addition, uLog supports data processing from multiple projects and/or activities and/or tasks and/or people at the same time. The uLog user experience can be used in projects as well as in the scope of projects. uLog allows a user to work with data from one or several projects simultaneously or serially, in real time or on a historical basis.

[01230] FIG. 146 is a schematic diagram of a system with a plurality of soldering stations 14410 in communication with a plurality of control and profile collection stations (computer systems) 14416, in accordance with an embodiment of the present disclosure. In one embodiment, weld data can be collected at a profile collection station 14416 associated with a weld station 14410. Control and profile collection stations 14416 can process the data for one or more welds and/or stations No. 14410. Data collection and/or processing may originate from piping construction, welding station equipment, operator, welder, or other means of data entry. In the non-limiting example, equipment processors, embedded processors, computers, sensors, process control devices, wired or wireless analog and digital devices, and manual data processors may be used to link, communicate and/or process the station. solder and/or solder system data. In one modality, one or more technicians can control the 14410 welding stations and 14416 profile and control collection stations. There is no limit to the number of 14416 profile and control collection stations that can be used with uLog. The 14416 record collecting station together with the 14410 soldering station for a 14422 soldering system.

[01231] FIG. 147 is a schematic diagram of a system with a plurality of soldering stations 14410, in communication with a plurality of control and profile collection stations 14416, in accordance with another embodiment of the present disclosure. In one embodiment, welding data can be collected from each 14410 welding station or 14422 welding system. In another embodiment, welding data can be collected from a number of 14410 welding stations or systems. There is no limit to the number of 14410 welding stations and/or 14422 welding systems.

[01232] FIG. 148 is a schematic diagram of soldering station 14410 in communication with a wireless network 14424 via a wireless connection (e.g., WiFi connection) 14426, in accordance with an embodiment of the present description. For example, the 14410 soldering station can be provided with a wireless communication capability such as Bluetooth, Wi-Fi, cellular communication, satellite phone or other wireless means. For non-limiting example, a welding station 14410 may have one or more of a welding process computer, server or processing unit 14416, which can collect and process data from the welding system. As shown in FIG. 148, soldering station 14410 includes two soldering machines or 14412 soldering systems. In one embodiment, 14412 soldering systems include an orbital soldering system. One of the 14412 welding machines is a clockwise welding machine (clockwise, CW) and another 14412 welding machine and a counterclockwise (counterclockwise, CCW) welding system or machine.

[01233] FIG. 149 is a schematic diagram of a plurality of workplaces 14430 in communication with a cloud server 14432 via a worldwide network (Internet), in accordance with an embodiment of the present invention. uLog can be configured on a local, regional, project or worldwide basis. The implementation of uLog has no geographic limitation. One or several 14430 workstations can be networked with uLog. In one modality, users, personnel, managers, engineers, departments, companies, specialists, workers, customers and a multitude of other parties can be networked to uLog. Each job site 14430 includes a 14410 welding station operated by the 14414 welder (as shown in FIG. 144), a 14434 lead technician and a 14436 welding engineer, etc. Each 14430 workplace is configured to communicate with cloud server 14432 via a dedicated communication line or communication channel 14440 or via the 14442 internet. Cloud server 14432 is accessible by a 14438 system manager and Engineering 14439. A storage device 14433 in communication with the cloud server may be provided for storing weld data.

[01234] FIG. 150 is a schematic diagram of a plurality of soldering stations 14410 in communication with the intermediate computing devices 14450 operated by the technical managers (principal technicians 14452, inspectors 14454, engineers 14456, etc.) through communication channels or lines 14458, in accordance with an embodiment of the present disclosure. For example, each 14410 welding station can communicate with one or more of the 14450 intermediate computing devices. Likewise, each 14450 intermediate computing device is configured to communicate with one or more of the 14410 welding stations. Intermediate computing 14450 are in turn configured to communicate with cloud server 14432 over the Internet 14442. Portions of the uLog program are configured to run on cloud server 14432, other portions of uLog are configured to run on computing devices 14450 intermediates and still other portions are configured to be deployed on the 14416 soldering station server/computer. Each portion or component of uLog works in synergy with other portions or components to provide continuous management of the entire system. In one modality, uLog can optionally have differentiated worldwide network capabilities and propagation of network capabilities. In another modality, all capabilities are fully integrated; and in yet another modality it may be undifferentiated.

[01235] FIG. 151 is a schematic diagram of a plurality of 14412 soldering stations in communication with an intermediate computer system 14450 (operated by Engineer, Quality and Technology terminals) via a 14426 wireless communication channel (e.g. WiFi) to the wireless communication network 14424, in accordance with an embodiment of the present disclosure. The intermediate computer system can be any type of computing device, including a tablet, phone, smartphone, PDA and/or other wireless devices for data input, processing, communication, input, output and other functions. The intermediate computer runs the uLog program and can be operated through engineering, quality control, users, supervisory technicians, and others. In one embodiment, the uLog executed at the intermediate computer 14450 provides data, processes data, and communicates the data or information to the computer of soldering station 14416 located at each of the soldering stations 14410.

[01236] FIG. 152 is a schematic diagram of a plurality of soldering stations 14410 in communication with an intermediate computer system 14450 via a wireless communication channel (e.g., WiFi) 14426 to wireless communication network 14424, according to a modality of this disclosure. FIG. 152 shows a propagated network configuration. The 14450 mid-range computer system has wireless capability, such as Wi-Fi or cellular (3G, 4G, etc.), allowing it to communicate wirelessly with any of the 14410 soldering stations. The 14450 mid-range computer can be any type of wireless mobile device such as a smartphone, tablet or PDA that can connect anywhere on the 14424 wireless network. In one modality, the uLog program or system can use mesh network processing data through a mesh network wireless (eg WiFi) 14424. For example, a 14416 soldering station server from a 14410 soldering station can communicate with a 14450 uLog device over a 14424 mesh wireless network and can connect to any place within the 14424 mesh network. In one embodiment, the mesh network may be used in a propagation network configuration.

[01237] FIG. 153 is a schematic diagram of a plurality of welding stations 14410 in communication with a plurality of intermediate computer systems 14450 (operated by Engineer 14456, inspectors 14454, principal technician 14452, etc.), which in turn are in communication with the cloud server 14432, in accordance with an embodiment of the present disclosure. FIG. 153 shows a data flow diagram for an overall network configuration. In one modality, the global network configuration can be a worldwide network configuration. General network configuration can be used by managers, engineers, inspectors, technicians, key technicians, welding engineers, welders and welding stations, as well as others. In one embodiment, the uLog global network configuration can optionally have a data stream differentiated by worldwide network capabilities and propagation network capabilities. In another modality, all capabilities are fully integrated without differentiation. Similar to the configuration shown in FIG. 150, for example, each welding station 14410 can communicate with one or more of the intermediate computing devices 14450. Each intermediate computing device 14450 is configured to communicate with one or more of the welding stations 14410. The intermediate computing devices 14450 are in turn configured to communicate with cloud server 14432 over the Internet 14442. Portions of the uLog program are configured to run on cloud server 14432, other portions of uLog are configured to run on intermediate computing devices 14450 and further other portions are configured to be implemented on the 14416 Soldering Station Server/Computer. Each portion or component of the uLog program or system works in synergy with other portions or components to provide ongoing management of the entire system. In one modality, uLog can optionally have differentiated worldwide network capabilities and propagation of network capabilities. In another modality, all capabilities are fully integrated; and in yet another modality it may be undifferentiated.

[01238] FIG. 154 shows an example graphical user interface (GUI) 14460 for a "Main Screen" of a cloud-based universal data logging (uLog) request implemented by a computer system at the welding station 14410, in intermediate computer system 14450 or in cloud server 14432, in accordance with an embodiment of the present disclosure. In one modality, uLog provides numerous features for data retrieval, data analysis, data mining, data warehousing and reporting. The 14460 GUI includes a plurality of icons 14461 to 14468. Each icon when activated (for example, by a mouse click or finger tap) opens an application. For example, the 14461 icon is associated with the Admin application configured to be operated by the administrator for creating uLog administrative features. Icon 14462 is associated with weld parameters configured for entering weld parameters. Icon 14463 is associated with the "Log" function. Icon 14464 is associated with "Report". Icon 14465 is associated with "Job Setup". Icon 14466 is associated with "Analytical". Icon 14468 is associated with uploading and saving data to the cloud (ie, saving data to cloud server 14432 or storage device 14433). Therefore, as can be appreciated, uLog's universal logging functionalities may include, but are not limited to processing data and information on: administration, weld parameters, logs, records, reports, job setup, inspection, quality control , coating, piping manipulation, diagnostics, analysis, and user and/or administrative data for on-premises and/or cloud processing.

[01239] The scope of this disclosure covers the methods and means to achieve the disclosed pipeline welding and construction support, as well as encompassing any article, product, means and methods to produce and use any software, application, executable computer code, programming, logical sequences, or any other form of electronic or automated means to achieve and/or use the methods in this document. Such products, articles and media include, for example, but are not limited to, a software application product provided on a fixed medium, such as a disk or in physical memory or on a memory card or as a software application product. software or as an application provided by digital download or provided by other means. This application expressly encompasses installed, uninstalled, compiled and uncompiled versions of any software product or equivalent product capable of being used, implemented, installed or actively using, achieving and/or practicing the methods described in this document. In addition to its normal and usual meanings, the motto "computer-readable program code means" is intended to be broadly interpreted to encompass any kind and type of computer-readable program code, executable code, software as a service , web service, cloud service or cloud-based process, embedded applications, software application product provided on a fixed media such as a disk or in physical memory or in flash memory or on a memory card or as a software product software application or as an application provided by digitally downloading or encoded into programmable hardware or provided by other means that may be employed to make, use, sell, practice, achieve, engage in, produce, function or operate the methods disclosed herein. document. The application must be fully explained in this regard and is not limited to any means of delivery or any form of product to provide or use, achieve and/or practice the products of computer-readable program code, means and/or methods disclosed in this document. In embodiments, all methods described in this document can be produced and provided to a user as software products, software applications, computer readable program code media or any other articles or devices that can be used to achieve any, some, or all results, calculations and/or numerical methods disclosed in this document.

[01240] In one modality, the user can configure an on-premises or cloud service. In a cloud-based example, a user may use and/or inherit service-related information from the cloud to be collected by or pushed to the user's device and/or machine (eg, computer 14416 associated with the welding machine 14412). Setting up a service on or through the cloud can enable device 14416 to inherit service-related information from the cloud to be pushed to device and/or machine 14416. In another embodiment, uLog provides integrity maintenance of single point data. Data storage and retrieval 'machine to cloud (M2C)' and 'cloud to machine (C2M)' data are also functions provided by uCloud.

[01241] In another modality, a centralized location can be used when service customer details can be entered, processed and maintained or automatically retrieved by uLog. uLog can also use a distributed approach to data management and processing. uLog can create and append parameter files for specific services to be deployed to a service managed by the correct authorities, with user privilege levels assigned. This job-related information can be inherited by the assigned user and pushed to 14416 computers associated with 14412 welding machines (cloud to machine, "C2M"). Changes made to work-related information are collected from 14416 computers associated with 14412 welding machines and synchronized (synchronized) back to the cloud (from machine to cloud, "M2C") (ie, cloud server 14432) . Cloud server 14432 provides a single point where some or all of the data is processed by uLog.

[01242] uLog can process, record, analyze and use data from one, more or all of the following types of equipment: welding machines, tube bending equipment, tube treatment equipment, final preparation equipment, clamps, welding equipment filling and/or crushing, double joining equipment and/or weighing systems, equipment and/or systems, transport equipment and/or systems, construction equipment and construction/management systems. uLog can also be an ERP (Enterprise Resource Planning) system or work with an ERP system.

[01243] uLog can utilize and/or process data from any one or more of the following types of welding equipment. Such welding equipment can be, for example, but is not limited to: manual welding equipment, automatic welding equipment, outer welding machine, inner welding machine, single torch welder, double torch welder, multiple torch welder, high productivity welding systems, control system, internal control system, external control system.

[01244] uLog can use and/or process data from any one or more of the following types of pipe bending equipment: bending machines, wedge chucks, hydraulic wedge chucks, connecting chucks, hydraulic plug chucks, chucks pneumatic, pneumatic wedge chucks. uLog may use and/or process data from one or more of the following types of pipe delivery equipment: DECKHAND® equipment (CRC-Evans, Houston, TX), vehicles, construction vehicles, and equipment adapted to produce data for use or processing. uLog can use and/or process data from one or more of the following types of equipment: bending assemblies and matrices, angle measuring equipment and devices, compressors, cradles, bars and/or supports, degaussing equipment, tires, wheels and rail wheels.

[01245] uLog can use and/or process data from one or more of the following types of equipment: a final preparation station to augment the ground in tube bevel, alignment station for tube alignment, and an external weld station cover filler for external solder cap application, internal soldering station for internal soldering application, trailer or power containers with diesel generator and solder rectifiers, tube shims and supports for tube transfer from station to station , internal pneumatic alignment clamps and pipe turning machines, sub-arc welding machines and processing equipment.

[01246] uLog may also use and/or process data from one or more of the following types of equipment: LayBarge equipment, pipe handling, double junction, junction coating equipment, coating equipment, onshore equipment, offshore equipment, equipment deep water equipment, shallow water equipment, roller units, conveyors, tube transfer equipment, support structures, support units, roller modules, longitudinal transport of roller modules, tube elevators, tube supports, tube supports tube rolls (PSA and PSF), tube transfer carts, PTC-V tube transfer carts, rear tube supports, height adjustable tube supports, SPSA roll type rear tube support, tube type TPSA, transverse conveyors, movable beam type conveyors and TV-CW transverse conveyors.

[01247] uLog can use and/or process data from any one or more of the following types of processes and methods: welding, tube welding, pipe welding, coating, joint coating, field coating, inspection, quality assurance , non-destructive testing, heat treatment, management, offshore management, onshore management, managed services, welding support, spoolbase and micro-alloy management.

[01248] In one modality, uLog can be used to roll out daily service statistics from the cloud and mobile device. PQR and/or WPS Creation and/or daily reports can be produced from a mobile and/or cloud platform or by other means. Analysis of data collected from cloud and mobile devices provides feedback to the control system to improve quality and defect prediction. In one modality, uLog allows for integrated pipe joint marking, synchronized with data logs. uLog can also use Single Point Capture of data profiles, provide machine configuration information and process software revisions.

[01249] uLog can also perform automatic error reporting of the equipment status, automatically stamp a service location in service logs, as well as perform the synchronized capture of service-related parameter change notes of all users for a given project. In addition, the Consolidated Project related report to single point customers can also be generated by uLog.

[01250] FIG. 155 shows an example of a GUI for a "Live Log" screen of the cloud-based universal data logging (uLog) request showing voltages as a function of time at a welding station, according to a modality of this disclosure. In one modality, uLog performs a centralized data capture of data from all tube weld manipulations, coating-related machines, as well as each of the data types relevant to such activities and machine. A current summary of live activity for welding, coating and inspection can be generated. Various parameters are reported in a table, including: an event number, a time stamp, a zone identification, a slope in degrees of the welding device or welding system, a welding device travel speed, volts or voltage mains applied to the welding wire, main amplifiers (A) or current applied to the welding wire, a main wire speed or welding wire speed, etc. For example, various parameters including the main welding wire speed (ie welding wire speed) and welding device speed (travel speed) as well as other parameters can be presented in tabular form and /or graphics. Furthermore, a voltage applied to the welding cable can also be presented in a table and/or as a graph as a function of time.

[01251] Optionally, electronic signatures to PQR/WPS documents can be supported by uLog. Optionally, uLog can process system parameter and parameter version control and rollback. In one modality, uLog also has functionality for deploying daily service statistics from cloud and/or mobile devices. For non-limiting example, uLog can perform data management and can provide user reports on the number of welds done over a given period of time (eg hourly, in a day, in a week, etc.) and can report the amount of a consumable (eg welding material) used for a given period (eg hourly, same day...) or other measurement. Service and error reports can also be produced by uLog.

[01252] In one modality, uLog can send an email and/or SMS (text message) or other notification to the competent authorities. uLog can also be used for financial functions, accounting auditing, time keeping and other management tasks. For example, uLog can generate an invoice for a customer in a timely manner. In one modality, the invoice can be generated based on the number of welds or based on usage and/or consumable waste. uLog provides a quantification system and supports the efficient generation of invoices and accounting for pipe welding projects.

[01253] The uLog can also be used for automatic replenishment of materials and/or equipment and/or other resources or inventory on a project. The many and varied functions of uLog disclosed in this document can reduce service disruption, downtime, waste, and other negative occurrences during construction.

[01254] IG. 156 shows a GUI example for a "Get Log" screen of the cloud-based universal data logging request (uLog) showing weld data parameters including weld event type, time, zone, velocity of solder displacement (speed of soldering of the welding system), speed of displacement of the main cable (speed of the main cable), in accordance with an embodiment of the present disclosure. FIG. 156 shows various parameters that are reported in a table, including: a weld ID or type number, an event number, a time stamp, a zone ID, a slope in degrees of the welding device or welding system , a speed of displacement of the welding device, main volts or voltage applied to the welding cable, main amplifiers (A) or current applied to the welding cable, and a speed of main cable (the speed of the welding cable). In one mode, uLog can automatically stamp the service location in service logs. In other examples, the data profiles may be time stamped and may reflect the time zones, as shown in table a depicted in FIG. 156. Time stamps can be synced from the GPS and/or based on present data and/or pushed to uLog so that the profiles reflect the time zone they were captured.

[01255] FIG. 157 shows a GUI example for a Cloud-based Universal Data Profiling Request (uLog) report summary screen displaying various solder parameters, including solder time, solder station ID number, arc voltage welding, etc., in accordance with an embodiment of the present disclosure. In one modality, uLog can create and/or generate PQR and/or WPS and/or summary reports and/or daily reports all coming from a mobile and cloud platform. PQR, WPS, summary and daily reports can be produced manually or generated automatically. uLog can generate one, more or all of these types of reports on a schedule, ad hoc or simultaneously. uLog provides the benefit of common and consistent data processing. The same collected data can be used to generate reports at the same or different locations and/or output devices.

[01256] Claim rules can be established with uLog and can be configurable. In one modality, critical data for a given project can be synchronized in the cloud. UuLog envisions the creation of a project qualification binder that is being sent to the user and/or customer of a user and/or another recipient at the end of a qualification process with electronic signatures for approval. uLog reduces time and costs in creating these approved reports and documents.

[01257] FIG. 158 shows an example GUI for a "Save Data on Log" screen of the cloud-based universal data logging (uLog) request displaying multiple, according to an embodiment of the present disclosure. uLog provides data storage services of an unlimited nature. The pipeline construction industry is global and its projects can be geographically dispersed. In addition, pipeline construction can take place in harsh environments and climates. uLog allows data to be stored and protected from anywhere a user and/or equipment may be present. Data can also be synchronized or processed. For example, data can be saved to the cloud from a job, profile, soldering station, soldering parameter, reports and workplaces. In one modality, location data can be saved in addition to technical and/or management data.

[01258] FIG. 159 shows an example GUI for an "Analysis" screen of the uLog request showing two icons for selecting a type of analysis performed (eg, trends, moving average) according to an embodiment of the present disclosure. In one modality, uLog analytics can process and provide data trends, moving averages and/or any type of data processing that a user requires. In one modality, uLog can have pipeline data cloud profiling and reporting and analysis system. For example, analysis can be performed on collected data to provide feedback to the control system to improve quality and detect prediction of welds and/or construction equipment, activities and operations. In one modality, data can be collected through the cloud and/or one or more mobile devices. In one modality, uLog supports a synchronized capture of service-related parameter change notes from all users for a given project. In another modality, uLog can monitor, analyze and report current live activity and provide live summary data and summary reports for welding, coating and inspection activities. The uLog system can perform system parameter versioning and rollback. The uLog system also achieves single point capture of data profiles, machine configuration information and software revisions. In yet another embodiment, integrated pipe joint marking can be achieved and synchronized with data profiles.

[01259] FIG. 160 shows a GUI example for a "Weld Parameter" (Weld Parameter) screen of the cloud-based universal data logging request (uLog) showing two different mechanisms for selecting a type of function to be performed (by example, get weld parameters (Weld Parameter, WP), weld parameter definition (WP), weld parameter display (WP), according to an embodiment of the present invention. In one embodiment, the base log in the uLog cloud you can perform any of the following activities and/or processes: get weld parameters, set weld parameters, view and process weld parameter notes, view and process weld parameter passes, and reverse weld parameters In a modality, the uLog may contain any, more or all of the following: Pipeline Miles rewards features, Pipe Miles features, uLog features, M2C features and C2M features.

[01260] A welder or welding technician can waste the welding cable if the welder replaces the coil long before all the cable is consumed. Additionally, the soldering process can be interrupted if the coil runs out of cable during the soldering process, causing downtime and repair failure. One method of solving these problems in the present embodiment is to rely on the speed of the cable feed motor to determine the speed of the main cable and thus determine the length of solder wire that is consumed over a period of time. However, this method may have errors due to cable slippage on the cable feed motor wheel or incorrect starting weight. As a result, a determination of wire length based on motor speed may not be accurate. In addition, an incorrect initial weight can lead the user to believe that there is enough cable available in the coil to perform a weld (if the initial weight is overestimated for example), whereas, in reality, the amount of cable remaining in the coil does not it is enough to complete a weld. In order to cure this deficiency, a device is used to measure the weight of the coil of cable in real time while the motor pulls on the welding cable. By measuring the weight of the spool, the user or welder can determine if there is enough cable in the coil to complete a weld before the weld starts. As a result, rope weight can be determined at all times which substantially eliminates uncertainty due to slip or initial unknown weight of the coil. In addition, the weight can be compared to the main cable's feed speed to determine if the feed cable is at its intended speed.

[01261] FIG. 161A schematically illustrates an example of a coil 14480 that is configured to carry a welding cable, in accordance with an embodiment of the present disclosure. FIG. 161B schematically depicts a side view of a hub-transducer 14482 that is configured to measure a weight of coil 14480, in accordance with an embodiment of the present disclosure. FIG. 161C illustrates another side view of the transducer-hub showing the placement of transducer elements or strain gauges/sensors 14484 for measuring weight strain when coil 14480 is mounted on hub 14482, in accordance with an embodiment of the present disclosure. As shown in FIG. 161B, when the spool is mounted on hub 14482, the weight of the spool will exert a force on shaft 14482A of hub 14482 which, in turn, will exert a tension on side hub 14482B. 14484 Strain sensors are provided on the 14482B side hub to detect strain applied by the weight of the coil. Examples of strain sensors that can be used to measure strain are piezoelectric elements. 14484 strain sensors convert a strain force into a measured strain. Thus, by measuring the voltage, the weight of the 14482 coil can be determined. In one embodiment, a temperature sensor (not shown) can be provided on the hub and positioned to capture the hub temperature in order to apply corrections to the strain sensor measurement over a wide temperature range.

[01262] FIG. 162 schematically depicts an arrangement in which a solder wire 14486 on coil 14480 mounted on hub 14482 is pulled by a motor assembly 14490 to feed cable 14482 to the solder device (not shown), in accordance with an embodiment of the present disclosure. Weld wire 14486 is pulled by motor assembly 14490. In one embodiment, the rotational speed of the motor assembly (used to determine main cable speed) can be measured by sensor 14492. In one embodiment, the motor assembly uses a motor with a suitable rotation speed (revolutions per minute or RPM measured by the 14492 sensor) to achieve a desired wire feed speed to the welding device. In another embodiment, the rotation of the motor assembly may be changed in accordance with a desired wire feed speed (main wire speed) measured by sensor 14492. Motor assembly 14490 is configured to supply or feed the solder wire 14486 to welding device 14500 to weld a workpiece 144101 (e.g., a tube, etc.). The speed of the 14500 welding device is measured by the 14502 speed sensor. The 14502 speed sensor is also configured to measure various welding parameters or welding data.

[01263] FIGs. 164A and 164B show enlarged side cross-sections of motor assembly 14490, in accordance with an embodiment of the present disclosure. As shown, the motor assembly includes a 14491 motor and a 14493 feed wheel. The 14491 motor engages the 14493 feed wheel to rotate the 14493 feed wheel. The 14490 motor assembly further includes a 14495 pinch roller that enters into contact with feed wheel 14493. A tension spring 14497 is provided to bias pinch roller 14495 toward feed wheel 14493. Welding wire 14486 is inserted between feed wheel 14493 and pinch roller 14495. Thus, pinch roller 14495 pushes yarn 14486 to bring yarn 14486 into contact with feed wheel 14493. As a result, a rotation of feed wheel 14493 and pinch roller 14495 as illustrated by the arrows in FIG. 164B would be translated, in theory, into a linear motion of wire 14486, as shown by the arrow. In one embodiment, teeth are provided on feed wheel 14493 to grip wire 14486 by friction and force cable 14486 to move. However, situations can occur where the cable 14486 is not tightly gripped by the feed wheel 14493. In this case, the cable 14486 may slip because, although the feed wheel 14493 rotates, this rotation of the feed wheel 14493 does not translate into Precise linear movement of cable 14486. For example, this can occur when the teeth on the feed wheel 14493 are worn out (thus not providing sufficient friction to securely grip the cable 14486) or when the pressure roller 14495 is worn out (therefore, not exerting sufficient pressure or force on cable 14486 to press cable 14486 against feed wheel 14493) or when tension spring 14497 loses its preload (thus causing pressure roller 14495 not to exert pressure or force enough on the handle 14486) or when the 14499 nut securing the feed wheel 14493 becomes loose (thus causing the feed wheel not to tighten the handle 14486 tightly) or any c combination thereof. As shown in FIG. 164A, motor assembly 14490 includes rotational speed sensor 14492 which is configured and arranged to measure rotational speed of motor 14491. An output 14498 is provided for inputting and outputting data into and from the assembly. motor 14490, the data including the speed of motor 14491. The data from output 14498 is sent to computer 14416 associated with soldering station 14410.

[01264] FIG. 165 is a diagram of a soldering system configuration describing the interconnections of various system components, in accordance with an embodiment of the present disclosure. As shown in FIG. 165, a rotational speed of the motor assembly 14490 is measured by rotational speed sensor (RPM sensor) 14492. In addition, the weight of the coil of the 14480 welding cable is measured by the weight sensors 14484 in the 14482 hub transducer. The speed of the welding device 14500 is measured by the speed sensor 14502. All parameters or data measured by the rotation speed sensor 14492, the weight sensor 14483 and the speed sensor 14502 are entered into the computer 14416 in the welding station 14410 In one embodiment, computer 14416 may be managed by intermediary computer 14450. Intermediate computer 14450 may be a wireless device such as a tablet, mobile device, smartphone, portable computer, etc. Therefore, intermediate computer 14450 can have access to data in computer 14416 including data from RPM sensor 14492, weight sensor 14484, and speed sensor 14502. Intermediate computer 14450 is still in communication (e.g. wireless) with cloud server 14432, where data from computer 14416 can be stored and/or further processed. In one embodiment of the present disclosure, the intermediary computer is not used. In this case computer 14416 is connected directly (eg wirelessly) to cloud server 14432.

[01265] As indicated in the above paragraphs, due to the potential for slippage, the measurement of the motor assembly speed (eg, feed wheel speed 14493) by itself, in some embodiments, may not be sufficient to provide an exact amount of welding cable that is used or consumed by the welding machine or system. Indeed, even if a rotation of the feed wheel 14493 is accurately measured, the rotation of the wheel would theoretically translate to a movement and therefore to a given length. However, due to slippage, the cable does not move and therefore the length determined based on the rotation or speed of rotation of the wheel does not correspond to an actual cable length. As a result, the weight of the welding cable coil can also be measured. In one embodiment, the weight of a new, unused cable reel is about 15 kg (15,000 grams). In one embodiment, the weight of the coil of wire is measured with an accuracy of about 100 grams over 15,000 grams, that is, with an accuracy of approximately 0.7%. Therefore, weight provides a relatively good measurement method for determining the amount of solder lead remaining in the coil. In one mode, the coil weight is periodically captured or measured and is profiled with a time stamp and communicated to uLog each time the coil stops rotating. An indicator such as a horn or flashing light or the like can indicate to the welder that it is time to recharge another coil. Also, in one modality, the welding machine may not start a welding operation in this case. The indicator may indicate a weight limit where a complete weld cannot be completed.

[01266] In one embodiment, RF modules are further provided to read a coil serial number, coil manufactured weight, coil type, design name and any details that are fed with the RF marking mounted on the coil. This data can be transferred in the cloud via uLog with any additional details required. If an old coil is reused, the system will compare the serial number against a database of already used coils and extract the last available weight from the cloud and compare it to the new weight reading before service starts. A horn or indicator light is available on the system to indicate to the operator that details about the RF tag have been read and communicated via CAN. Using the RF system will eliminate any work of keeping manual accounting records necessary to keep track of the number of coils used, their serial numbers and identification of the workstations they are used on. In welding cables that have wrong composition/diameters, the system can identify this from the RF marking properties, warning the operator of this deviation. This could go unnoticed if the system were completely manual.

[01267] In one mode, the DW difference between a W1 weight measured at time T1 and a W2 weight measured at a later time T2 can be calculated. The DW weight difference (where DW=W1-W2) corresponds to the weight of the cable that is consumed during a welding process. This weight difference DW can be compared to a theoretical weight TW. The theoretical weight TW can be obtained using the rotational speed R of the motor or a linear speed of the cable S (the linear speed S depends on the rotational speed R). The theoretical weight TW can be calculated using the following equation (1).

[01268] TW = (T2-T1) x S x (Diameter of wire) 2 x (Density of wire material) x π/4 (1)

[01269] If hypothetically there is no slip, then the theoretical weight TW should equal the measured weight DW. If on the other hand hand slip occurred during a process between time T1 and time T2, then the theoretical weight TW would be greater than the measured weight DW; in this case, a ratio R between theoretical weight TW and measured weight DW is greater than 1 (R = TW/DW> 1) and/or the difference Δ between theoretical weight TW and measured weight DW is greater than zero (Δ =TW - DW > 0). As a result, if after a certain period of time or number of measurements it is noticed that the difference between the measured weight and the theoretical/calculated weight persists, the 14490 motor speed can be adjusted or compensated in order to have a calculated weight/ substantially equal to the measured weight. Thus, the measured weight is compared to the theoretical weight (determined from the wire feed speed) to determine whether the wire is fed at the intended feed speed. In one embodiment, this determination can be performed locally on the welder side or using the uLog system on cloud server 14432.

[01270] FIG. 163 is a flowchart describing a method of comparing measured weight and determined theoretical weight based on yarn feed speed, in accordance with an embodiment of the present disclosure. As can be appreciated from the above paragraphs, the process starts by measuring a first weight W1 of the cable reel at a first time (T1), in S10. The process also includes measuring a second weight W2 of the coil at a second time T2, after a certain period of time T1, at S12 (T2> T1). The process also includes calculating a difference between the first measured weight W1 and the second measured weight at time T2, at S14. The process includes calculating a theoretical weight based on the cable feed speed in S16. In S18 the theoretical weight based on the cable feed speed is compared to the calculated weight difference and whether the theoretical weight is greater or less than the calculated weight difference, in S18 a speed of the pulling motor assembly the cable is adjusted in S20. The process is repeated after another increment of time, after the motor package speed is adjusted. If the theoretical weight is the same as the calculated weight difference, then the process is also repeated after another increment in time, without adjusting the motor package speed. This process is repeated in a multiplicity of time increments in order to monitor and/or correct any potential slip of the 14490 motor package.

[01271] This process can be applied locally by the uLog system on the computer 14416 associated with the 14410 soldering station or implemented by the uLog system on the cloud server 14432 or implemented by the uLog system on the intermediate computer 14450 described in the previous paragraphs.

[01272] In one embodiment, it may be desirable to monitor cable utilization at different 14410 soldering stations to assess the overall efficiency of the soldering system. For example, this will allow a predictive indication of the amount of coil needed in large projects based on previous learning. For example, the coil usage can be sent to the uLog system stored and processed by the cloud server 14432. For example, each of the 14410 soldering stations can send the coil usage data for the uLog system to the cloud server using the previously described network configurations and based on a usage history of a number of cable spools and using a machine learning algorithm (MLA), the uLog system can predict an average future use of cable spools (or amount of solder cable). For example, based on usage patterns across certain weld parameters, the uLog system can determine a threshold at which a complete weld cannot be completed. As a result, the uLog system can alert the welder, using an indicator (eg a beep, flashing light, etc.) that the cable in the coil has run out and that a complete weld cannot be completed based on a theoretical threshold determined using the machine learning algorithm. For example, cloud server 14432 running uLog can be configured to provide feedback to one or more within the plurality of weld station computer 14416 to alert a welder that a complete weld cannot be completed based on a theoretical threshold determined using the machine learning algorithm.

[01273] In another modality, when there is a discrepancy between the theoretical weight determined based on the cable feed speed (measured by sensor 14492) and the measured weight (W2-W1), where W2 and W1 are measured by sensors weight 14484, instead of adjusting the speed of the 14490 motor assembly, a speed of the 14500 welding device (or the displacement speed) can be adjusted to match a speed V obtained from the measured weight W2-W1.

[01274] As can be appreciated from the above paragraphs, a soldering system comprising a plurality of soldering stations 14410 is provided. Each soldering station 14410 includes a soldering station computer 14416 and a soldering system 14412 in communication with solder station computer 14416. Each solder station 14410 includes one or more sensors 14492, 14502, with one or more sensors 14492, 14502 configured to measure solder data including lead wire speed data (measured by the sensor of speed 14492), as depicted, for example, in FIG. 162. The system further includes a plurality of wireless devices 14450 in communication with the one or more soldering station computers to receive the soldering data, including the main cable speed measured data. The system also includes a cloud server 14432 in communication with the wireless devices 14450, the cloud server 14432 being configured to process the weld data including the main cable speed data and configured to determine a quantity of consumable weld material used by the plurality of soldering stations 14410 for a given period of time. Cloud server 14432 is configured to communicate the amount of consumable solder used for one or more of the wireless devices.

[01275] In one embodiment, the weld data further includes welding system displacement speed data. In one embodiment, the 14450 wireless devices are configured to further receive the displacement speed data from the welding system. In one embodiment, cloud server 14432 is further configured to process the displacement speed data.

[01276] As can be appreciated from the above paragraphs, a soldering system having a soldering station is also provided, the soldering station including a soldering station computer and a soldering system in communication with the soldering station computer. solder. The soldering system includes a solder material supply 14480, a solder device 14500 and a solder feed motor assembly 14490 which moves solder material 14486 on the solder feed material 14480 to the solder device. The soldering system further includes a weighting device 14482 operatively connected to soldering station computer 14416 and configured to measure a weight of solder material supply 14480 and to communicate the weight of solder material supply 14480 to the soldering station computer. 14416 in the form of weight data and a sensor 14492 operatively connected to the weld supply motor assembly 14490 and the weld station computer 14416 so as to communicate the speed of the weld supply motor assembly 14490 to the welding computer. 14416 soldering station in the form of velocity data. Solder station computer 14416 is operatively connected to solder supply motor assembly 14490 and is configured to control the speed of motor assembly 14490 based on the weighting data.

[01277] As can be further appreciated from the above paragraphs, a soldering system is provided which includes a plurality of soldering stations 14410, each soldering station 14410 including a soldering station computer 14416 and the soldering system 14500 at communicating with solder station computer 14416, each solder station 14410 including one or more sensors 14492, the one or more sensors 14492 configured to measure solder data including main cable speed data. The soldering system also includes a plurality of wireless devices 14450 in communication with the one or more soldering station computers 14416 to receive the soldering data, including the main cable speed measured data. Each soldering station computer 14416 is configured to process the solder data, including the main cable speed data, to the 14500 solder system for communication therewith. Welding station computer 14416 is further configured to determine an amount of consumable weld material used by welding system 14500 for a certain period of time and generate the consumption data based on this.

[01278] In some embodiments, each 14410 soldering station further includes a 14490 motor for moving the main cable at the speed of the main cable, wherein the cable speed data is determined based on the speed of the 14490 motor, each soldering station 14410 further comprising a weight sensor 14484 that detects a decrease in the weight of the consumable material. Weight sensor 14484 provides output signals to soldering station computer 14416. Soldering station computer 14416 uses the output signals to determine consumption data. In one embodiment, the soldering station computer 14416 uses the consumption data to control the speed of the engine 14490. In one embodiment, the system further includes a cloud server 14432 to receive the consumption data, along with the speed data. cable, to correlate the consumption data with the speed data of the main cable.

[01279] FIG. 166 shows a system overview that can be used with a wide variety of test and inspection equipment, media, processes, and methods. In the generic example of FIG. 166, tubing 16610 can be constructed at the request of a proprietary company 16670 by connecting a plurality of tubing segments together by circumferential welds. This construction can be done by the company that owns 16670, a third party or another party. During the construction process, non-destructive testing and inspection can be performed to ensure that the pipeline will not fail in its specified service within quality control parameters. To support this objective, for example, one or more welds, such as circumference welds, may be inspected and tested by one or more test means, processes, or methods, such as ultrasonic testing or radiographic testing.

[01280] For example, a 16650 field worker can place a test device such as a 16620 imaging device in the pipeline in the vicinity of each of the circumferential welds. The testing device, which may be an imaging device, can collect data about the inner structure of the girth weld for analysis. This data can be any type of data desired for analysis by an inspector or other person or needed for any computer processing. For example, if an ultrasound test method or a radiographic test method or both are used, one or more signals can be transmitted to a pipe and/or a weld, such as a girth weld, and the data and information in response such signals can be collected, processed and analyzed by one or more computers and/or one or more people.

[01281] In one embodiment, responses to the signals may be received, processed, digitized, compressed, transmitted and communicated (16625) to a separate device or receiver (or which may be separate from the test device that generated the signal(s) (s) and/or received the response(s), and which may be located remotely or at a remote facility 16630. In this document, the device, facility or computer that receives data from the test unit and which is separate or may be detached The test unit will be referred to as the “remote entity.” The remote entity is broadly encompassing any device, facility, person, or other that may receive, use, perceive, process, or transform any data from the test unit. The scope of this term can range from a memory device, such as a memory bar, to a distributed control system, a cloud-based processor, a cell phone, a smart phone, a computer, a process. digital server, a receiver, a capability, an enterprise-wide control system, or a remote facility or remote central processing facility, or other device, person, or location. In one embodiment, the remote entity can be a remote facility that can be a computing, processing, and monitoring center. The remote entity, such as a remote facility, can be networked, wireless, cloud-based, based on a hybrid cloud, or located at a physical facility or associated with a person, company, capacity, usage, entity or another. In one modality, the remote entity can be owned and/or controlled by any person, customer, company, organization, inspector, third party, operator, worker or other.

[01282] In one embodiment, the remote entity, such as the remote facility, may use a computer to process test and/or inspection data, such as compressed data, to determine the size, shape, location and orientation of any defects present in the solder and/or pipe. Test data and/or inspection data, or analytical results, may be communicated (16635) to a 16640 inspection specialist who can examine the data or verify the analytical results, or otherwise use all or part of the data provided to one skilled in the art 16640. Here, "test data" and "non-destructive test data" are used synonymously. As an example, results or results verified by the skilled person can be communicated (16645) to the 16650 field worker. This supports defect repair or management of defect repair processes for welds and piping. Optionally, the verified results can be communicated to the Quality Assurance Inspector 16660 and to the Company 16670.

[01283] The technologies, processes, means and methods used in this document can be extended and used for testing and inspection of pipes. The equipment, processes and devices disclosed in this document have a range of use that extends far beyond welding.

[01284] FIG. 167 shows a modality of the system that can be used with any of a wide variety of testing methodologies and with many types of equipment. As shown in FIG. 167, in one embodiment, one or more circumferential welds may be inspected. The 167110 circumferential welds that have the 167100 piping together can be inspected before the piping can be put into service. A 167500 field personnel or a plurality of 167500 field personnel may travel along a pipe with one or more of a 167110 grommet. They may stop at each grommet and use 167200 imaging equipment to take images of the internal structure, respectively, or more, of the 167110 circumferential weld. The number of 167500 circumferential welds to be inspected can range from 1 to a very large number, such as 5 million.

[01285] Inspection data and images can be generated, processed, recorded, detected, digitized, compressed and transmitted on site or to a remotely located facility, such as a remotely located central facility 167300. In a remotely located central facility 167300, a computer 167310 may process inspection data and images (which may be digital images, or another data image, or dataset) to determine the size, shape, orientation, and location of any defects present in a tested weld. The computer can also identify which defects are significant enough and/or large enough to have a significant effect on the integrity of the pipeline by running the computer's executable code using the computer's executable logic. If a defect is identified by computer processing, one or more defects may be reported to a person skilled in the art 167400 who can verify the presence and meaning of defects identified by the computer.

[01286] Alternatively, the inspector can view the inspection data directly and draw a conclusion from the inspector's training and experience. Optionally, the inspector's conclusions can be verified by computer processing.

[01287] The verified results, computer generated or generated by human beings, can then be transmitted to the 167500 field workers by computer means, or by telephone, so that the welds can be repaired. Inspection results can also be sent to a 167600 Quality Assurance Inspector, the company that owns the 167700 piping, or other interested or destined party.

[01288] In one embodiment, pipe 167100 can be constructed at the request of the proprietary company 167700 by connecting a plurality of pipe segments 167120A, 167120B together by means of circumference welds 167110. To ensure that the pipe does not fail to service, the builder , or others, want circumferential welds to be inspected by non-destructive means. These means can include magnetic particle inspection, ink penetrant inspection, ultrasonic testing, and X-ray radiography. Ultrasonic testing and X-ray radiography are data intensive imaging methods.

[01289] Analytical work for evaluating test and/or inspection data requires one or more highly trained technicians 167400, 167520 and specialized imaging equipment 167200. The imaging equipment that can be used may have a 167210 emitter, a 167220 receiver and a 167230 analog-to-digital (A/D) converter. One or more 167520 field workers may transport the 167200 imaging equipment for a weld along the pipeline by means of a 167530 support truck or other vehicle.

[01290] Imaging equipment can be of any useful type, such as ultrasound or radiography.

[01291] In a segment connection, field workers can place the imaging equipment on or near the piping in the vicinity of the 167110 girth weld. A field worker can activate the imaging equipment. The emitter portion may send a signal (167215) on the tube segments and/or on the perimeter weld. The signal can be ultrasonic sound wave pulses in the case of ultrasonic testing or it can be X-ray radiation in the case of X-ray radiography.

[01292] In the case of ultrasonic testing, the ultrasonic pulses may reflect outside the limits where the density of the 167110 circumferential weld changes. The boundaries between metal and air give the strongest reflections. Reflected pulses can be detected by the receiver. The receiver can measure the strength of the reflected pulse (167222) and can produce an electronic signal proportional to the strength of the reflected pulse. In one modality, the sender and receiver can have multiple elements. Optionally, the emitter elements can be selectively activated to target the ultrasonic pulse at a specific location.

[01293] In the case of X-ray radiography, the intensity of the X-ray is attenuated by the material in the tube segments and in the perimeter weld. The receiver can measure the intensity of radiation as it passes through the material (167224).

[01294] In one embodiment, the imaging equipment can be mounted on a motorized cart that can move along the circumferential weld at a constant speed. The A/D converter can digitize the signal (167226) from the receiver and can compress the digitized data. The compressed image data and transport location (167235) can be communicated to a 167310 computer at a remote entity such as a 167300 remote facility. Communication can be via cable, physical media transport, wireless, network , cloud, radio broadcast or other.

[01295] In the non-limiting example of FIG. 167, at remote installation 167300, computer 167310 can analyze the data (167235). Analysis can be performed in one or more steps. For example, the computation engine 167320 may identify signals (167222, 167224) that may indicate the presence of anomalies in the circumferential weld 167110. The anomalous signals (167325) may be communicated to the AI engine 167330. The AI engine may be a computer that executes computer executable code, relational logic, and/or artificial intelligent programming. The AI engine can determine the size, shape, orientation, and location of defects (167335) that caused the anomalous signals (167325). The AI engine can execute the computer's executable program code using rule-based logic to determine which defects are significant to the integrity of the pipeline and should be repaired, which are not. Computer 167310 can send data (167335) describing zero or more defects to inspection technician 167400, quality assurance inspector 167600, company owner 167700, and field personnel 167500 or others.

[01296] In one modality, the inspection technician may choose to review (167215) the data (167335) before being communicated to the quality assurance inspector, owner company, field personnel or others. The inspection technician may also change the identification of a defect from significant to non-significant or non-significant to significant, or otherwise modify or annotate any computer-produced or otherwise produced results. Defect data (167335) associated with a significant defect may be communicated to field personnel 167500. The amount of data that can be transmitted to the surface may be limited to 167520. Field worker(s) may mark locations and size of significant defects in the weld(s) and/or piping (167525) for repair by repair welder 167510 or others. Alternatively, data can be transmitted directly to the 167510 repair welder or others.

[01297] FIG. 168 shows an ultrasonic test modality. As shown in FIG. 168, in one modality, one or more circumferential welds can be inspected by ultrasonic testing. The 168110 circumferential welds that have the 168100 piping together can be inspected before the piping can be put into service. A 168500 field personnel or a plurality of 168500 field personnel can travel along a pipe with one or more of a 168110 girth weld. They can stop at each girth weld and use 168200 ultrasonic test equipment to take images of the internal structure of the weld. These images can be digitized, compressed and transmitted to a remote facility such as a 168300 remotely located central facility. At the remotely located central facility, a 168310 computer can process inspection data such as ultrasonic data, image data, or images to determine the size, shape, orientation, and location of any defects present in a tested weld. The number of 168110 circumferential welds inspected can range from 168 to a very large number such as 5 million.

[01298] The computer can also identify which defects are significant enough and/or large enough to have a significant effect on the integrity of the pipeline by executing the computer's executable code using the computer's executable logic. If a defect is identified by computer processing, one or more defects may be reported to a 168400 person skilled in the art, who may be a specialist in ultrasonic testing, who can verify the presence and significance of a defect identified by the computer.

[01299] Alternatively, the inspector can view the inspection data directly and draw a conclusion from the inspector's training and experience. Optionally, the inspector's conclusions can be verified by computer processing.

[01300] The verified results, computer generated or generated by human beings, can then be transmitted to the 168500 field personnel by computer means, or by telephone, so that the welds can be repaired. Inspection results can also be sent to a 168600 Quality Assurance Inspector, the company owning the 168700 piping, or other interested or destined party.

[01301] In the embodiment of FIG. 168, a pipe 168100 is constructed at the request of Proprietary Company 168700 connecting a plurality of Pipe Segments 168120A, 168120B together by means of circumferential welds 168110. destructive. These means can include magnetic particle inspection, ink penetrant inspection, ultrasonic testing, and X-ray radiography. Ultrasonic testing is a data-intensive imaging method. Requires one or more highly trained technicians 168400, 168520 and specialized imaging equipment 168200.

[01302] The imaging equipment may have a 168210 emitter, a 168220 receiver, and a 168230 A/D converter. One or more 168520 field workers may transport the 168200 imaging equipment along the pipeline via the 168530 or support truck another vehicle. Field workers can place the imaging equipment in the pipeline in the vicinity of the 168110 perimeter weld, on the perimeter weld, which is to be tested. A field worker can activate the imaging equipment. The emitter portion can send ultrasonic pulses (168215) in the tube segments and in the perimeter weld. Pulses can be sent at a rate of 1 Hz to 20,000 Hz. The frequency of the ultrasonic sound wave can range from 0.5 MHz to 23 MHz. pipe. The boundaries between metal and air give the strongest reflections. Reflected pulses can be detected by the receiver. The receiver measures the intensity of the reflected pulse (168222) and produces an electronic signal proportional to the intensity. The sender and receiver can have multiple elements. Emitter elements can be selectively activated to target the ultrasonic pulse at a specific location.

[01303] The imaging equipment can be mounted on a motorized cart that can move along the circumferential weld at a constant speed. The A/D converter can digitize the signal (168226) from the receiver and can compress the digitized data. The compressed image data and transport location (168235) can be communicated to a remote entity such as a 168310 computer which can optionally be in a 168300 remote facility. Communication can be done via cable, physical media transport, wireless, network, cloud, radio broadcast or other.

[01304] In the embodiment of FIG. 168, in remote installation 168300, computer 168310 can analyze the data (168235). The analysis can be done in stages. A computation engine 168320 can identify signals (168222) that may indicate the presence of anomalies in the circumferential weld 168110. The anomalous signals (168325) are communicated to the AI engine 168330. The AI engine can determine size, shape, orientation and the location of the defects (168335) that caused the anomalous signs (168325). The AI motor can determine which defects are significant to piping integrity and must be repaired. Computer 168310 sends data (168335) describing zero or more defects to inspection technician 168400, quality assurance inspector 168600, company owner 168700, field personnel 168500, or others.

[01305] Optionally, the inspection technician can receive the data directly and perform an analysis in addition to the AI. Optionally, in such a scenario, the inspection technician can use the AI to verify or confirm the inspection technician's results.

[01306] Optionally, the inspection technician may choose to review (168405) the data (168335) before being communicated to the quality assurance inspector, owning company and/or field personnel, or others. The inspection technician can also change the identification of a defect from significant to non-significant or non-significant to significant.

[01307] Defect data (168335) that is associated with a significant defect may be communicated to field personnel 168500. The amount of data that can be transmitted to the surface may be limited to 168520. One or more field workers may mark the locations and size of significant pipeline defects (168525) for further repair by the 168510 repair welder. Alternatively, data can be transmitted directly to the 168510 repair welder.

[01308] FIG. 169 shows a radiographic test modality. As shown in FIG. 169, in one embodiment, one or more circumferential welds may be inspected by radiographic testing. 169110 circumferential welds that have 169100 piping together can be inspected before the piping can be put into service. A 169500 field personnel or a plurality of 169500 field personnel may travel along a pipeline with one or more of a 169110 circumference weld. They may stop at each 169110 circumference weld and use 169200 X-ray equipment to collect data and/or take images of the internal structure of each 169110 circumference weld.

[01309] Inspection data and/or images can be digitized, compressed and transmitted to a remote facility, such as a 169300 remote central facility. In the remotely located central facility, a 169310 computer can process inspection data, such as ultrasonic data, image data or images to determine the size, shape, orientation, and location of any defects present in a tested weld. The number of 169110 circumferential welds inspected can range from 1 to a very large number, such as 5 million.

[01310] The computer can also identify which defects are significant enough and/or large enough to have a significant effect on the integrity of the pipeline by executing the computer's executable code using the computer's executable logic. If a defect is identified by computer processing, one or more defects may be reported to a person skilled in the art 169400, who may be a specialist in radiographic testing, who can verify the presence and significance of a defect identified by the computer.

[01311] Alternatively, the inspector can view the inspection data directly and draw a conclusion from the inspector's experience. Optionally, the inspector's conclusions can be verified by computer processing.

[01312] The verified results, computer generated or generated by human beings, can then be transmitted to the 169500 field workers by computer means, or by telephone, so that the welds can be repaired. Inspection results can also be sent to a 169600 Quality Assurance Inspector, the company that owns the 169700 piping, or other interested or destined party.

[01313] In an embodiment as shown in FIG. 169, a 169100 pipe can be constructed at the request of the 169700 proprietary company by connecting a plurality of 169120A, 169120B pipe segments together by means of 169110 circumference welds. non-destructive means. These means can include magnetic particle inspection, ink penetrant inspection, ultrasonic testing, and X-ray radiography. Ultrasonic testing and X-ray radiography are data-intensive imaging methods. They require one or more highly trained technicians 169400, 169520, and specialized 169200 imaging equipment. The imaging equipment can consist of a 169210 emitter, a 169220 receiver, and a 169230 A/D converter. One or more 169520 field workers can carry the 169200 imaging equipment along piping via support truck 169530. At each segment connection, field workers can place imaging equipment on or near piping in proximity to 169110 circumferential weld. A field worker can activate the imaging equipment. The emitter portion can send X-ray radiation (169215) into the tube and girth weld segments. The X-ray intensity can be attenuated by the material in the tube segments and the circumferential weld. The receiver can measure the intensity of radiation as it passes through the material (169224).

[01314] The imaging equipment is mounted on a motorized transport that can move along the circumferential weld at a constant speed. The A/D converter can digitize the signal 169226 from the receiver and can compress the digitized data. The compressed image data and car location (169235) can be communicated to a 169310 computer at a 169300 remote facility. Communication can be via cable, physical media transport or radio transmission.

[01315] In the example as shown in FIG. 169, at remote installation 169300, computer 169310 can analyze the data (169235). Analysis can be performed in steps. The computation engine 169320 can identify signals (169224) that may indicate the presence of anomalies in the circumferential weld 169110. The anomalous signals (169325) can be communicated to the AI engine 169330. The AI engine can determine size, shape, orientation and the location of defects (169335) that caused the anomalous signs (169325). The AI motor can determine which defects are significant to piping integrity and must be repaired. Optionally, these steps can be conducted by the inspection technician based on test and/or inspection data with or without AI support.

[01316] In the embodiment of FIG. 169, the 169310 computer can send the data (169335) to describe zero or more defects to the 169400 inspection technician, 169600 quality assurance inspector, 169700 proprietary company, and 169500 field personnel, or others. The inspection technician may choose to review (169405) the data (169335) before it is communicated to the quality assurance inspector, owner company and/or field personnel. The inspection technician can also change the identification of a defect from significant to non-significant or non-significant to significant.

[01317] Defect data (169335) that is associated with a significant defect may be communicated to 169500 field personnel.

[01318] The amount of data that can be transmitted to the surface may be limited 169520. One or more field workers may mark the locations and size of significant defects in the pipeline (169525) for further repair by the repair welder 169510. Alternatively , the data can be transmitted directly to the 169510 repair welder.

[01319] In one embodiment, a computer system may comprise a first device that has a processor that processes pipeline construction data, wherein the first device communicates pipeline construction data to a cloud-based memory and data from Pipe construction are processed by a cloud based processor.

[01320] In one embodiment, the pipe construction data comprises welding data, pipe handling data, coating data, inspection data, or other data.

[01321] In one embodiment, the first device comprises a welding station equipment, a distribution pipe welding operation equipment, an automatic welding tool, a vision welding system, an inspection system, or other device.

[01322] In one embodiment, first data may be communicated from a first device to a second device, wherein the first data comprises data relating to a pipe construction. The first data can be processed by cloud-based network means.

[01323] In one embodiment, the first data (communicated from the first device to the second device) may comprise welding data, pipe handling data, coating data, inspection data, management data or other data.

[01324] In one embodiment, a computer program product for welding support may comprise computer readable program code means providing a computer memory of welding data; computer-readable program code means that it supplies memory with data from a data set that includes pipe data; and computer readable program code means it processes weld data and piping data to provide a log output.

[01325] In one embodiment, the welding support computer program product may comprise an executable program code of a rule-based logic for processing the welding data by a welding support program code, an executable code of a rule-based logic program for processing the weld data by an inspection program code, a rule-based logic program executable code used to process the weld data by a management program code or an inspection code quality control program or other executable program code.

[01326] In one embodiment, a welding system may comprise a plurality of welding stations, each welding station including a welding station computer and a welding system in communication with the welding station computer, wherein each station The welding device comprises one or more sensors and one or more sensors configured to measure welding data comprises binding wire speed data. The welding system may comprise a plurality of wireless devices in communication with one or more of the computers of the welding station to receive the welding data including the measured lead wire speed data; and a cloud server communicating with wireless devices. The cloud server is configured to process the welding data comprising the main wire speed data and configured to determine an amount of consumable welding material used by the plurality of welding stations during a certain period of time. The cloud server is configured to communicate the amount of consumable solder material used for one or more of the wireless devices.

[01327] In one embodiment, the welding system may comprise an orbital welder. As an example, the orbital welder can comprise a clockwise (CW) and counterclockwise (CCW) welding system.

[01328] In one embodiment, the measured welding data may further comprise welding system travel speed data. In one embodiment, the plurality of wireless devices are configured to further receive displacement speed data from the welding system. In one embodiment, the cloud server is further configured to process displacement speed data.

[01329] In one embodiment, if a current in the welding system is high, the welding station computer instructs the welding system to slow down a welding system speed or control a position of a torch in the welding system.

[01330] In one embodiment, a welding system may comprise a welding station. The soldering station may comprise a soldering station computer and soldering system in communication with the soldering station computer. The welding system may comprise a supply of solder material, a solder device and a solder supply motor assembly which moves the solder material to the solder device. In one embodiment, the welding system may further comprise a weighing device operatively connected to the soldering station computer and configured to measure a weight of the supply of solder material and to communicate the weight of the supply of solder material to the station computer in the form of weight data and a sensor operatively connected to the solder supply motor assembly and the soldering station computer so as to communicate the speed of the solder supply motor assembly to the solder station computer at the Velocity data form. The solder station computer is operatively connected to the solder supply motor assembly and is configured to control the motor assembly speed based on the weighting data.

[01331] In one embodiment, the welding device may comprise an orbital welding machine. In one embodiment, the supply of solder material includes a spool configured to carry a solder wire. In one embodiment, the weighting device includes a hub transducer, where the hub transducer is configured to transport the coil. In one embodiment, the weighting device includes strain sensors mounted on a hub of the transducer-hub. In one embodiment, the strain sensor is configured and arranged to detect a strain applied by the weight of the coil. In one embodiment, the motor assembly comprises a motor and a feed wheel operatively connected to the motor. In one embodiment the motor assembly comprises a pressure roller configured to push a welding cable to contact the welding cable with the supply wheel such that a rotation of the supply wheel results in movement of the cable. In one embodiment, the supply wheel is configured to engage the cable to move the cable rotationally.

[01332] In one embodiment, a welding station computer is configured to measure a weight difference between a weld material supply weight measured at a first time and a weld material supply weight measured at a second subsequent time at the first time, the weight difference corresponding to the measured weight of solder material consumed between the first time and the second time. In one embodiment, the soldering station computer is configured to calculate a theoretical weight of solder material consumed based on a rotational speed of the solder supply motor assembly. In one embodiment, the soldering station computer is configured to calculate a difference or a ratio or both between a measured weight of solder material and a theoretical weight of consumed solder material. In one embodiment, the soldering station computer is configured to compare the measured weight of solder material and the theoretical weight of solder material consumed, and if there is a discrepancy, where the soldering station computer indicates that slip has occurred and controls the speed of the motor package to adjust the rotation speed of the motor package. In one embodiment, the soldering station computer is configured to repeat a comparison between the measured weight of solder material and the theoretical weight of solder material consumed at a multiplicity of increments in time.

[01333] In one embodiment, the welding system may comprise a cloud server in communication with the welding station computer, where the cloud server is configured to process the speed of the welding supply motor assembly and the weight of the supply of solder material received from the computer soldering station to store historical data on the use of solder material.

[01334] In one embodiment, the cloud server is further configured to process the speed of the weld feed motor assembly and the weight of the weld material supply received from a plurality of welding station computers associated with a plurality of soldering stations by storing a data history about a solder material usage at each of the plurality of soldering stations. In one embodiment, the cloud server is configured to predict an average future use of solder material based on historical data and using a machine learning algorithm. In one embodiment, the cloud server is configured to determine a weld material limit required to complete a full weld based on usage patterns and historical data. In one embodiment, the cloud server running uLog can be configured to provide feedback to one or more within the welding station computer plurality to alert a welder that a complete weld cannot be completed based on a given theoretical threshold using the machine learning algorithm.

[01335] In one embodiment, the soldering station computer is configured to control a soldering device speed to adjust the soldering device speed to match a speed obtained from the measured weight of the solder material supply.

[01336] In one embodiment, a first weight of a supply of solder material at a first time can be measured using a weight measuring device. A second weight of the weld material supply can be measured using the weight measuring device a second time after the first time. A difference in measured weight between the first weight and the second weight can be calculated using a computer, where the difference in the corresponding measured weight to measure the used weld material. A theoretical weight of the weld material used is calculated using the computer based on the speed of a motor assembly that feeds the weld material to a welding device. The theoretical weight of the used solder material can be compared by the computer with the measured weight of the used solder material. The speed of the power train can be adjusted by the computer to correct a slip of the power train.

[01337] In one modality, the measurement of the first weight and the measurement of the second weight, the calculation of the weight difference corresponding to the measured weld material used, the calculation of the theoretical weight of the used weld material, the comparison of the theoretical weight of the solder material used to the measured weight of solder material used, in a multiplicity of time increments, and the adjustment of the motor package speed when motor package slip occurs can be repeated.

[01338] In one embodiment, a welding system may comprise a plurality of welding stations, where each welding station includes a welding station computer and a welding system in communication with the welding station computer, wherein each soldering station includes one or more sensors and one or more sensors are configured to measure solder data includes lead wire speed data. The soldering system may further comprise a plurality of wireless devices in communication with the one or more soldering station computers to receive the soldering data including the main cable speed measured data. Each of the soldering station computers is configured to process the soldering data, including the main cable speed data for the soldering system in communication with it, and the soldering station computer is configured to determine a quantity of consumable solder material, used by the soldering system for a certain period of time and generating consumption data based on it.

[01339] In one embodiment, each welding station of the welding system may comprise a motor to move the lead wire at the speed of the main wire, where lead wire speed data is determined based on the speed of the motor, each station The welding machine further comprises a weight sensor that detects a weight reduction of the consumable material, the weight sensor provides output signals to the soldering station computer, and the soldering station computer uses the output signals to determine the data. consumption. In one modality, the soldering station computer uses the consumption data to control the motor speed.

[01340] In one embodiment, the welding system may further comprise a cloud server to receive the consumption data, along with the lead wire speed data, to correlate the consumption data with the main wire speed data .

[01341] In one embodiment, a system for pipe testing may comprise a testing device adapted to generate non-destructive test data with respect to at least a portion of weld. The testing device can communicate the non-destructive test data to a second device that is adapted to receive the non-destructive test data. The testing device can be adapted to operate remotely from a means of analyzing the non-destructive test data.

[01342] In one embodiment, the testing device is adapted to transmit non-destructive test data for wireless communication. In one embodiment, the testing device is adapted to transmit non-destructive testing data to a recording medium that is not permanently attached to the testing device. In one embodiment, the testing device is adapted to transmit non-destructive testing data to an external digital recording device.

[01343] In one embodiment, a system for non-destructive pipe testing may comprise imaging equipment adapted to generate non-destructive test data with respect to a portion of a welded pipe; and a remote processing device adapted to receive and process inspection data with respect to the portion of the welded tube.

[01344] In one embodiment, the remote processing device is adapted to analyze data from pipes. In one embodiment, the remote processing device is adapted to analyze weld data. In one embodiment, the remote processing device is adapted to execute computer executable code to identify significant solder defects from the non-destructive test data.

[01345] In one embodiment, the remote processing device is adapted to execute computer executable code of an algorithm to identify significant weld defects from the non-destructive test data. In one embodiment, the remote processing device is adapted to execute computer executable code of an artificial intelligence to identify significant weld defects from the non-destructive test data. In one embodiment, the remote processing device is adapted to execute computer executable code to identify significant solder defects from the non-destructive test data.

[01346] In an embodiment, the non-destructive test data may comprise one or more of the following data: location, size, orientation, shape, and meaning of any defects that caused anomalies in the non-destructive test data. In one modality, non-destructive test data can be analyzed without human calculations or analytical intervention. In one embodiment, non-destructive test data can be analyzed in part through computer analysis and in part by human labor.

[01347] In one embodiment, a non-destructive pipe testing method may comprise providing an imaging equipment; generating non-destructive test data; providing a means to provide the non-destructive test data for analysis; and non-destructive testing data provided for analysis at a location remote from the tested portion of a tube and the equipment near the tested portion of a tube.

[01348] In one embodiment, the method may further comprise providing the non-destructive test data for analysis at a remote location of the tested portion of a tube and a support vehicle. In one embodiment, the method may further comprise providing an analysis at a remote location of the tested portion and any computer near the tested portion of a tube or the testing location.

[01349] In one embodiment, the method may further comprise processing digital NDT data at a location substantially removed from where the data is collected. In one embodiment, the method may further comprise communicating NDT data to a substantially removed location from which data is collected via wireless data transmission. In one embodiment, the method may further comprise communicating NDT data with a location substantially removed from where the data is collected via physical media transport. In one embodiment, the method may further comprise communicating NDT data with a substantially removed location from where the data is collected via a data transmission cable. In one embodiment, the method may further comprise communicating NDT data with a location substantially removed from where the data is collected via a combination of methods.

[01350] In one embodiment, the method may further comprise communicating the analysis results at the substantially removed location to the location where the data is collected. In one embodiment, the method may further comprise communicating test results at the substantially removed location to experts at another substantially removed location.

[01351] In one embodiment, the method can further comprise the analysis of digital automated ultrasonic test data. In one embodiment, the method may further comprise communicating automated ultrasonic test data to a location substantially removed from where the data is collected via wireless data transmission; and processing digital automated ultrasonic test data in a location substantially removed from where the data is collected. In one embodiment, the method may further comprise communicating automated ultrasonic test data with a location substantially removed from where the data is collected via physical media transport.

[01352] In one embodiment, the method may further comprise communicating automated ultrasonic test data to a substantially removed location from where the data is collected via wireless data transmission. In one embodiment, the method may further comprise communicating automated ultrasonic test data with a location substantially removed from where the data is collected via a combination of methods. In one embodiment, the method may further comprise the use of a computer algorithm to identify significant weld defects from automated ultrasonic test data.

[01353] In one embodiment, the method may further comprise processing digital radiographic data at a location substantially removed from where the data is collected. In one embodiment, the method may further comprise communicating digital radiographic data to a substantially removed location from which the data is collected via wireless data transmission. In one embodiment, the method may further comprise communicating digital radiographic data with a location substantially removed from where the data is collected via physical media transport. In one embodiment, the method may further comprise communicating digital radiographic data to a substantially removed location from which the data is collected via a data transmission cable.

[01354] In one embodiment, the method may further comprise communicating digital radiographic data with a location substantially removed from where the data is collected by a combination of methods. In one embodiment, the method may further comprise the use of a computer algorithm to identify significant weld defects from digital radiography data.

[01355] In one embodiment, a system for piping construction may comprise a system for real-time recording of weld data, where the weld data is provided for analysis by computerized means and/or by specialists in question. In one embodiment, the welding data comprises welding data, pipe handling data, coating data, inspection data, management data, or other data. In one embodiment, the system may further comprise a system for aggregating all available weld data into a single dataset with all data relating to each weld related or adapted for analysis by computerized means and/or subject matter experts.

[01356] In one embodiment, the system can further comprise a program logic based on machine readable code execution rules to identify correlations between different data on a weld and to identify defects in that weld. In one embodiment, the system may further comprise program logic based on machine-readable code execution rules to identify correlations between the same data on different welds and the presence or absence of defects in those welds.

[01357] In one embodiment, a system for aligning and welding together two segments of a tube may comprise a welding mechanism for applying a weld to a face joint of the two segments. The welding mechanism may include an articulating torch, a laser sensor to read a profile of the face joint, and an electronic controller to receive information signals from the laser sensor to control the position and/or orientation of the torch. The system may further comprise an alignment mechanism for manipulating the longitudinal axis orientation of at least one of the segments relative to the other. The welding mechanism may further include a carriage for securing a position of the welding mechanism to the tube and a welding portion capable of pivoting with respect to the support portion within the tube. The torch and laser sensor can be rotationally supported by the welding portion so that, during welding, the torch follows the laser sensor along the face joint.

[01358] In one embodiment, the welding mechanism may further include a camera to optically detect an articular face. In one embodiment, pivotal movement of a torch head on the torch may include a radial translational movement toward and away from the face joint, translational movement in the direction of the longitudinal axis of the segments, rotational movement relative to the gear mechanism. welding about an axis that is parallel to the longitudinal axis of the tube segment and rotational movement relative to the weld head about an axis that is perpendicular to the longitudinal axis of the tube segment.

[01359] In one embodiment, the alignment mechanism manipulates the orientation of the at least one segment by contacting an exterior of the at least one segment. In one embodiment, the electronic controller receives a signal from the laser sensor to direct the alignment mechanism to adjust the relative positions of the pipe segments based on predetermined alignment parameters.

[01360] In one embodiment, the weld mechanism rotates in and relative to an interior of a two-segment face joint such that the torch follows the laser sensor and the laser sensor provides continuous face joint profile data to the electronic controller which, in turn, continuously directs torch placement.

[01361] In one embodiment, the camera follows the torch along a weld path and the camera sends a signal to an operator station display to allow an operator to inspect an image of a portion of the weld.

[01362] In one embodiment, a method of aligning and welding together two segments of a tube may comprise placing a first segment of tube over an alignment device; insert an internal welding machine with a laser and welding torch into the first tube segment; generally align the a second tube segment with the first tube segment and internal welding machine; taking an outer portion of the first and second pipe segments to adjust an axial position of the inner welding machine so as to generally align with a face joint of the first and second pipe segments; adjust a relative alignment of the first and second pipe segments through the alignment device based on a signal from the internal welder; begin a root weld cycle in which the laser sweeps the face joint, the torch follows the laser and the laser output is used to control the position of the articulated torch, where the position and orientation of the torch relative to the face joint is controlled to produce a quality weld; determining a laser face join profile; releasing the alignment device and removing the inner welding machine from one end of the open pipe segment; and repositioning a next sequential pipe segment on the outer alignment mechanism in preparation for welding a next joint.

[01363] In one embodiment, the method may further comprise providing a rotating mechanism in which the laser and torch rotate to perform an initial scan of the face joint by laser sensor; and; generating a rotating laser signal to direct the alignment of the first and second tube by the alignment device before welding begins.

[01364] In one embodiment, an internal heat exchanger (IHEX) for pipe welding may comprise a drive system configured to move the IHEX to a position within at least one pipe section close to a weld joint position with another section of tube; a cooling section including a 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 in position within the at least one pipe section.

[01365] In one modality, the IHEX Plus can include a connection member configured to secure the IHEX to an internal connection clamp. In one embodiment, the drive system may comprise at least one roller activated by a motor controlled by the controller and configured to move the IHEX within the at least one section of tube in forward and backward directions. In one embodiment, the cable and winch system, wherein the winch is configured to anchor at an external location to at least one section of pipe and the cable extends between the winch and an IHEX support structure that includes the controller and the cooling section.

[01366] In one embodiment, the controller is additionally in communication with a remote control device in order to facilitate selective activation of the cooling section via the remote control device. In one embodiment, the cooling section comprises at least one nozzle configured to spray a coolant toward an interior wall surface portion of the at least one pipe section; and a coolant supply source configured to supply coolant to the at least one nozzle.

[01367] In one embodiment, the IHEX may further comprise a frame including a first section that includes the coolant supply source, an intermediate section that includes the cooling section, and a third section that includes the controller. In one embodiment, the coolant supply source comprises a coolant pump located remotely from the cooling section such that the coolant pump is located outside at least one pipe section when the cooling section is disposed within the at least one pipe section, and the coolant pump is connected to the at least one nozzle by means of at least one fluid duct. In one embodiment, the at least one nozzle comprises a plurality of nozzles disposed in a plurality of rows, and the rows are disposed around a periphery of a central support member of the cooling section.

[01368] In one embodiment, the cooling section comprises a plurality of fin members extending radially outward from and spaced around a periphery of a central support member of the cooling section. In one embodiment, at least one fin member includes at least one channel extending through the fin member, and the cooling section further comprises at least one fan that is controlled by the controller and is in proximity and aligned with at least one fin member thus for directing a flow of air through the at least one channel of the at least one fin member.

[01369] In one embodiment, at least one fin member comprises a hollow housing that includes an inlet and an outlet, and the cooling section further comprises a circulating refrigerant flow circuit to selectively drain the cooling fluid through the housing. hollow of at least one fin member.

[01370] In one embodiment, the IHEX may comprise one or more temperature sensors arranged in one or more locations along the IHEX and in communication with the controller. The one or more temperature sensors measure a temperature at one or more locations within the at least one pipe section and provide measured temperature information to the controller, and the controller is configured to selectively control the activation and operation of the cooling section based on in the measured temperature information.

[01371] The technology described in this document lies in the important technical problem of how to test, inspect and ensure the quality of thousands and millions of welds in piping systems using reliable and technically sound equipment and methods. In one embodiment, a pipe testing system may have a test device adapted to generate non-destructive test data ("NDT") with respect to at least a portion of a weld or an entire weld. The testing device can communicate the non-destructive test data to a second device that is adapted to receive the non-destructive test data. The testing device can be adapted to operate remotely from a means of analyzing the non-destructive test data. The system for pipe testing may have a test device adapted to transmit non-destructive test data for wireless communication. The piping test system may have a test device adapted to transmit non-destructive test data to recording media that is not permanently attached to the test device. The pipe testing system may have a test device adapted to transmit non-destructive test data to an external digital recording device. A system for non-destructive pipe testing may have: an imaging device adapted to generate non-destructive test data with respect to a portion of a welded pipe; a remote processing device adapted to receive and process inspection data with respect to the portion of welded tube. The non-destructive pipe testing system may have a remote processing device adapted to analyze pipe data. The non-destructive pipe testing system may have a remote processing device adapted to analyze weld data. The non-destructive pipe testing system may have a remote processing device adapted to run computer executable code to identify significant weld defects from the non-destructive test data. The system for non-destructive pipe testing may have a remote processing device adapted to run computer executable code of an algorithm to identify significant weld defects from the non-destructive test data. The system for non-destructive pipe testing may have a remote processing device adapted to run computer executable code from an artificial intelligence to identify significant weld defects from the non-destructive test data. The system for non-destructive pipe testing may have a remote processing device adapted to run computer executable code of rule-based logic to identify one or more significant weld defects from the non-destructive test data. The identified weld defects can be of different types, such as occlusions, lack of material, material properties, brittleness, density, thickness, air bubbles, gas bubbles and others. The non-destructive pipe testing system may have non-destructive test data, such as one or more of the following data: location, size, orientation, shape, and meaning of any defects that caused anomalies in the scan. The system for testing non-destructive pipelines which can have non-destructive test data that can be analyzed by the system automatically and without human calculations or human analytical intervention. In one embodiment, a non-destructive pipeline test method may have the steps of: providing an imaging equipment; generating non-destructive test data; providing a means to provide the non-destructive test data for analysis; and providing the non-destructive test data for analysis at a location remote from the tested portion of a tube and the equipment near the tested portion of a tube. The non-destructive pipe testing method can have the step of providing the non-destructive test data for analysis at a remote location from the tested portion of a pipe and a supporting vehicle. The non-destructive piping test method may have the step of providing the non-destructive test data for analysis at a location remote from the tested portion and any computer near the tested portion of a pipe or test location. The non-destructive piping test method can have the step of processing digital NDT data at a location substantially removed from where the data is collected. The non-destructive pipe testing method can have the step of communicating NDT data to a substantially removed location from where the data is collected via wireless data transmission. The non-destructive pipeline testing method may have the step of communicating the NDT data to a substantially removed location from where the data is collected via physical media transport. The non-destructive pipe testing method may have the step of communicating NDT data to a substantially removed location from where the data is collected via a data transmission cable. The non-destructive piping test method may have the step of communicating NDT data to a substantially removed location from where the data is collected through a combination of methods. The non-destructive piping test method may have the step of: Communicating the analysis results from the substantially removed location to the location where the data is collected. The non-destructive piping test method may have the step of communicating the analysis results at the substantially removed location to experts at another substantially removed location. The non-destructive piping test method can have the step of analyzing digital automatic ultrasonic test data (also as digital "AUT" data). The non-destructive pipeline testing method can have the step of processing automated digital ultrasonic test data in a substantially removed location from where the data is collected. The non-destructive pipe testing method can have the step of processing automated digital ultrasonic test data at a location substantially removed from where the data is collected via wireless data transmission. The non-destructive piping test method can have the step of communicating automated ultrasonic test data to a location substantially removed from where the data is collected via wireless data transmission. The non-destructive piping test method can have the step of communicating the automated ultrasonic test data to a substantially removed location from where the data is collected via physical media transport. The non-destructive piping test method may have the step of communicating automated ultrasonic test data to a location substantially removed from where the data is collected via a data transmission cable. The non-destructive piping test method can have the step of communicating automated ultrasonic test data to a location substantially removed from where the data is collected through a combination of methods. The non-destructive piping test method can include the step of using a computer algorithm to identify significant weld defects from automated ultrasonic test data. The non-destructive piping test method can have the step of processing digital radiographic data at a location substantially removed from where the data is collected. The non-destructive piping test method may have the step of communicating digital radiographic data to a location substantially removed from where the data is collected via wireless data transmission. The non-destructive piping test method may have the step of communicating the digital radiographic data to a location substantially removed from where the data is collected via physical media transport. The non-destructive pipe testing method may have the step of communicating NDT data to a substantially removed location from where the data is collected via a data transmission cable. The non-destructive piping test method may have the step of communicating digital radiographic data to a location substantially removed from where the data is collected through a combination of methods. The non-destructive piping test method may include the step of using a computer algorithm to identify significant weld defects from digital radiography data. In one embodiment, the universal cloud logging system ("uLog") disclosed in this document may have a computer system that has a first device with a processor that processes pipeline construction data, the first device can communicate the data of Pipe construction for a memory cloud base. Pipeline construction data can be processed by a cloud-based processor. uLog can process any one or more pipe construction data, for example, but not limited to: welding data, pipe handling data, coating data, and inspection data. uLog can process data from any one or more of the following devices and/or equipment: a welding station, a pipe welding operation, a welding tool, an automatic welding tool, a manual welding tool, a welding system. vision welding, single welding machine or automatic torch welder, automatic torch welder or automatic welder, external welder or welding machine, internal welder or welding machine, inspection system, smartphone, cellphone, personal data assistant ( PDA), laptop, tablet, computer, digital device, wireless device, and equipment used by a welder, technician, worker, inspector, coater, and/or manager. uLog can use a data management method running on a computer, comprising the steps of: communicating a first data from a first device to a second device, the first data being data relating to a construction of a pipe; and the processing of the first data by a cloud-based network means. The data that can be communicated by the first device and/or processed by the second device and/or processed by the uLog network can be one or more of the following: weld data, tube manipulation data, coating data, weld data, inspection data, heat treatment data and management data or other construction and/or management data relating to the pipeline. In one embodiment, the method of managing data via uLog may include the step of the further method of processing the first data and/or data by a network medium which may be a wired network medium or a wireless network medium . In another embodiment, the method of data management through uLog may include the step of the additional method of processing the first data and/or data by network means which is a wireless network means, telecommunications means or WiFi means. in another embodiment, the method of data management through uLog may include the step of the additional method of processing the first data by the network means which is a cloud-based network. In one embodiment, the uLog may be a computer program product for soldering support having: a computer readable program code medium that provides a computer memory for soldering data; a computer-readable program code means that it supplies the memory with data from a data set comprising pipe data; and computer readable program code means that it processes weld data and piping data to provide recording output and/or output resulting from logic execution and/or program analysis. In one embodiment, the welding support computer program product may further have an executable program code of rule-based logic that processes the weld data by a welding support program code. In another embodiment, the computer program product for welding support may further have an executable program code of rule-based logic that processes the welding data by an inspection program code. In yet another embodiment, the computer program product for welding support may further have an executable program code of a rule-based logic that processes the welding data by a management program code or a quality control program code . A piping construction system may have a system for real-time recording of weld data. Weld data is provided for analysis by computer means and/or subject matter experts. The pipe construction system can use weld data that has one or more weld data, pipe manipulation data, casing data, inspection data, and management data. The piping construction system may also have a system to aggregate all available welding data into a single dataset with all data relating to each weld related or adapted for analysis by computerized means and/or subject matter experts. The piping construction system may further have machine readable code that executes rule-based program logic to identify correlations between different data about a weld and to identify defects in that weld. The piping system may further have machine readable code that executes rule-based program logic to identify correlations between the same data on different welds.

[01372] In one embodiment, the universal cloud logging system ("uLog") disclosed in this document may have a computer system that has a first device with a processor that processes pipeline construction data, the first device can communicate Pipe construction data to a memory cloud base. Pipeline construction data can be processed by a cloud-based processor. uLog can process any one or more pipe construction data, for example, but not limited to: welding data, pipe handling data, coating data, and inspection data. uLog can process data from any one or more of the following devices and/or equipment: a welding station, a pipe welding operation, a welding tool, an automatic welding tool, a manual welding tool, a welding system. vision welding, single welding machine or automatic torch welder, automatic torch welder or automatic welder, external welder or welding machine, internal welder or welding machine, inspection system, smartphone, cellphone, personal data assistant ( PDA), laptop, tablet, computer, digital device, wireless device, and equipment used by a welder, technician, worker, inspector, coater, and/or manager.

[01373] The uLog can use a data management method executed on a computer, comprising the steps of: communicating a first data from a first device to a second device, the first data being data relating to a pipeline construction; and the processing of the first data by a cloud-based network means. The data that can be communicated by the first device and/or processed by the second device and/or processed by the uLog network can be one or more of the following: weld data, tube manipulation data, coating data, weld data, inspection data, heat treatment data and management data or other construction and/or management data relating to the pipeline. In one embodiment, the method of managing data via uLog may include the step of the further method of processing the first data and/or data by a network medium which may be a wired network medium or a wireless network medium . In another embodiment, the method of data management through uLog may include the step of the additional method of processing the first data and/or data by network means which is a wireless network means, telecommunications means or WiFi means. in another embodiment, the method of data management through uLog may include the step of the additional method of processing the first data by the network means which is a cloud-based network. In one embodiment, the uLog may be a computer program product for soldering support having: a computer readable program code medium that provides a computer memory for soldering data; a computer-readable program code means that it supplies the memory with data from a data set comprising pipe data; and computer readable program code means that it processes weld data and piping data to provide recording output and/or output resulting from logic execution and/or program analysis.

[01374] In one embodiment, the welding support computer program product may further have an executable program code of a rule-based logic that processes the welding data by a welding support program code. In another embodiment, the computer program product for welding support may further have an executable program code of rule-based logic that processes the welding data by an inspection program code. In yet another embodiment, the computer program product for welding support may further have an executable program code of a rule-based logic that processes the welding data by a management program code or a quality control program code . The present patent application in its various aspects and modalities solves the problems discussed above and significantly advances the technology of welding, pipe handling, coating, pipeline construction, construction, management and inspection technologies.

[01375] Although the present patent application has been described in detail for the purpose of illustration, it should be understood that such detail is solely for that purpose and that the present patent application is not limited to the disclosed modalities, but, on the contrary, is intended to cover modifications and equivalent provisions which are within the spirit and scope of the appended claims. Furthermore, it is to be understood that the present application contemplates that, as far as possible, one or more features of any one embodiment may be combined with one or more features of any other embodiment.

Claims (37)

1. Field system (5004) for welding two tubes (1022a, 1022b), characterized in that it comprises: a first tube engaging structure (5052) configured to engage the inner surface (5130) of a first tube ( 1022a) to allow the first tube engaging structure to be secured relative to the first tube; a second tube engaging structure (5054) configured to engage the interior surface (5132) of a second tube (1022b) to allow the second tube engaging structure to be secured relative to the second tube; one or more welding torches (5502) configured to be positioned within the tubes to create an internal weld at an interface region (5136) between the tubes; a motor (5124) operatively associated with the one or more welding torches for rotating the one or more welding torches along the region of interface between the tubes; and one or more processors (5140) which control the motor and the one or more welding torches, the one or more processors operating the motor and the one or more welding torches to generate a complete circumferential weld along the rotating interface region one or more welding torches along the interface region in a single rotational direction until the complete circumferential weld is completed, wherein the one or more processors are configured to cooperate with the motor and allow the motor to change a lead angle (θ) of the one or more torches during the welding operation in which the one or more torches rotate along the interface region in the only rotational direction until the complete circumferential weld is completed, and in which the one or more torches are configured to travel in a generally vertical plane in the only rotational direction, while the angle of advance is changed by the one or more processors and the motor accommodates changes in gravitational forces in welding during rotation in the vertical plane, until the complete circumferential weld is completed 2. Field system according to claim 1, characterized in that the one or more welding torches comprise a plurality of welding torches (5502), and wherein at least one of the plurality of welding torches welds in one upward direction against the force of gravity while at least one of the plurality of welding torches welds in a downward direction with the force of gravity. 3. Field system according to claim 1, characterized in that it further comprises an inspection detector (5056) and in which the motor drives the inspection detector to inspect the interface region before the one or more torches of welds generate the complete circumferential weld, with the inspection detector providing information to the one or more processors to control the movement and articulation of the one or more welding torches. 4. Field system according to claim 3, characterized in that the inspection detector is configured to check the complete 360 degrees of the interface region between the tubes and generate signals based on a profile of the interface region between the tubes. 5. Field system according to claim 1, characterized in that the one or more welding torches comprise a first welding torch and a second welding torch, in which, during the welding operation, the first welding torch and the second welding torch deposit the welding material between the tubes simultaneously, wherein the first welding torch and the second welding torch are moved circumferentially by the motor in the same rotational direction while depositing the welding material , wherein, during the welding operation, the first welding torch moves in an upward direction against the force of gravity for at least part of its movement while depositing the weld material, and the second welding torch moves in a downward direction with the force of gravity for at least part of its movement while depositing the weld material. 6. Field system according to claim 5, characterized in that the one or more welding torches further comprise a third welding torch which deposits the welding material between the tubes simultaneously with the first and second welding torches , in which the third welding torch is circumferentially moved by the motor in the same rotational direction as the first and second welding torches while depositing the welding material, where, during the welding operation, the third welding torch moves upwards against the force of gravity while depositing the weld material and also moves downwards with the force of gravity while depositing the weld material. 7. Field system according to claim 1, characterized in that the one or more processors are configured to change the advance angle of the one or more welding torches based on whether the corresponding welding torch is traversing a ascending direction against the force of gravity or a descending direction with the force of gravity. 8. Field system according to claim 1, characterized in that the advance angle is an angle measured between a line (R) from an axial center of the tubes being welded and a weld tip (5503) of the corresponding welding torch, and a line passing through a longitudinal axis of the corresponding welding torch soldering tip. 9. Field system according to claim 1, characterized in that the advance angle of the one or more welding torches is in the range of between 3 and 7 degrees. 10. Field system according to claim 1, characterized in that the angle of advance of the one or more welding torches is greater when the corresponding welding torch moves in an upward direction against the force of gravity and smaller when the corresponding welding torch moves in a downward direction with the force of gravity. 11. Field system according to claim 1, characterized in that the advance angle of the one or more welding torches is negative when the corresponding welding torch moves in a clockwise direction. 12. Field system according to claim 1, characterized in that the advance angle of the one or more welding torches is positive when the corresponding welding torch moves in a counterclockwise direction. 13. Field system according to claim 1, characterized in that the motor operatively associated with the one or more welding torches comprises a plurality of motors (5124), each being configured to rotate an associated torch of the one or more welding torches. 14. Field system according to claim 1, characterized in that the angle of advance changes continuously through the displacement of an associated torch among the one or more welding torches. 15. Field system according to claim 1, characterized in that the angle of advance changes continuously as a torch associated among the one or more welding torches is moved circumferentially along the region of interface between the tubes. 16. Field system according to claim 1, characterized in that the interface region between the tubes extends circumferentially around the tubes, wherein the circumferentially extends interface region includes a plurality of circumferential sectors having sector boundaries, where the feed angle changes at sector boundaries. 17. Field system according to claim 1, characterized in that the first tube engaging structure comprises a first clamp (5142) and the second tube engaging structure comprises a second clamp (5144). 18. Field system according to claim 1, characterized in that the first pipe engaging structure comprises a first seal (5146) and the second pipe engaging structure comprises a second seal (5148). 19. Field system according to claim 1, characterized in that the first tube engaging structure comprises a clamp (5142) and the second tube engaging structure comprises a seal (5146). 20. Field system according to claim 1, characterized in that the first pipe engaging structure comprises a first clamp (5142) and a first seal (5146), and wherein the second pipe engaging structure comprises a second clamp (5144) and a second seal (5148). 21. Field system according to claim 1, characterized in that the one or more processors are configured to operate the first tube engaging structure and/or the second tube engaging structure to change the interface region between the tubes before the welding operation. 22. Field system according to claim 1, characterized in that the one or more processors are configured to change the interface region between the tubes before the welding operation by operating a motor to rotate the first structure of pipe engaging about an axis of the first pipe engaging structure with respect to the second pipe engaging structure. 23. Field system according to claim 1, characterized in that the one or more processors are configured to change the interface region between the tubes before the welding operation by activating the first tube coupling structure and/ or the second tube engaging structure to change the roundness of the first tube and/or the second tube. 24. Field system according to claim 1, characterized in that the one or more processors are configured to rotate the first tube engaging structure in relation to the second tube engaging structure, so as to rotate the first tube in relation to the second tube to change the interface region between the tubes before the welding operation. 25. Field system according to claim 1, characterized in that it further comprises a sensor (5056) configured to detect a position of the one or more welding torches and/or a characteristic of the interface region between the tubes to rotating signals based thereon, whereby the one or more processors, in response to signals from the sensor, are configured to cooperate with the motor to allow the motor to change the advance angle of the one or more welding torches during the operation of welding in which the one or more welding torches rotate along the interface region in the only direction of rotation until the complete circumferential weld is completed. 26. System according to claim 1, characterized in that the one or more welding torches do not reverse direction in a generally vertical plane during the welding operation in which the one or more welding torches rotate along the interface region in the only direction of rotation until the complete circumferential weld is completed. 27. Field system (5004) for welding two tubes (1022a, 1022b), characterized in that it comprises: a first tube engaging structure (5052) configured to engage the inner surface (5130) of a first tube ( 1022a) to allow the first tube engaging structure to be secured relative to the first tube; a second tube engaging structure (5054) configured to engage the interior surface (5132) of a second tube (1022b) to allow the second tube engaging structure to be secured relative to the second tube; a welding torch (5502) configured to be positioned within the tubes to create an internal weld at an interface region (5136) between the tubes; a motor (5124) operatively associated with the welding torch for rotating the welding torch along the region of interface between the tubes; and one or more processors (5140) that control the motor and welding torch, the one or more processors operating the motor and welding torch to generate a complete circumferential weld along the interface region by rotating the welding torch along of the interface region in a single rotational direction until the complete circumferential weld is completed, at which the one or more processors are configured to cooperate with the motor and allow the motor to change a lead angle (θ) of the welding torch during the welding operation, so that the welding torch rotates at least 360 degrees, in both an upward direction against the force of gravity and a downward direction with the force of gravity, in the only rotational direction to complete the circumferential weld, and in that the welding torch is configured to travel in a generally vertical plane in the only rotational direction by at least 360 degrees, while the angle of advance is changed by one or more processes. Operators and the motor accommodate changes in gravitational forces in the weld during rotation in the vertical plane, until the complete circumferential weld is completed. 28. Field system according to claim 27, characterized in that the tubes are arranged in a horizontal configuration, further comprising a frame (5026, 5068, 5278) configured to be placed inside the tubes arranged horizontally and a plurality of rollers (6530) configured to rotatably support the frame for horizontal movement within horizontally disposed tubes, and wherein the first tube engaging structure and the second tube engaging structure are disposed on the frame. 29. Field system according to claim 27, characterized in that the first tube coupling structure and the second tube coupling structure have a longitudinal axis, in which the welding torch rotates in a generally vertical plane which is perpendicular to the longitudinal axis of the first tube engaging structure and the second tube engaging structure. 30. Field system according to claim 27, characterized in that it further comprises a sensor (5056) configured to detect a position of the one or more welding torches and/or a characteristic of the interface region between the tubes to rotating signals based on them, whereby the one or more processors, in response to the sensor signals, are configured to cooperate with the motor to allow the motor to change the advance angle of the welding torch during the welding operation, from so that the welding torch rotates at least 360 degrees, in both an upward direction against the force of gravity and a downward direction with the force of gravity, in the only rotational direction to complete the circumferential weld. 31. Field system according to claim 27, characterized in that the welding torch does not reverse direction in a generally vertical plane during the welding operation in which the welding torch rotates along the interface region in the single direction of rotation until the complete circumferential weld is completed. 32. Method for welding two tubes (1022a, 1022b), characterized in that it comprises: engaging the inner surface (5130) of a first tube (1022a) of the two tubes with a first tube engaging structure (5052) to allowing the first tube engaging structure to be secured relative to the first tube; positioning one or more welding torches (5502) within the tubes to create an internal weld at an interface region (5136) between the tubes, the one or more welding torches being operatively connected with the first tube engaging structure; rotating, using one or more motors (5124) operatively associated with the one or more welding torches, the one or more welding torches along the region of interface between the tubes; and operating, using one or more processors (5140) that control the one or more motors and the one or more welding torches, the one or more motors and the one or more welding torches to generate a complete circumferential weld over the region by rotating the one or more welding torches along the interface region in a single direction of rotation until the circumferential weld is complete, and to change a lead angle (θ) of the one or more welding torches during the welding operation, in which the one or more welding torches rotate along the interface region in the single direction of rotation until the complete circumferential weld is complete, where the one or more torches are configured to travel in one plane generally vertical in the only rotational direction, while the angle of advance is changed by the one or more processors and the motor to accommodate changes in gravitational forces in the weld during rotation in the vertical plane, until the complete circumferential weld is completed 33. The method of claim 32, wherein the one or more welding torches comprise a plurality of welding torches (5502), and wherein at least one of the plurality of welding torches welds in one direction upward against the force of gravity while at least one other of the plurality of welding torches welds in a downward direction with the force of gravity. 34. Method according to claim 32, characterized in that it further comprises the verification, using an inspection detector (5056) operatively associated with the motor, of the complete 360 degrees of the interface region between the tubes and the generation of signals based on a profile of the interface region between the tubes. 35. The method of claim 32, further comprising engaging the inner surface (5132) of a second tube (1022b) of the two tubes with a second tube engaging structure (5054) to enable the second tube engaging structure is secured relative to the second tube, with the second tube engaging structure being operatively coupled to the one or more welding torches. 36. Method according to claim 32, characterized in that it further comprises detecting, using a sensor (5056), a position of the one or more welding torches and/or a characteristic of the interface region between the tubes to rotate signals based thereon, and operate using the one or more processors, the one or more motors, and the one or more welding torches to change the advance angle of the one or more welding torches in response to rotated sensor signals and during a welding operation in which the one or more welding torches rotate along the interface region in the single direction of rotation until the complete circumferential weld is completed. 37. Method according to claim 32, characterized in that the one or more welding torches do not reverse direction in a generally vertical plane during the welding operation in which the one or more welding torches rotate along the interface region in the only direction of rotation until the complete circumferential weld is completed.

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