CN113001070A - Pipeline cooling system - Google Patents

Pipeline cooling system Download PDF

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Publication number
CN113001070A
CN113001070A CN202110266287.2A CN202110266287A CN113001070A CN 113001070 A CN113001070 A CN 113001070A CN 202110266287 A CN202110266287 A CN 202110266287A CN 113001070 A CN113001070 A CN 113001070A
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CN
China
Prior art keywords
pipe
welding
frame
duct
welded
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202110266287.2A
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Chinese (zh)
Inventor
桑卡·T·拉贾戈帕兰
西达尔特·马利克
布莱恩·L·柯克
约瑟·C·布什
詹森·W·克勃
乔纳森·B·凯特凯博
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kerry Kevins Pipeline International Co ltd
CRC Evans Pipeline International Inc
Original Assignee
Kerry Kevins Pipeline International Co ltd
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Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=56978897&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=CN113001070(A) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Priority claimed from PCT/US2015/022665 external-priority patent/WO2015148765A1/en
Priority claimed from PCT/US2015/047603 external-priority patent/WO2016033568A1/en
Application filed by Kerry Kevins Pipeline International Co ltd filed Critical Kerry Kevins Pipeline International Co ltd
Publication of CN113001070A publication Critical patent/CN113001070A/en
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
    • B23K37/053—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work aligning cylindrical work; Clamping devices therefor
    • B23K37/0531—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work aligning cylindrical work; Clamping devices therefor internal pipe alignment clamps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/02—Carriages for supporting the welding or cutting element
    • B23K37/0276—Carriages for supporting the welding or cutting element for working on or in tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/02—Carriages for supporting the welding or cutting element
    • B23K37/0282—Carriages forming part of a welding unit
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
    • B23K37/053—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work aligning cylindrical work; Clamping devices therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/02—Seam welding; Backing means; Inserts
    • B23K9/028—Seam welding; Backing means; Inserts for curved planar seams
    • B23K9/0282—Seam welding; Backing means; Inserts for curved planar seams for welding tube sections
    • B23K9/0284—Seam welding; Backing means; Inserts for curved planar seams for welding tube sections with an electrode working inside the tube
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B23K9/0953—Monitoring or automatic control of welding parameters using computing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B23K9/0956—Monitoring or automatic control of welding parameters using sensing means, e.g. optical
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/127—Means for tracking lines during arc welding or cutting
    • B23K9/1272—Geometry oriented, e.g. beam optical trading
    • B23K9/1274—Using non-contact, optical means, e.g. laser means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L13/00—Non-disconnectible pipe-joints, e.g. soldered, adhesive or caulked joints
    • F16L13/02—Welded joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/04—Tubular or hollow articles
    • B23K2101/06—Tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/04—Tubular or hollow articles
    • B23K2101/10—Pipe-lines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys

Abstract

A pipe cooling system comprising: a frame configured to be positioned within at least one of a plurality of welded pipes, the plurality of welded pipes secured together via a welded joint; a plurality of rollers configured to rotatably support the frame; a drive motor driving the plurality of rollers to move the frame within the at least one duct; a braking system that resists movement of the frame at a desired location within the at least one conduit; one or more battery cells carried by the frame, the battery cells configured to power the drive motor and the braking system; a cooler carried by the frame, the cooler including a fan configured to blow a cooling gas within the at least one duct and in a direction toward the weld joint to facilitate cooling of the weld duct; and one or more processors operatively connected to the drive motor, the brake system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe.

Description

Pipeline cooling system
This application is a divisional application of an inventive patent application entitled "system and method for welding pipe sections of a pipeline" filed on international filing date on 24/11/2015 with national phase accession number 201580080511.1.
Background
Cross Reference to Related Applications
This application is a continuation-in-part application of PCT/US2015/047603 filed on 28/8/2015, which requires priority of US provisional application number 62/043,757 filed on 29/8/2014. This application is also a continuation-in-part application of PCT/US2015/022665 filed on day 26 at 3/2015 and U.S. patent application No. 14/228,708 filed on day 28 at 3/2014. PCT/US2015/022665 claims the benefit of U.S. patent application No. 14/228,708. This application is also a continuation-in-part application of PCT/US2014/039148 filed on day 5/22 2014 and U.S. patent application number 14/272,914 filed on day 5/8 2014, both of which PCT/US2014/039148 and which U.S. patent application number 14/272,914 claim priority to U.S. provisional application number 61/826,628 filed on day 5/23 2013. PCT/US2014/039148 claims the benefit of U.S. patent application No. 14/272,914. This application also claims priority from U.S. provisional application No. 62/175,201 filed on 12/6/2015 and U.S. provisional application No. 62/189,716 filed on 7/2015. The contents of all of these applications are incorporated by reference herein in their entirety.
FIELD
The present patent application relates to various field systems and methods for the purpose of welding pipe segments of a pipeline.
Pipeline systems for transporting fluids, such as water, oil, and natural gas, between two locations (e.g., from a source, which may be a land or water based source, to a suitable storage location) may include elongated sections or pipe segments (e.g., miles of pipe segments) comprising steel, stainless steel, or other types of metals. The construction of pipeline systems typically involves joining together lengths of pipe having suitable diameters and lengthwise dimensions by means of, for example, welded seams capable of providing a liquid-tight seal for the joined lengths of pipe.
In forming a welded joint between two pipe segments (e.g., two pipe segments having the same or similar transverse cross-sectional dimensions), the end of one pipe portion or pipe segment is brought into close proximity or contact with the end of a second pipe portion or pipe segment. The pipe sections are fixed relative to each other and a weld joint is formed using a suitable welding process to connect the two ends of the pipe sections. After the weld is completed and cleaned, the weld may be inspected. After inspection, it may be desirable to apply an outer protective coating to the weld joint.
Conventional internal welders often include internal alignment mechanisms that expand radially outward to contact the interior of the pipe. Alignment of the two pipe sections is accomplished from the inside when the extension members of the central member contact the interior of the pipe on either side of the seam, relatively close to the joint face of the pipe sections, as shown in U.S. patent nos. 3,461,264, 3,009,048, 3,551,636, 3,612,808 and GB 1261814 (each of which is incorporated herein by reference in its entirety). To weld the seam, the structure of the expander should be configured to allow sufficient space to accommodate the rotating torch. It would therefore be advantageous to provide internal alignment that allows sufficient space for a rotating or articulating torch, or to align the tube segments externally in order to eliminate the need for an internal expander that could create significant internal clutter.
Further, conventional internal welding processes typically involve internal or external alignment and insertion of an internal welder such that the welding torch is aligned with the face seam. In this process, it is sometimes difficult to assess the accuracy of the positioning of the internal welder in general and the positioning of the torch specifically. It is even more difficult to assess the accuracy of the torch position as it traverses the inside of the pipe along its orbital path during welding. It would therefore be advantageous to provide a system that tracks the structure or location of the pipe edge at the pipe joint in order to control the welding torch by using the tracked joint state. In particular, it is advantageous to first track the profile of the joint using the laser and then send a signal to the electronic controller to guide the position and orientation of the welding torch relative to the tracked pipe joint profile.
In addition, conventional pipeline welding systems that employ external alignment mechanisms typically support two sections on rollers and manipulate the position and orientation of the sections until the alignment is satisfactory. Whether the alignment is satisfactory typically depends, for example, on industry-accepted high and low gauges that are fairly accurate and are manually operated and positioned at discrete locations and not over the entire pipe joint. In any case, the profile or configuration of the joint as viewed from the inside of the pipe is generally not a consideration for the quality of the alignment. It is therefore advantageous to provide an alignment system in which information about the contour of the joint, as read by a laser, during an external alignment process is used as an input parameter. In particular, it is advantageous to provide information from the torch control laser to a controller that uses the information to control the external alignment mechanism.
In addition, conventional pipeline systems for welding pipe sections often lack the ability to visually verify the weld applied by the welding torch. It would therefore be advantageous to provide a camera that follows the torch weld application and a display for displaying images of the weld so that the operator can visually inspect the weld quality. Other advantages of the present disclosure will be apparent from a review of the present disclosure. The advantages of the available patents are not limited to those highlighted in this section. Moreover, the advantages emphasized herein should be considered independent of each other and independent of each other, unless explicitly stated otherwise herein. Further advantages are also described in the claims provided in the present application.
In a welding operation, the pipe is typically preheated to a suitable temperature prior to welding, and significant heat is also generated during the welding process.
At some time after the weld is completed and cleaned, the weld may be inspected. It is desirable to inspect the weld at a temperature that is closer to the pipe operating temperature than the elevated weld temperature. Therefore, it may be desirable to cool after the welding process, and then perform an inspection. After inspection, it may be desirable to apply an outer protective coating to the seam. To facilitate this coating, heat may be added to the pipe to raise the pipe temperature required for application of certain external coatings (e.g., polypropylene).
After this heating, the pipe connection is desirably allowed to cool to a suitable temperature, after which further processing steps performed (e.g., after which the connected pipe portion is coiled or treated/placed in water or at some other suitable location on land) take place.
During some pipe manufacturing steps (e.g., after welding and before inspection), the outer portion of the joining pipe is readily accessible and cooling at the outer surface is an option. However, during some portions of the process (e.g., after certain materials have been externally applied to the outside surface of the pipe), the exterior surface is not available for the pipe cooling process to be performed thereon.
Internal cooling may be available during certain portions of the manufacturing process (i.e., even when external cooling is available). Internal cooling within the duct can be challenging due to the size of the duct and the difficulty of accessing the interior portions of the duct portions at or near the weld joint. It is therefore particularly desirable to provide internal cooling so that during portions of the process where the external surface of the pipe is inaccessible, cooling can be achieved to more quickly condition the pipe for future steps (e.g., winding) that require lower temperatures.
Existing pipeline weld inspection processes, such as ultrasonic testing and x-ray photography, can be challenging. For example, some processes may require a large team of trained personnel (e.g., 4 or more personnel) to travel to a remote location where a pipeline is constructed; it may be desirable to transport a durable computer by a special purpose truck to a remote location having a harsh environment and use the computer in the remote location; providing; using inspection equipment tethered ("tethered") to dedicated rugged computer equipment and trucks by network wires; may be inefficient because each member of the team may only be needed for certain steps of the process; a trained technician is required to interpret the test results in the field; and the desired analysis needs to be completed and the results written about the pipe, after which the team can proceed to inspect the next weld. Of course, these are general cases, and not all of these problems exist in all systems.
Currently, pipe joining technology is still an area that relies on avoiding mistakes by workers applying the welds. Some welding technologies require adequate data management, work control, and activity monitoring. Because of such challenges, weld quality, completion time, and economics may also be challenging the present patent application provides improvements over prior art systems and methods.
SUMMARY
The present application relates to a field system and method that may be deployed in a pipe welding application. The field system provides a number of embodiments relating to pipe welding systems and methods that can be used in combination with one another or alone. Such welding systems and methods include, for example, internal welding systems and methods, joint welding systems and methods, pipe inspection systems and methods, pipe handling systems and methods, internal pipe cooling systems and methods, non-invasive testing systems and methods, and remote interfaces and database systems and methods (uLog), to name a few. The present application also relates to welded pipes produced by some or all of such processes.
One aspect of the present patent application provides a pipe cooling system comprising: a frame configured to be positioned within at least one of a plurality of welded pipes secured together via a welded joint; a plurality of rollers configured to rotatably support the frame; a drive motor driving the plurality of rollers to move the frame within the at least one duct; a braking system that resists movement of the frame at a desired location within the at least one conduit; one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system; a cooler carried by the frame, the cooler including a fan configured to blow a cooling gas within the at least one duct and in a direction toward a weld joint to facilitate cooling of the weld duct; and one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe.
Another aspect of the present application provides a pipe cooling system, comprising: a frame configured to be positioned within at least one of a plurality of welded conduits; a plurality of rollers configured to rotatably support the frame; a drive motor driving the plurality of rollers to move the frame within the at least one duct; a braking system that resists movement of the frame at a desired location within the at least one conduit; one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system; a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; and one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe; wherein the cooler comprises a heat exchanger carrying a cooling fluid therein, the heat exchanger having a tube contacting surface that contacts an inner surface of the welded tube to facilitate cooling of the welded tube.
Another aspect of the present application provides a pipe cooling system, comprising: a frame configured to be positioned within at least one of a plurality of welded conduits; a plurality of rollers configured to rotatably support the frame; a drive motor driving the plurality of rollers to move the frame within the at least one duct; a braking system that resists movement of the frame at a desired location within the at least one conduit; one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system; a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe; and a temperature sensor sensing a temperature of the welded pipe, the temperature sensor in operable communication with the one or more processors, the one or more processors sending operating instructions to the chiller based on signals received from the temperature sensor.
Another aspect of the present application provides a pipe cooling system, comprising: a frame configured to be positioned within at least one of a plurality of welded conduits; a plurality of rollers configured to rotatably support the frame; a drive motor driving the plurality of rollers to move the frame within the at least one duct; a braking system that resists movement of the frame at a desired location within the at least one conduit; one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system; a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; and one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe; wherein the one or more processors are communicatively connected to a remote computer system and configured to transmit the pipe cooling data to the remote computer system.
Another aspect of the present application provides a pipe cooling system, comprising: a frame configured to be positioned within at least one of a plurality of welded conduits; a plurality of rollers configured to rotatably support the frame; a drive motor driving the plurality of rollers to move the frame within the at least one duct; a braking system that resists movement of the frame at a desired location within the at least one conduit; one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system; a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; and one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe; wherein the one or more processors are configured to calculate an expected time required until the temperature of the welded pipe is below a threshold temperature, wherein the calculation is based at least in part on the size of the welded pipe.
Another aspect of the present application provides a pipe cooling system, comprising: a frame configured to be positioned within at least one of a plurality of welded conduits; a plurality of rollers configured to rotatably support the frame; a drive motor driving the plurality of rollers to move the frame within the at least one duct; a braking system that resists movement of the frame at a desired location within the at least one conduit; one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system; a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; and one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe; wherein the one or more processors are communicatively connected to a remote computer system and configured to transmit coolant consumption data.
Another aspect of the present application provides a pipe cooling system, comprising: a frame configured to be positioned within at least one of a plurality of welded conduits; a plurality of rollers configured to rotatably support the frame; a drive motor driving the plurality of rollers to move the frame within the at least one duct; a braking system that resists movement of the frame at a desired location within the at least one conduit; one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system; a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; and one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe; wherein the cooling gas comprises air, and wherein the cooler comprises at least one fan configured to force air through a heat exchanger element of the duct cooling system.
Another aspect of the present application provides a pipe cooling system, comprising: a frame configured to be positioned within at least one of a plurality of welded conduits; a plurality of rollers configured to rotatably support the frame; a drive motor driving the plurality of rollers to move the frame within the at least one duct; a braking system that resists movement of the frame at a desired location within the at least one conduit; one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system; a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; and one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe; wherein the cooling gas comprises air, and wherein the cooler comprises at least one fan configured to force air through an interior surface of the welded conduit, wherein the conduit cooling system further comprises a temperature sensor that senses a temperature of the welded conduit, the temperature sensor being in operable communication with the one or more processors that send operating instructions to the at least one fan based on signals received from the temperature sensor.
Another aspect of the present patent application provides an in-situ system for welding two pipes. The field system includes: a first conduit engagement structure; a second conduit engagement structure; inspecting the detector; one or more orientation motors; one or more processors; and a welding torch assembly. The first conduit engagement structure is configured to engage an interior surface of the first conduit to enable the first conduit engagement structure to be fixed relative to the first conduit. The second conduit engagement structure is configured to engage an interior surface of the second conduit to enable the second conduit engagement structure to be fixed relative to the second conduit. A verification detector is positioned axially between the first and second pipe engagement structures, the verification detector configured to verify a joint region between the pipes and generate profile data based thereon. One or more orientation motors are operatively associated with the inspection detectors to direct the inspection radiation beams along the joint region between the pipes. One or more processors are operatively associated with the inspection detectors and configured to receive the profile data from the inspection detectors to determine one or more characteristics of a joint region between the pipes. The welding torch assembly includes a welding torch and at least one welding torch motor actuated by one or more processors to produce a weld between the pipes based on one or more characteristics of a joint area between the pipes.
Yet another aspect of the present patent application provides an in-situ system for welding two pipes. The field system includes: a frame configured to be placed within a duct; a plurality of rollers configured to rotatably support the frame; a driving motor driving the roller to move the frame within the duct; a braking system that fixes the frame at a desired position within the duct without movement; an inspection detector carried by the frame, the inspection detector configured to detect a characteristic of a joint region between pipes; a welding torch carried by the frame; one or more battery cells carried by the frame, the one or more battery cells configured to power the drive motor, the inspection detector, and the welding torch; and one or more processors operatively connected to the drive motor, the inspection detector, and the welding torch.
Yet another aspect of the present patent application provides a method for welding a pair of insulated pipes to one another. Each tube includes a metal tube interior surrounded by an insulator material. The end portions of the pipe to be welded expose the interior of the metal pipe. The method comprises the following steps: aligning the exposed metal pipe ends to be welded; welding the exposed metal pipe ends to each other; heat welding the exposed end portions of the pipes; applying an insulator to the heated exposed end portion of the welded pipe such that the insulator adheres to the exterior surface of the interior of the metal pipe, thereby insulating the previously exposed end portion of the pipe; and applying cooling energy from within the pipe to the interior surface of the metal pipe.
Yet another aspect of the present patent application provides a system for welding a pair of insulated pipes to one another. Each tube includes a metal tube interior surrounded by an insulator material. The end portions of the pipe to be welded expose the interior of the metal pipe. The system comprises: a welding torch configured to weld the exposed metal pipe ends to each other; a heater configured to heat the exposed end portions of the welded conduits; an insulator supply configured to apply an insulator material to the heated exposed end portion of the welded pipe such that the insulator adheres to an exterior surface of the interior of the metal pipe, thereby insulating the previously exposed end portion of the pipe; and a cooler system configured to be positioned within the pipe, the cooler system applying cooling energy to an interior surface of the metal pipe to facilitate cooling of the metal pipe after the insulator material is applied.
Yet another aspect of the present patent application provides a method for welding a pair of insulated pipes to one another. Each tube includes a metal tube interior surrounded by an insulator material. The end portions of the pipe to be welded expose the interior of the metal pipe. The method comprises the following steps: aligning the exposed metal pipe ends to be welded; welding the exposed metal pipe ends to each other; heat welding the exposed end portions of the pipes; applying an insulator to the heated exposed end portion of the welded pipe such that the insulator adheres to the exterior surface of the interior of the metal pipe, thereby insulating the previously exposed end portion of the pipe; and applying cooling energy to the interior surface of the metal pipe from within the pipe after applying the insulator; and performing a pipeline deployment procedure. Applying cooling energy reduces the latency between applying the insulator and performing the pipeline deployment procedure.
Yet another aspect of the present patent application provides a welded pipe assembly. The welded pipe assembly comprises: a first metal tube having a length of at least 30' and an outer diameter of less than 24 "; a second metal tube having a length of at least 30' and an outer diameter of less than 24 "; a weld material connecting the first pipe with the second pipe, the weld material including a plurality of weld channel layers including a root channel layer and a heat channel layer disposed on top of the root channel layer, wherein the heat channel layer is positioned closer to an inner longitudinal axis of the welded first and second pipes than the root channel layer.
Yet another aspect of the present patent application provides a welded pipe assembly. The assembly includes: a first metal tube having a length of at least 30' and an outer diameter of less than 24 "; a second metal tube having a length of at least 30' and an outer diameter of less than 24 "; a weld joint connecting a first metal tube and a second metal tube, the weld joint including a first internal chamfer formed in the first metal tube and a second internal chamfer formed in the second metal tube, and a root passage layer of weld material disposed in an area defined by the first internal chamfer and the second internal chamfer.
Yet another aspect of the present patent application provides a pipe cooling system. The pipe cooling system includes a frame, a plurality of rollers, a drive motor, a braking system, a cooler, and one or more processors. The frame is configured to be placed within a welded pipe. The plurality of rollers is configured to rotatably support the frame. A motor is driven to drive the rollers to move the frame within the duct. The braking system fixes the frame at a desired position within the duct without movement. The cooler is a cooler carried by the frame that applies cooling energy to the interior surface of the metal pipe to facilitate cooling of the welded metal pipe. The one or more processors are operatively connected to the drive motor, the braking system, and the cooler. The one or more processors operate the cooler to reduce the temperature of the welded pipe to a predetermined level.
Yet another aspect of the present patent application provides a welded pipe assembly. A welded pipe assembly comprising: a first metal pipe; a second metal pipe; and a welding material connecting the first metal pipe with the second metal pipe. The first metal pipe has a length of at least 30 feet and an outer diameter of less than 24 inches. The second metal pipe has a length of at least 30 feet and an outer diameter of less than 24 inches. The weld material includes a plurality of weld channel layers. The plurality of weld channel layers includes a root channel layer and a thermal channel layer disposed on top of the root channel layer. The thermal channel layer is positioned closer to the inner longitudinal axis of the welded first and second conduits than the root channel layer.
Yet another aspect of the present patent application provides a welded pipe assembly. A welded pipe assembly comprising: a first metal pipe; a second metal pipe; and a weld joint connecting the first metal pipe and the second metal pipe. The first metal pipe has a length of at least 30 feet and an outer diameter of less than 24 inches. The second metal pipe has a length of at least 30 feet and an outer diameter of less than 24 inches. The weld joint includes a first internal chamfer formed in the first metal tube and a second internal chamfer formed in the second metal tube, and a root passage layer of weld material disposed in an area defined by the first internal chamfer and the second internal chamfer.
Yet another aspect of the present patent application provides an in-situ system for welding two pipes. The field system includes: a first conduit engagement structure configured to engage an interior surface of a first conduit to enable the first conduit engagement structure to be fixed relative to the first conduit; a second conduit engagement structure configured to engage an interior surface of a second conduit to enable the second conduit engagement structure to be fixed relative to the second conduit; one or more welding torches configured to be positioned within the pipes to produce an internal weld at a joint region between the pipes; a motor operatively associated with the one or more welding torches to rotate the one or more welding torches along a joint region between the pipes; and one or more processors controlling 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 joint region by rotating the one or more welding torches along the joint region in a single rotational direction until the complete circumferential weld is completed.
Yet another aspect of the present patent application provides an inspection system for pre-inspecting a joint region between two pipes to be end-to-end welded. The system comprises: a frame configured to be placed within a duct; a plurality of rollers configured to rotatably support the frame; a driving motor driving the roller to move the frame within the duct; a braking system that fixes the frame at a desired position within the duct without movement; a sensor movable with the frame, which detects a joint region between the pipes; a verification detector configured to generate a signal based on a profile of a joint region between pipes; a motor that rotationally moves the inspection detector along the joint region; and one or more processors operatively associated with the drive motor, the sensors, the inspection detectors, and the motor, the one or more processors operating the drive motor to move the frame through at least one of the pipes until the sensors detect the joint region, the one or more processors operating the braking system to fix the frame against non-movement at a position within the pipes where the inspection detectors are positioned relative to the joint region to enable the inspection detectors to detect the profile of the joint region between the pipes; the one or more processors operate the inspection detector and the motor to scan a joint region between the pipes, and in response to detecting one or more undesirable characteristics of the joint region, the one or more processors send instructions based thereon.
Yet another aspect of the present patent application provides an in-situ system for pre-verifying a joint area between two pipes to be end-to-end welded. The system comprises: a frame configured to be placed within a duct; a plurality of rollers configured to rotatably support the frame; a driving motor driving the roller to move the frame within the duct; a braking system that fixes the frame at a desired position within the duct without movement; a verification detector configured to generate a signal based on a profile of a joint region between pipes; one or more orientation motors that rotationally move the inspection detector along the joint region; and one or more processors operatively associated with the drive motor, the inspection detectors, and the motor, the one or more processors operating the braking system to secure the frame against movement at a position within the pipes where the inspection detectors are positioned relative to the joint regions to enable the inspection detectors to detect a profile of the joint regions between the pipes; the one or more processors operate the inspection detector and the motor to scan a joint region between the pipes to generate pre-weld profile data, and in response to detecting one or more undesirable characteristics of the pre-weld profile data, the one or more processors send instructions based thereon.
Yet another aspect of the present patent application provides a method for pre-verifying a joint region between two pipes to be end-to-end welded. The method comprises the following steps: moving the frame within at least one of the pipes to be welded; detecting a joint region between the pipes; the frame is fixed against movement at the joint area between the pipes; detecting a profile of a joint region between pipes; and in response to detecting one or more undesirable characteristics of a joint region between the pipes, generating instructions based thereon.
Yet another aspect of the present patent application provides a pipe cooling system. The pipe cooling system includes: a frame configured to be placed within a welded pipe; a plurality of rollers configured to rotatably support the frame; a driving motor driving the roller to move the frame within the duct; a braking system that fixes the frame at a desired position within the duct without movement; a cooler carried by the frame, the cooler applying cooling energy to an interior surface of the metal pipe to facilitate cooling of the welded metal pipe; and one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe to a predetermined level.
One aspect of the present patent application provides a method of welding two pipes. The method comprises the following steps: internally center-tightening the first pipe using a first clamp; clamping the second pipe internally using a second mandrel, the first pipe and the second pipe being clamped such that they are disposed in end-to-end abutting relationship with a joint region therebetween; scanning the joint region from a position within the pipe and between the clamps to obtain profile data from the joint region; welding two pipes in an end-to-end relationship based on the profile data; and internally inspecting the welded pipe from a position within the pipe and between the clamps
One aspect of the present application provides a welding process system for facilitating pipe welding that is remote from an on-site system for performing a pipe welding operation between a first pipe and a second pipe. For example, the remote field system includes: an inspection detector configured to emit an inspection radiation beam to scan a profile of a joint region between the first pipe and the second pipe; and a welding torch configured to produce a weld between the first and second conduits based on a profile of a joint area between the first and second conduits. The welding processing system includes: a receiver configured to receive profile data from a remote welding system determined from a scan of a joint region between pipes by an inspection detector; one or more processors configured to compare one or more characteristics of the scanned profile data of the joint region to one or more characteristics of predefined profile data of a predetermined joint region, and configured to determine control operation data of the remote field system based on the comparison; and a transmitter configured to transmit the control operation data to a remote field system. The control operation data is configured to cause the welding torch to perform one or more welding operations on a joint region between the pipes.
One aspect of the present application provides a method for welding pipes. The method comprises the following steps: aligning the ends of two pipes to be welded, the pipes comprising a metal pipe interior surrounded by an insulator material, the metal pipe interior being exposed at a portion of the pipe adjacent to the ends of the pipes to be welded; welding aligned ends of the tubes to one another from within the tubes to form a weld joint; generating welding data during welding of the aligned ends, the welding data corresponding to welding parameters associated with the welding; inspecting the weld joint from within the welded pipe using an inspection laser to derive internal weld inspection data; inspecting the weld joint using an inspection radiation source to derive radiation inspection data; transmitting the welding data, the internal weld inspection data, and the radiation inspection data to a remote computer system to derive additional welding data; and receiving the derived additional weld data. The additional weld data is derived from the transmitted data and additional inspection data received by the remote system from inspection of other pipes.
One aspect of the present patent application provides a field system for facilitating field testing and physical operations based thereon. The field system includes: a field device configured to perform an operation that physically affects an object; an inspection device configured to scan an object; and one or more processors communicatively connected to the inspection device and configured to receive inspection data associated with the scanning of the object from the inspection device. The one or more processors are communicatively connected to a remote computer system and configured to transmit the verification data to the remote computer system. The one or more processors are configured to receive data related to performing an operation from a remote computer system in response to transmitting the inspection data, and to cause the field device to perform an operation that physically affects the object based on the operation-related data. The operation-related data is derived from the inspection data and further inspection data associated with a separate scan of a further object.
One aspect of the present patent application provides a method for facilitating field testing and physical operations based thereon. The method comprises the following steps: scanning the object by an inspection device of the field system to provide inspection data associated with the scanning of the object to the one or more processors; transmitting, by one or more processors of the field system, the inspection data to a remote computer system; receiving, by the one or more processors and in response to the transmission verification data, data from a remote computer system related to performing an operation that physically affects the object; and causing, by the one or more processors, a field device of the field system to perform an operation that physically affects the object based on the operation-related data. The operation-related data is derived from the inspection data and further inspection data associated with a separate scan of a further object.
One aspect of the present patent application provides a computer system for facilitating field testing and physical operations based thereon that is remote from a field system in which the field testing and physical operations occur. The remote field system includes: an inspection device configured to scan an object; and a field device configured to perform an operation that physically affects the object. The computer system includes: a receiver configured to receive inspection data associated with a scan of an object by an inspection device from a remote field system; one or more processors configured to process the inspection data to generate data related to performing an operation that physically affects the object; and a transmitter configured to transmit the operation-related data to a remote field system to cause the remote field system to perform an operation that physically affects the object, wherein the operation is performed based on the operation-related data.
One aspect of the present patent application provides a method for facilitating field testing and physical operations based thereon remotely from a field system where the field testing and physical operations occur. The remote field system includes: an inspection device configured to scan an object; and a field device configured to perform an operation that physically affects the object. The method comprises the following steps: receiving, by a receiver, inspection data associated with a scan of an object by an inspection device from a remote field system; processing, by one or more processors, the inspection data to generate data related to performing an operation that physically affects the object; and transmitting, by the transmitter, the operation-related data to the remote field system to cause the remote field system to perform an operation that physically affects the object, wherein the operation is performed based on the operation-related data.
One aspect of the present patent application provides a computer system for facilitating field testing and physical operations based thereon at a field system. The field system includes: an inspection device configured to scan an object; and one or more field devices configured to perform one or more operations that physically affect the object. The computer system includes a receiver configured to receive inspection data associated with a scan of an object by an inspection device from a field system. The scanning of the object by the inspection device is subsequent to performing one or more operations that physically affect the object by one or more field devices. The one or more operations are performed using a first set of input parameters. The computer system also includes one or more processors configured to: detecting a defect associated with the object based on the inspection data; generating an operation protocol associated with at least one operation type of the one or more operations in response to the defect detection, wherein the operation protocol includes a second set of input parameters having at least one input parameter different from the first set of input parameters; selecting an operation protocol for performing a subsequent operation similar to at least one of the one or more operations; and generating data related to performing a subsequent operation based on the at least one input parameter of the operating protocol. The computer system also includes a transmitter configured to transmit the operation-related data to one or more field systems to cause the one or more field systems to perform a subsequent operation. The subsequent operation is performed based on the operation-related data.
One aspect of the present patent application provides a method for facilitating field testing and physical operations based thereon at a field system. The field system includes: an inspection device configured to scan an object; and one or more field devices configured to perform one or more operations that physically affect the object. The method includes receiving, by a receiver, inspection data associated with a scan of an object by an inspection device from a field system. The scanning of the object by the inspection device is subsequent to performing one or more operations that physically affect the object by one or more field devices. The one or more operations are performed using a first set of input parameters. The method further comprises the following steps: detecting, by one or more processors, a defect associated with the object based on the inspection data; generating, by one or more processors, an operation protocol associated with at least one operation type of the one or more operations in response to the defect detection, wherein the operation protocol includes a second set of input parameters having at least one input parameter different from the first set of input parameters; selecting, by one or more processors, an operating protocol for performing a subsequent operation similar to at least one of the one or more operations; generating, by the one or more processors, data related to performing the subsequent operation based on the at least one input parameter of the operating protocol; and transmitting, by the transmitter, the operation-related data to one or more field systems to cause the one or more field systems to perform a subsequent operation. The subsequent operation is performed based on the operation-related data.
One aspect of the present patent application provides a computer system for facilitating field testing and physical operations based thereon at a field system. The field system includes: an inspection device configured to scan an object; and one or more field devices configured to perform one or more operations that physically affect the object. The computer system includes a receiver configured to receive inspection data associated with a scan of an object from a field system. The scanning of the object is after performing one or more operations that physically affect the object. The one or more operations are performed using a first set of input parameters. The computer system also includes one or more processors configured to: determining, based on the inspection data, whether a quality of one or more aspects of the object resulting from the one or more operations exceeds a quality criterion indicated by a predefined quality profile; generating an operation protocol associated with at least one operation type of the one or more operations, wherein the operation protocol is generated to include one or more of the set of input parameters in response to a quality of one or more aspects of the object exceeding a quality criterion indicated by a predefined quality profile; selecting an operation protocol for performing a subsequent operation similar to at least one of the one or more operations; and generating data related to performing a subsequent operation based on the at least one input parameter of the operating protocol. The computer system also includes a transmitter configured to transmit the operation-related data to one or more field systems to cause the one or more field systems to perform a subsequent operation. The subsequent operation is performed based on the operation-related data.
One aspect of the present patent application provides a method for facilitating field testing and physical operations based thereon at a field system. The field system includes: an inspection device configured to scan an object; and one or more field devices configured to perform one or more operations that physically affect the object. The method includes receiving, by a receiver, inspection data associated with a scan of an object from a field system. The scanning of the object is after performing one or more operations that physically affect the object. The one or more operations are performed using a first set of input parameters. The method further comprises the following steps: determining, by the one or more processors, based on the inspection data, whether a quality of one or more aspects of the object resulting from the one or more operations exceeds a quality criterion indicated by the predefined quality profile; generating, by one or more processors, an operation protocol associated with at least one operation type of the one or more operations, wherein the operation protocol is generated to include one or more of the set of input parameters in response to a quality of one or more aspects of the object exceeding a quality criterion indicated by a predefined quality profile; selecting, by one or more processors, an operating protocol for performing a subsequent operation similar to at least one of the one or more operations; generating, by the one or more processors, data related to performing the subsequent operation based on the at least one input parameter of the operating protocol; and transmitting, by the one or more processors, the operation-related data to one or more field systems to cause the one or more field systems to perform a subsequent operation. The subsequent operation is performed based on the operation-related data.
One aspect of the present patent application provides a computer system for facilitating field testing and physical operations based thereon. The computer system includes one or more processors configured to: data relating to observations of one or more operations performed on a plurality of objects is obtained from one or more field systems. The plurality of objects includes: (i) one or more objects determined to have defects resulting from the one or more observed operations; and (ii) one or more objects free of said defects. The one or more processors are further configured to: comparing, based on the observation-related data, a first set of observations of operations performed on the object determined to have the defect with one or more other sets of observations of operations performed on one or more other objects that do not have the defect; based on the comparison, determining that the first set of observations has common differences with the one or more other sets of observations; and causing an operational trigger to be implemented based on the common difference such that when a condition corresponding to the common difference occurs in the course of a subsequent operation that physically affects one or more additional objects, the field system is caused to perform an operation associated with the operational trigger.
One aspect of the present patent application provides a method for facilitating field testing and physical operations based thereon. The method includes obtaining, by one or more processors, data from one or more field systems relating to observations of one or more operations performed on a plurality of objects. The plurality of objects includes: (i) one or more objects determined to have defects resulting from the one or more observed operations; and (ii) one or more objects free of said defects. The method further comprises the following steps: comparing, by the one or more processors, a first set of observations of operations performed on the objects determined to have defects with one or more other sets of observations of operations performed on one or more other objects that are not defective based on the observation-related data; determining, by the one or more processors, that the first set of observations has common differences from the other one or more sets of observations based on the comparison; and causing, by the one or more processors, an operation trigger to be implemented based on the common difference, such that when a condition corresponding to the common difference occurs in the course of a subsequent operation that physically affects one or more additional objects, causing the field system to perform an operation associated with the operation trigger.
One aspect of the present patent application provides a system for aligning and welding together two sections of a pipe. The system comprises: a welding mechanism for applying a weld to a face joint of two sections, the welding mechanism comprising a welding torch that articulates, a laser sensor for reading a profile of the face joint, and an electronic controller for receiving information signals from the laser sensor to control a position and/or orientation of the welding torch; an alignment mechanism for regulating the orientation of the longitudinal axis of at least one of the segments relative to the other; and wherein the welding mechanism further comprises: a bracket for fixing the position of the welding mechanism in the pipe; and a welding portion rotatable within the pipe relative to the support portion; and wherein the welding torch and the laser sensor are rotatably supported by the welding portion such that the welding torch follows the laser sensor along the face seam during welding.
One aspect of the present application provides a method of aligning and welding together two sections of a pipe. The method comprises the following steps: placing the first tube segment on an alignment device; inserting an internal welding machine having a laser and a welding torch into the first pipe segment; substantially aligning the second pipe segment with the first pipe segment and the internal welding machine; clamping exterior portions of the first and second pipe segments to adjust an axial position of the internal welding machine to substantially align with the face seams of the first and second pipe segments; adjusting, by an alignment device, a relative alignment of the first and second pipe segments based on a signal from the internal welder; starting a root welding cycle in which a laser scans a face seam, a welding torch follows the laser, and the position of the articulating welding torch is controlled using output from the laser, wherein the position and orientation of the welding torch relative to the face seam is controlled to produce a quality weld; determining a face seam profile from the laser; releasing the alignment device and removing the internal welding machine from the open pipe section end; and repositioning the next sequential tube segment on the external alignment mechanism in preparation for welding the next joint.
One aspect of the present patent application provides an Internal Heat Exchanger (IHEX) for pipeline welding. The internal heat exchanger includes: a drive system configured to move the IHEX into a position within at least one pipe section near a weld joint location with another pipe section; a cooling portion comprising a cooling structure configured to selectively cool one or more interior surface portions of at least one conduit portion; and a controller in communication with the cooling structure and configured to activate the cooling portion when the IHEX is at the location within the at least one conduit portion.
One aspect of the present patent application provides a system for welding. The system for welding includes: a plurality of welding stations, each welding station comprising a welding station computer and a welding system in communication with the welding station computer, each welding station comprising one or more sensors configured to measure welding data comprising lead speed data; a plurality of wireless devices in communication with one or more of the welding station computers to receive welding data including measured wire speed data; and a cloud server in communication with the wireless devices, the cloud server configured to process welding data including the lead speed data and configured to determine an amount of consumable welding material used by the plurality of welding stations over a given time period, wherein the cloud server is configured to communicate the amount of consumable welding material used to one or more of the wireless devices.
One aspect of the present patent application provides a system for welding. The system for welding includes: a welding station including a welding station computer and a welding system in communication with the welding station computer, the welding system including a supply of welding material, a welding device, and a welding supply motor assembly to move the welding material to the welding device; a weighing device operatively connected with the weld station computer and configured to measure a weight of the supply of weld material and to transmit the weight of the supply of weld material to the weld station computer in the form of weight data; and a sensor operatively connected with the weld supply motor assembly and the weld station computer for communicating the speed of the weld supply motor assembly in the form of speed data to the weld station computer; wherein the weld station computer is operatively connected to the weld supply motor assembly and configured to control a speed of the motor assembly based on the weight data.
One aspect of the present patent application provides a method of controlling welding. The method comprises the following steps: measuring a first weight of the supply of welding material using a weight measuring device at a first time; measuring a second weight of the supply of welding material using the weight measuring device at a second time after the first time; calculating, using a computer, a difference in measured weight between the first weight and the second weight, the difference in measured weight corresponding to the measured weld material used; calculating, using a computer, a theoretical weight of welding material used based on a speed at which the motor assembly feeds the welding material to the welding device; comparing, by the computer, the theoretical weight of the welding material used with the measured weight of the welding material used; and adjusting, by the computer, the speed of the motor assembly so as to correct slippage of the motor assembly.
One aspect of the present patent application provides a system for welding. The system for welding includes: a plurality of welding stations, each welding station comprising a welding station computer and a welding system in communication with the welding station computer, each welding station comprising one or more sensors configured to measure welding data comprising lead speed data; a plurality of wireless devices in communication with one or more of the welding station computers to receive welding data including measured wire speed data; and each welding station computer is configured to process welding data including the lead speed data for the welding system with which it is in communication, the welding station computer configured to determine an amount of consumable welding material used by the welding system over a given period of time and generate consumption data based thereon.
One aspect of the present patent application provides a system for pipeline testing. The system includes a testing device adapted to generate non-invasive test data relating to at least a portion of a weld; the testing device communicating the non-invasive test data to a second device adapted to receive the non-invasive test data; and the testing device is adapted to operate remotely from the device analyzing the non-invasive test data.
One aspect of the present patent application provides a system for non-invasive pipeline testing. The system comprises: an imaging device adapted to generate non-invasive test data relating to a portion of a welded conduit; a remote processing device adapted to receive and process inspection data regarding the portion of the welded pipe.
One aspect of the present patent application provides a method of non-invasive line testing. The method comprises the following steps: providing an imaging device; generating non-invasive test data; providing means for providing the non-invasive test data for analysis; and providing the non-invasive test data for analysis at a location of the apparatus remote from and adjacent to the test portion of the conduit.
One aspect of the present patent application provides a system for pipeline construction. The system includes a system for recording welding data in real time; and the welding data is provided for analysis by computerized means and/or by subject matter experts.
One aspect of the present patent application provides a computer program product for welding support. The computer program product comprises: computer readable program code means providing welding data to a computer memory; computer readable program code means for providing data from a data set comprising pipeline data to the memory; computer readable program code means that processes the welding data and the pipeline data to provide a recorded output.
One aspect of the present patent application provides a method of data management performed on a computer. The method comprises the following steps: transferring first data from a first device to a second device, the first data being data relating to a pipeline configuration; processing, by a cloud-based network device, the first data.
One aspect of the present patent application provides a computer system. The system includes a first device having a processor that processes pipeline configuration data, the first device transferring the pipeline configuration data to a cloud-based memory, the pipeline configuration data being processed by the cloud-based processor.
These and other aspects of the present patent application, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. In one embodiment of the present patent application, the structural components shown herein are drawn to scale. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the present patent application. It is also understood that features of one embodiment disclosed herein may be used in other embodiments disclosed herein. As used in the specification and in the claims, the singular forms "a", "an" and "the" include plural referents unless the context clearly dictates 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 understood that some of the components and features discussed herein may be discussed in connection with only one (singular) of such components, and additional similar components that may be disclosed herein may not be discussed in detail for the sake of reducing verbosity. For example only, where a single welding torch head is described, the same configuration may be used in additional welding torch heads provided in the same system (e.g., in an internal welding system), and may also be used in other welding systems described herein (such as a joint internal welder). Similarly, various components (such as clamps, seals, brakes, weld consumption detection systems, or other components described herein) may be used with the various embodiments described herein. For example, a braking system, motor, clamp, seal as described in one embodiment may be applied to other embodiments described herein, as will be appreciated by those skilled in the art.
Brief Description of Drawings
FIGS. 1A and 1B show block diagrams of a method for welding pipe segments according to an embodiment of the present patent application, where FIG. 1A shows a high level block diagram of the method and FIG. 1B shows a more detailed block diagram of the method;
FIG. 2 illustrates a cross-sectional view of a weld joint connecting a first pipe and a second pipe according to an embodiment of the present patent application;
FIGS. 2A and 2B show bevel details of a single pipe section and a seam (before welding) between two pipe sections according to embodiments of the present patent application;
2C-2F illustrate front, perspective, side, and detailed views of a bevel gauge for gauging the bevel of a pipe according to an embodiment of the present patent application;
2G-2I show cross-sectional views of a pipeline having a weld joint formed between its pipes according to an embodiment of the present patent application, where FIG. 2G shows a weld joint with a root pass weld layer and a hot pass weld layer formed by an internal welding system and a fill pass weld layer and a facing pass weld layer formed by an external welding system, FIG. 2H shows a weld joint with a root pass weld layer formed by an internal welding system and a hot pass weld layer, a fill pass weld layer and a facing pass weld layer formed by an external welding system, and FIG. 2I shows a weld joint formed by an external welding system;
3-7 illustrate block diagrams of methods for welding pipe segments for different welding situations according to embodiments of the present patent application;
figures 7A and 7B show views of an external clamp for clamping pipes together from the outside according to an embodiment of the present patent application;
FIG. 8 shows a perspective view of a system for welding two pipe segments according to an embodiment of the present patent application;
FIG. 9 shows an enlarged view of a pipe joint of two pipe segments to be welded using the system of FIG. 8, according to an embodiment of the present patent application;
FIG. 9A shows a partial cross-sectional view of a pipeline with a welding torch ideally aligned with an internal bevel (along the longitudinal axis of the pipe) according to an embodiment of the present patent application;
FIG. 10-1 shows the system of FIG. 8 with an internal welding system inserted into a first pipe segment according to an embodiment of the present patent application;
10-2 and 10-3 illustrate the system of FIG. 8 with an internal welding system inserted into a first pipe segment and a second pipe segment aligned with the first pipe segment according to an embodiment of the present patent application;
10A and 10B show views of an internal welding system constructed and arranged to be positioned in a pipe having an outer diameter of 26 to 28 inches and a pipe having an outer diameter of less than 24 inches, respectively, according to embodiments of the present patent application;
Figures 10C and 10D show left and bottom perspective views of a rack for carrying and moving a first and second conduit according to an embodiment of the present patent application;
10E and 10F illustrate two types of duct alignment errors, with FIG. 10E illustrating an angular duct alignment error and FIG. 10F illustrating a positional duct alignment error;
FIG. 11 illustrates an internal welding system for welding two pipe segments according to an embodiment of the present patent application;
fig. 11A illustrates a view of an umbilical cable operatively connected to an internal welding system according to an embodiment of the present patent application;
FIG. 12 shows a detailed view of a forward-most portion of an internal welding system, according to an embodiment of the present patent application;
13-22 illustrate views of various components of a forward-most portion of an internal welding system, according to embodiments of the present patent application;
fig. 22A shows an exemplary wire spool according to an embodiment of the present patent application;
fig. 22B illustrates an exemplary welding feed assembly according to an embodiment of the present patent application;
fig. 23 and 24 show front and cross-sectional views of a central portion of an internal welding system according to an embodiment of the present patent application;
25-31 illustrate views of various components of a central portion of an internal welding system according to embodiments of the present patent application;
FIGS. 32A and 32B illustrate side and top views of a drive portion of an internal welding system according to an embodiment of the present patent application;
FIG. 33 shows a view of a central portion of an internal welding system positioned inside a pipe segment, where both a clamp and a seal engage an inner surface of a pipe, and where some components of the central portion are not shown for clarity, according to an embodiment of the present patent application;
FIG. 34 shows a cross-sectional view of a central portion of an internal welding system positioned inside a pipe segment, where some components of the central portion are not shown for clarity, according to an embodiment of the present patent application;
FIG. 35 shows a view of a central portion of an internal welding system positioned inside a pipe segment, where only clamps engage an inner surface of the pipe, and where some components of the central portion are not shown for clarity, according to an embodiment of the present patent application;
fig. 35A and 35B show cross-sectional views of a central portion of an internal welding system with the clamp in its extended and retracted positions, respectively, and with some components of the central portion not shown for clarity, according to embodiments of the present patent application;
FIG. 35C shows a side (front) view of an internal welding system according to an embodiment of the present patent application;
FIG. 36 illustrates a view of a clamp brake hoop of an internal welding system according to an embodiment of the present patent application;
FIG. 37 illustrates a view of a spider member of a clamp of an internal welding system according to an embodiment of the present patent application;
FIG. 38 illustrates a view of a clamp brake hoop pin member of an internal welding system according to an embodiment of the present patent application;
FIGS. 39 and 40 show views of a hub of a clamp of an internal welding system to which a clamp brake hoop pin member and a link member are connected, according to an embodiment of the present patent application;
fig. 41 and 42 show front and rear perspective views of a weld head assembly of an internal welding system according to an embodiment of the present patent application;
fig. 43 illustrates another rear perspective view of a welding head assembly of the internal welding system in which a welding torch of the welding head assembly is raised to a desired welding position, according to an embodiment of the present patent application;
44-46 illustrate left side perspective, and cross-sectional views of a welding head assembly according to an embodiment of the present patent application, wherein some components of the welding head assembly are not shown for clarity;
fig. 47, 48, and 49 show perspective views of a welding head assembly according to an embodiment of the present patent application, with the welding torch positioned in its centered axial position in fig. 47 by an axial positioning system, and the welding torch positioned in right and left axial positions in fig. 48 and 49, respectively, by an axial positioning system;
Fig. 50 and 51 show left side perspective and exploded views of a welding head assembly according to an embodiment of the present patent application, with some components of the welding head assembly not shown for clarity;
fig. 52 illustrates a bottom perspective view of a top positioning member of a welding head assembly according to an embodiment of the present patent application;
fig. 53 illustrates a top elevation view of a welding head assembly according to an embodiment of the present patent application, wherein some components of the welding head assembly are not shown for clarity;
fig. 54 shows a cross-sectional view of a welding head assembly according to an embodiment of the present patent application, with the welding torch positioned in a normal, non-tilted position;
fig. 55 and 56 show a rear perspective view and a cross-sectional view, respectively, of a welding head assembly according to an embodiment of the present patent application, wherein the welding torch is positioned to be tilted to an angle of +5 ° by a tilt positioning system;
fig. 56A shows a cross-sectional view of a welding head assembly according to an embodiment of the present patent application;
fig. 57 and 58 show a rear perspective view and a cross-sectional view, respectively, of a welding head assembly according to an embodiment of the present patent application, wherein the welding torch is positioned to be tilted to an angle of-5 ° by a tilt positioning system;
fig. 59 shows an exploded view of a welding head assembly according to an embodiment of the present patent application, wherein some components of the welding head assembly are not shown for clarity;
FIGS. 60A-63 illustrate schematic views of an internal welding system having one welding torch, an inspection camera, and two inspection detectors, according to embodiments of the present patent application;
64-69 illustrate schematic views of an internal welding system having two welding torches, an inspection camera, and an inspection detector, according to an embodiment of the present patent application;
FIG. 70 illustrates a schematic diagram showing compressed air flowing through an internal welding system, according to an embodiment of the present patent application;
FIG. 71 illustrates a schematic diagram of a flow-through internal welding system displaying power (including welding power), communication data, and control data, according to an embodiment of the present patent application;
FIG. 72 shows a schematic diagram showing shielding gas flow through an internal welding system, according to an embodiment of the present patent application;
72A, 72B, and 72C show close-up views of an internal welding torch used in a prior art system and the internal welding system, respectively, with the tubes having a clearance and radial offset (Hi-Lo) alignment;
FIG. 72D illustrates exemplary welding parameters for an uphill and downhill welding procedure, according to an embodiment of the present patent application;
FIG. 73 shows a perspective view of a system for welding two outer alignment tube segments supported on an alignment mechanism according to an embodiment of the present patent application;
FIG. 74 shows an enlarged exterior view of a pipe joint of two pipe segments to be welded using the system of FIG. 73 according to an embodiment of the present patent application;
FIG. 75 illustrates a system of inserting a welding system into pipe segments, where one of the pipe segments is not shown for clarity, according to an embodiment of the present patent application;
fig. 76 shows an enlarged view of the portion of fig. 75 showing the welding portion of the welding system positioned for welding in a pipe segment, where one of the pipe segments is not shown for clarity, according to an embodiment of the present patent application.
FIG. 77 illustrates a cross-sectional view of FIG. 76 taken along axis B-B showing the arrangement of various weld section elements, according to an embodiment of the present patent application;
FIGS. 78 and 79 illustrate side views of the welding system of FIG. 75 with a pipe segment not shown for clarity, according to an embodiment of the present patent application;
fig. 80 illustrates a perspective view of the system of fig. 73 in a configuration illustrating a first procedure in which a tube segment is placed on an external alignment mechanism, according to an embodiment of the present patent application;
FIG. 81 illustrates a perspective view of the system of FIG. 73 in a configuration illustrating a process subsequent to that of FIG. 80 in which the welding system is inserted into a pipe segment, according to an embodiment of the present patent application;
FIG. 82 illustrates a side view of a welding portion of the system of FIG. 73 according to an embodiment of the present patent application;
FIG. 83 illustrates an enlarged perspective view of a portion of the welding portion of the system of FIG. 73 according to an embodiment of the present patent application;
FIG. 84 illustrates another enlarged perspective view of a portion of the welding portion of the system of FIG. 73 according to an embodiment of the present patent application;
figure 85 shows an enlarged perspective view of a rotation mechanism of the system of figure 73 according to an embodiment of the present patent application;
FIG. 86 illustrates a purge and verification system according to an embodiment of the present patent application;
FIG. 87 shows a detailed view of the forwardmost portion of the purging and inspection system according to an embodiment of the present patent application;
FIG. 88 illustrates a purge assembly of a purge and verification system according to an embodiment of the present patent application;
FIGS. 89 and 90 show front and cross-sectional views of a central portion of a purge and verification system according to an embodiment of the present patent application;
FIG. 91 illustrates a purge seal of a purge and verification system according to an embodiment of the present patent application;
FIG. 92 illustrates a rotatable hub of a purge and verification system according to an embodiment of the present patent application;
FIG. 93 illustrates a detailed view of a drive portion of a purge and verification system according to an embodiment of the present patent application;
FIG. 94 shows a schematic diagram showing the flow of purge gas through the purge and verification system, according to an embodiment of the present patent application;
FIG. 95 shows a schematic diagram showing the flow of compressed air through a purge and verification system, according to an embodiment of the present patent application;
FIG. 96 shows a schematic diagram showing the flow of purge gas through a purge and verification system according to another embodiment of the present patent application;
FIG. 97 illustrates a partial view of a purge and verification system according to an embodiment of the present patent application;
FIG. 98 illustrates a close-up view of an external welding torch of an external welding system used in a purge and verification system according to an embodiment of the present patent application;
FIGS. 99 and 100 show close-up views of the external welding torch of the external welding system used in the prior art system and the purge and verification system, respectively, with the conduit having a clearance and a radially offset (staggered) alignment;
FIG. 101 illustrates a joint internal welding system according to an embodiment of the present patent application;
FIG. 102 illustrates a detailed view of the power portion of the joint internal welding system according to an embodiment of the present patent application;
FIG. 103 shows a schematic diagram of a welding system within a joint displaying power (including welding power), communication data, and control data flow, according to an embodiment of the present patent application;
Fig. 103A shows a cross-sectional view of a central portion of a joint internal welding system according to an embodiment of the present patent application with the clamp in its retracted position, and with some components of the central portion not shown for clarity;
FIG. 103B illustrates a method for aligning two pipes, pre-verifying a joint area between two pipes to be end-to-end welded, welding the two pipes, post-welding verifying a weld joint formed between the two pipes, according to an embodiment of the present patent application;
FIG. 103C shows a side view of a joint internal welding system according to another embodiment of the present patent application;
FIG. 103D shows a perspective view of a joint internal welding system according to another embodiment of the present patent application;
fig. 103E shows a perspective view of a welding head assembly of the joint internal welding system according to another embodiment of the present patent application;
fig. 103F illustrates a front view of a welding head assembly of a joint internal welding system according to another embodiment of the present patent application;
103G-103J illustrate a process in which one or more welding head assemblies according to another embodiment of the present patent application operate in a clockwise and counterclockwise direction to perform a welding operation in an intra-joint welding system;
FIG. 104 shows a perspective view of an exemplary internal cooling system for pipeline welding according to an embodiment of the present patent application;
FIG. 105 shows a perspective view of the internal cooling system of FIG. 104 about to be inserted within an end of a pipe section, according to an embodiment of the present patent application;
FIG. 106 shows a perspective view of the internal cooling system of FIG. 104 positioned within a first pipe section secured to a second pipe section by a weld joint according to an embodiment of the present patent application;
FIG. 107 shows another view of FIG. 106 with an internal cooling system located within the first and second pipe segments in position relative to the weld joint to facilitate internal cooling at the weld joint according to an embodiment of the present patent application;
fig. 108 shows a perspective view of the internal cooling system of fig. 104 connected with a joint clamp according to an embodiment of the present patent application;
fig. 109 shows a perspective view of the internal cooling system of fig. 104 connected with a joint clamp according to another embodiment of the present patent application;
FIGS. 110A and 110B show perspective and partial perspective views, respectively, of an internal cooling system for pipeline welding according to another embodiment of the present patent application;
111A and 111B show partial perspective views of portions of an internal cooling system for pipeline welding according to another embodiment of the present patent application, wherein portions of the internal heat exchanger are within two pipe sections secured to each other by a weld seam, and a water pump is provided at an end of a portion of the pipe section;
112A and 112B show partial perspective views of portions of an internal cooling system for pipeline welding according to another embodiment of the present patent application, wherein portions of the internal heat exchanger are within two pipe segments secured to each other by a weld joint, and a water pump is provided at an end of a portion of the pipe section;
figure 113 shows a cross-sectional view of a pipe according to an embodiment of the present patent application with exposed metal pipe ends of the pipe aligned;
FIG. 114 shows a cross-sectional view of a pipe with a weld joint formed between exposed metal pipe ends of the pipe according to an embodiment of the present patent application;
115A and 115B illustrate a cross-sectional view and a perspective view, respectively, of a duct with a weld joint formed between exposed metal duct ends of the duct and a heater positioned on the duct to heat the exposed end portions of the welded duct, according to an embodiment of the present patent application;
116A and 116B show cross-sectional and perspective views, respectively, of a pipe with a weld joint formed between exposed metal pipe ends of the pipe and an insulator supply positioned on the pipe to apply an insulator material to a heated exposed end portion of the welded pipe, according to an embodiment of the present patent application;
fig. 117A and 117B show cross-sectional and perspective views of a pipe with a weld joint formed between exposed metal pipe ends of the pipe and an insulator supply positioned on the pipe to apply insulator material to a heated exposed end portion of the welded pipe, according to an embodiment of the present patent application;
FIG. 118 shows a cross-sectional view of a pipe with a weld joint formed between exposed metal pipe ends of the pipe and an insulator bonded to the exterior surface of the interior of the metal pipe to insulate previously exposed end portions of the pipe, according to an embodiment of the present patent application;
FIG. 119 shows a perspective view of a chiller system configured to apply cooling energy to an interior surface of a pipe to facilitate cooling of the pipe after application of an insulator material according to an embodiment of the present patent application;
FIG. 120 illustrates a partial cross-sectional view of a chiller system positioned within a duct according to an embodiment of the present patent application;
fig. 121 and 122 show partial cross-sectional views of a chiller system positioned within a pipe according to an embodiment of the present patent application, where fig. 121 shows a heat exchanger of the chiller system positioned in contact with an interior surface of the welded pipe to remove heat from the welded pipe, and fig. 122 shows the heat exchanger in its retracted position and not in contact with the interior surface of the welded pipe;
FIG. 123 shows a perspective view of a cooler system according to another embodiment of the present patent application, showing a fluid nozzle configured to apply a cooling liquid to an interior surface of a welded pipe to remove heat from the welded pipe;
fig. 124 and 125 show perspective and front views of a heat exchanger element or fin member of a chiller system according to another embodiment of the present patent application;
126-128 illustrate perspective views of systems configured to facilitate placement of a cooler system within a duct and/or removal of the cooler system from the duct, according to another embodiment of the present patent application;
figure 129 illustrates a partial perspective view of a chiller system according to another embodiment of the present patent application showing a plurality of rollers configured to engage an interior surface of one or more of the tubes and a drive motor configured to drive the rollers to move the frame assembly of the chiller assembly;
FIG. 130 shows a perspective view of a chiller system according to another embodiment of the present patent application;
figure 131 shows a top view of a motor power supply carried by a frame assembly of a chiller system according to another embodiment of the present patent application;
FIG. 132 illustrates a heat exchanger of a chiller system according to another embodiment of the present patent application positioned in contact with an interior surface of a welded tube to remove heat from the welded tube;
fig. 133 and 134 show perspective views of a chiller system according to another embodiment of the present patent application;
fig. 135 and 136 show perspective and partial cut-away views of a chiller system according to another embodiment of the present patent application;
FIG. 136A shows a perspective view of an ultrasonic inspection station configured to inspect welds between welded metal pipes according to an embodiment of the present patent application;
FIG. 136B illustrates a method showing a pipeline deployment procedure, according to an embodiment of the present patent application;
fig. 136C and 136D show schematic diagrams of an S-lay and a J-lay procedure according to embodiments of the present patent application;
fig. 136E shows an S-lay and J-lay unwind barge according to embodiments of the present patent application;
FIG. 137A illustrates a system for facilitating field system testing or operation thereof according to another embodiment of the present patent application;
FIG. 137B illustrates a communication link between a remote computer system, a field computer system of a field system, and other components of the field system according to another embodiment of the present patent application;
FIG. 137C illustrates a communication link between a remote computer system and a component of a field system without the field computer system according to another embodiment of the present patent application;
FIG. 138 illustrates a flow diagram of a method for facilitating field testing and physical operations based thereon by a field system in accordance with another embodiment of the present patent application;
FIG. 139-142 illustrates a flow diagram of a method for facilitating field testing and physical operations based thereon by a computer system in accordance with other embodiments of the present patent application;
FIG. 143 depicts an example of a pipeline according to another embodiment of the present patent application;
FIG. 144 shows a weld station according to another embodiment of the present patent application;
FIG. 145 shows a plurality of pipeline welding stations according to another embodiment of the present patent application;
FIG. 146 is a schematic view of a system having multiple welding stations in communication with multiple control and log collection stations according to another embodiment of the present patent application;
FIG. 147 is a schematic view of a system having multiple welding stations in communication with multiple control and log collection stations according to another embodiment of the present patent application;
FIG. 148 is a schematic view of a welding station communicating with a network via a WiFi connection according to another embodiment of the present patent application;
FIG. 149 is a schematic diagram of a plurality of job sites communicating with a cloud server over a global network (Internet) according to another embodiment of the present patent application;
FIG. 150 is a schematic view of a plurality of welding stations in communication with an intermediate computing device (guide technician, inspector, engineer, etc.) that in turn communicates with a cloud server over the Internet, according to another embodiment of the present patent application;
FIG. 151 is a schematic diagram of a plurality of welding stations communicating with an intermediate computer system (engineer, quality and technology terminal) over a wireless (e.g., WiFi) communication channel in accordance with another embodiment of the present patent application;
FIG. 152 is a schematic diagram of a plurality of welding stations communicating with a computer system via a wireless (e.g., WiFi) communication channel in accordance with another embodiment of the present patent application;
FIG. 153 is a schematic view of a plurality of welding stations in communication with a plurality of intermediate computer systems (engineers, quality and technology terminals) which in turn are in communication with a cloud server, according to another embodiment of the present patent application;
FIG. 154 illustrates an exemplary graphical user interface ("GUI") of a "home screen" of a cloud-based universal data logging (uLog) application implemented by a computer system at a welding station, at an intermediate computer system, or at a cloud server according to another embodiment of the present patent application;
FIG. 155 illustrates an exemplary GUI showing a "field Log" screen of an application of a cloud-based Universal data record (uLog) of voltage versus time at one welding station according to another embodiment of the present patent application;
fig. 156 illustrates an exemplary GUI of a "get log" screen displaying an application of a cloud-based universal data log (uLog) including weld event type, time, area, weld travel speed, wire travel speed weld data parameters according to another embodiment of the present patent application;
fig. 157 illustrates an exemplary GUI of a summary report screen displaying an application of a cloud-based universal data record (uLog) including various welding parameters of welding time, welding station identification number, welding arc voltage, etc., according to another embodiment of the present patent application;
FIG. 158 illustrates an exemplary GUI of a "save data on Log" screen displaying various cloud-based universal data logging (uLog) applications according to another embodiment of the present patent application;
Fig. 159 shows an exemplary GUI of an "analytics" screen displaying an application of a cloud-based universal data record (uLog) for selecting two icons of the type of analysis performed (e.g., trend, moving average), according to another embodiment of the present patent application;
FIG. 160 illustrates an exemplary GUI displaying a "welding parameters" screen for selecting an application of two varying cloud-based universal data records (uLog) of types of functions to be performed according to another embodiment of the present patent application;
fig. 161A schematically depicts an example of a wire spool configured to carry wire in accordance with another embodiment of the present patent application;
figure 161B schematically depicts a side view of a hub transducer configured to measure the weight of a spool according to another embodiment of the present patent application;
fig. 161C depicts another side view of the hub transducer showing the positioning of the transducer element or strain sensor/strain gauge for measuring weight strain when the spool is mounted to the hub according to another embodiment of the present patent application;
fig. 162 schematically depicts an arrangement in which a weld line mounted into a wire spool of a hub is pulled by a motor assembly for feeding line 82 to a welding device (not shown), according to another embodiment of the present patent application;
FIG. 163 is a flow chart depicting a process of comparing a measured weight to a theoretical weight determined based on a line feed speed, in accordance with another embodiment of the present patent application;
fig. 164A and 164B depict enlarged side cross-sectional views of a motor assembly according to another embodiment of the present patent application;
FIG. 165 is a diagram of a configuration of a welding system depicting the interconnection of various components of the system, according to another embodiment of the present patent application;
figure 166 shows a non-invasive testing system overview according to another embodiment of the present patent application;
fig. 167 illustrates a general embodiment of a non-invasive testing system according to another embodiment of the present patent application;
figure 168 shows an ultrasonic testing embodiment of a non-invasive testing system according to another embodiment of the present patent application; and
figure 169 illustrates a radiographic testing embodiment of a non-invasive testing system according to another embodiment of the present patent application.
Detailed Description
Fig. 1A and 1B illustrate a block diagram of a method 1000 for welding together pipe sections or pipe segments 1022 (e.g., 1022a and 1022B as shown in fig. 2) of a pipeline 1024 (as shown in fig. 2). For example, FIG. 1A shows a high-level block diagram of method 1000, while FIG. 1B shows a more detailed block diagram of method 1000.
Fig. 2 shows a cross-sectional view of a weld joint 1026 connecting pipe segments 1022 (e.g., 1022a and 1022b) of pipeline 1024. The pipe segments 1022 (e.g., 1022a and 1022b) may be referred to herein interchangeably as pipes or pipe portions. In one embodiment, the weld seam 1026 is a complete circumferential weld that circumferentially connects the pipe segments 1022 (e.g., 1022a and 1022b) end-to-end. In one embodiment, the weld seam 1026 may be referred to as an annular weld or a butt weld. In one embodiment, tube segments 1022a and 1022b are welded together at beveled end portions thereof, as described in detail below.
In one embodiment, the first and second tube segments 1022a, 1022b have a length of at least 30 feet. In one embodiment, the first and second tube segments 1022a, 1022b have a length of at least 31.5 feet. In one embodiment, the first and second tube segments 1022a, 1022b have a length of at least 33 feet. In one embodiment, the first and second tube segments 1022a, 1022b have a length of at least 34.5 feet. In one embodiment, the first and second tube segments 1022a, 1022b have a length of at least 36 feet.
In one embodiment, the first and second tube segments 1022a and 1022b have an outer diameter of 24 inches or less. In one embodiment, the outer diameter of a pipe segment may also be referred to as the outer diameter of the pipe segment.
In one embodiment, the first and second tube segments 1022a, 1022b have a nominal outer diameter of 24 inches or less. In one embodiment, the first and second tube segments 1022a and 1022b each have an outer diameter of 24.1875 inches or less. In one embodiment, the first and second tube segments 1022a and 1022b each have an outer diameter of 23.8125 inches or less.
In one embodiment, the first and second tube segments 1022a, 1022b have an outer diameter of 22.8 inches or less. In one embodiment, the first and second tube segments 1022a and 1022b have an outer diameter of 21.6 inches or less. In one embodiment, the first and second tube segments 1022a and 1022b each have an outer diameter of 20.4 inches or less. In one embodiment, the first and second tube segments 1022a and 1022b each have an outer diameter of 19.2 inches or less.
In one embodiment, the first and second tube segments 1022a and 1022b each have an outer diameter in the range of 26 to 28 inches.
In one embodiment, the first and second tube segments 1022a and 1022b are made of a metallic material. In one embodiment, the first and second tube segments 1022a, 1022b are made of a carbon steel material. In one embodiment, the first and second tube segments 1022a and 1022b are made of a steel alloy material. In one embodiment, the first and second tube segments 1022a and 1022b are made of a low alloy steel material. In one embodiment, the first and second tube segments 1022a and 1022b are made from a stainless steel material. In one embodiment, the first and second tube segments 1022a, 1022b can be made from american petroleum institute specification (API)5L grade X52 (i.e., 52000PSI minimum yield strength and 66000PSI minimum tensile strength) materials. In one embodiment, the first and second tube segments 1022a, 1022b can be made from API 5L grade X60 (i.e., 60000PSI minimum yield strength and 75000PSI minimum tensile strength) materials.
In one embodiment, first tube segment 1022a and second tube segment 1022b may be made, in whole or in part, of a Corrosion Resistant Alloy (CRA). In one embodiment, the corrosion-resistant alloy may include both iron-based alloys (such as various grades of stainless steel) or nickel-based alloys (i.e., commonly known under the trade name Inconel (Inconel))
In one embodiment, some CRA materials may require protective gas on both sides of the weld. In one embodiment, in this case, a purge and verification system 7001 (as will be described in detail with reference to fig. 86-100) may be used within the conduits 1022a, 1022b to provide a purge gas chamber inside the conduits to be welded (at the joint area of the conduits), and an external welding system 7500 (as shown in fig. 97) may be used outside the conduits 1022a, 1022 b. In one embodiment, external welding system 7500 can be configured to provide shielding gas outside of the pipe to be welded (e.g., at the joint of the pipe).
In one embodiment, the first and second tube segments 1022a and 1022b can be made of the same material. In one embodiment, the first and second tube segments 1022a and 1022b can be made of different materials.
In one embodiment, first and second pipe segments 1022a, 1022b can be made of a bimetallic material, wherein the inner portion of the pipe segments is a CRA material and the outer portion of the pipe segments can be carbon steel or a different CRA material than the inner portion.
In one embodiment, as shown in fig. 2G, the first and second pipe segments 1022a and 1022b include a metal pipe interior 5244 surrounded by an insulator/coating material 5246. In one embodiment, the end portions of the first and second pipe segments 1022a, 1022b to be welded have the insulator/coating material 5246 removed and the metal pipe interior 5244 exposed.
In one embodiment, when the first and second pipe sections 1022a, 1022b are used in a corrosive environment (e.g., sea/salt water/sea, chemicals, etc.), the first and second pipe sections 1022a, 1022b may be coated with a corrosion resistant material/coating on the exterior surfaces thereof. In one embodiment, the first and second tube segments 1022a and 1022b can be coated with a wear resistant material/coating on their exterior surfaces. In one embodiment, the first and second tube segments 1022a and 1022b can be coated with an insulator material/coating on their exterior surfaces. In one embodiment, the first and second tube segments 1022a and 1022b can be coated on their interior surfaces with a corrosion-resistant material/coating, a wear-resistant material/coating, an insulator coating/material, or a combination thereof. In one embodiment, the first and second tube segments 1022a and 1022b can be coated with a corrosion-resistant material/coating, a wear-resistant material/coating, an insulator coating/material, or a combination thereof, on both the interior and exterior surfaces thereof.
In one embodiment, as shown in fig. 2A and 2B, an end 1038a of the conduit 1022A is welded to a second end 1038B of the conduit 1022B. In one embodiment, the end 1038a of the conduit 1022a has an inner beveled surface 5228 and an outer beveled surface 5230. In one embodiment, the end 1038b of the conduit 1022b has an inner beveled surface 5232 and an outer beveled surface 5234. In one embodiment, as will be apparent from the following discussion, when the root passage weld layer is deposited from within the conduits 1022a, 1022b using the internal welding system 5004, the weld material of the root passage weld layer is disposed in the region IBR defined by the first interior slashface surface 5228 and the second interior slashface surface 5232.
In one embodiment, the exterior beveled surfaces 5230 and 5234 may each comprise a first exterior beveled surface 5230a and 5234a and a second beveled surface 5230b and 5234b, respectively. In one embodiment, the first exterior beveled surfaces 5230a and 5234a are at an angle EB relative to an axis N-N perpendicular to the longitudinal axis a-a of the tube segments 1022a, 1022b1And (5) chamfering. In one embodiment, angle EB1May be 5.
In one embodiment, second exterior beveled surfaces 5230b and 5234b are at an angle EB relative to axis N-N2And (5) chamfering. In thatIn one embodiment, angle EB2Greater than angle EB1. In one embodiment, angle EB2May be 45.
In one embodiment, the outer beveled surfaces 5230 and 5234 may each comprise a single beveled surface. In one embodiment, the exterior beveled surfaces 5230 and 5234 may each comprise a single continuous surface having a J-shaped configuration.
In one embodiment, the interior bevel surfaces 5228 and 5232 are chamfered at an angle IB relative to the axis N-N. In one embodiment, angle IB may be 37.5 °. In one embodiment, the inner ramp surfaces 5228 and 5232 can have a distance B measured along axis N-N from their respective inner tube faces 5130 and 5132. In one embodiment, the distance B measured along the axis N-N from its respective inner pipe face 5130 and 5132 is 0.05 inches.
In one embodiment, the exterior beveled surfaces 5230 and 5234 and the interior beveled surfaces 5228 and 5232 may be separated from one another by non-beveled surfaces. In one embodiment, the non-beveled surface may have a distance NB measured along axis N-N. In one embodiment, distance NB is 0.05 inches measured along axis N-N. In one embodiment, the non-beveled surfaces are optional, and the outer beveled surfaces 5230 and 5234 and their corresponding inner beveled surfaces 5228 and 5232 may be adjacent to (and in contact with) each other.
In one embodiment, the interior beveled surfaces 5228 and 5232 of the tube segments 1022a, 1022b can have the same bevel angle. In one embodiment, the exterior beveled surfaces 5230 and 5234 of the tube segments 1022a, 1022b can have the same bevel angle. In another embodiment, the bevel angle of the interior bevel surfaces 5228 and 5232 of the tube segments 1022a, 1022b can vary. In another embodiment, the angle of the outer beveled surfaces 5230 and 5234 of the tube segments 1022a, 1022b can vary.
In one embodiment, the dimension of the interior bevel surface B, the dimension of the non-bevel surface NB, and the bevel angles IB, EB1And EB2May vary and is dependent upon the thickness T of the tube segments 1022a, 1022 b.
In one embodiment, the end 1038a of the conduit 1022a and the end 1038b of the conduit 1022b are joined to have a weld groove 5236 formed therebetween. In one embodiment, weld groove 5236 can have a V-shaped cross-section. In one embodiment, the end 1038a of the conduit 1022a and the end 1038b of the conduit 1022b are constructed and arranged to have a J-shaped configuration such that the weld bevel formed by joining the end 1038a of the conduit 1022a and the end 1038b of the conduit 1022b together has a U-shaped configuration. In another embodiment, the shape of the weld groove is dependent on a welding parameter or condition.
Referring to fig. 2, in one embodiment, the welding material 1034 is configured to connect the first and second tube segments 1022a, 1022 b. In one embodiment, the welding material 1034 may include Inconel or Inconel alloy material. In one embodiment, the welding material 1034 may include a material having a higher strength than the material of the pipe. In one embodiment, the welding material 1034 may be a different material than the pipe material. For example, in one embodiment, the weld material may include inconel or inconel alloy material, and the material of the first and second tube segments 1022a, 1022b may include stainless steel material.
In one embodiment, the solder material 1034 and/or the solder joint 1026 include a plurality of via solder layers 1014, 1016, 1018, and 1020. For example, in one embodiment, the plurality of via weld layers 1014, 1016, 1018, and 1020 may include a root via weld layer 1014, a hot via weld layer 1016, one or more fill via weld layers 1018, and a cap via weld layer 1020, as will be explained in detail below. The channel-welded layer may be interchangeably referred to herein as a channel layer. In one embodiment, the weld channel (e.g., root channel, hot channel, fill channel, cap channel) may be a single advance of the welding tool or welding system along the weld joint 1026. In one embodiment, a weld bead or weld layer is formed as a result of each weld pass.
In one embodiment, referring to fig. 1A, 1B, and 2, a method 1000 for welding pipe sections or pipe segments 1022a and 1022B together generally includes a root pass welding process 1002, a hot pass welding process 1004, a fill and cap pass welding process 1006, a weld inspection process 1008, a heating process 1010, and a coating process 1012. In one embodiment, the fill and cap via welding process 1006 may include one or more of a fill via welding process 1006a and a cap via welding process 1006 b. In one embodiment, the method 1000 is generally a multi-pass welding or multi-layer welding process including, for example, a root-pass welding process 1002, a hot-pass welding process 1004, and a fill and cap welding process 1006.
In one embodiment, one or more of the weld lanes (e.g., root lanes, hot lanes, fill lanes, cap lanes) of the multi-lane welding or multi-layer welding method 1000 may be performed at different times by the same welding system or tool. In one embodiment, the welding passes may be performed sequentially by the same welding system or tool. For example, in one embodiment, the root pass welding process and the hot pass welding process may be performed sequentially from inside the pipe by an internal welding system 5004 (as will be described in detail below). In one embodiment, the fill and cap pass welding processes may be performed sequentially from outside the pipe by an external welding system 7500.
In one embodiment, internal welding system 5004 is generally configured to weld pipe segments 1022a and 1022b from inside pipeline 1024, and external welding system 7500 is generally configured to weld pipe segments 1022a and 1022b from outside pipeline 1024. In one embodiment, welding performed by internal welding system 5004 can result in a K-shaped bead or weld layer, and welding performed by external welding system 7500 can result in a J-shaped bead or weld layer.
In one embodiment, the hot pass welding process, the fill and cap pass welding process can be performed sequentially from outside the pipe by an external welding system 7500, while only the root pass welding process is performed from inside the pipe by an internal welding system 5004 (as will be described in detail below).
In one embodiment, one or more of the weld lanes (e.g., root lanes, hot lanes, fill lanes, cap lanes) of the multi-lane or multi-layer welding method 1000 may be performed by different welding systems or tools at the same or different times. In one embodiment, the welding passes may be performed sequentially by different welding systems or tools.
In one embodiment, each of the hot channel welding process, the fill and cap channel welding process may be performed from outside the pipe in its corresponding welding booth (weld shack). In one embodiment, the welding booth is a relatively small enclosure, for example, approximately 12 feet wide, 10 feet long, and 8 feet high, in which the external welding system is installed and carried from one weld joint to the next by a rear end trailer. The welding booth is typically a lightweight metal frame covered with thin metal sheets. The welding booth has a special bottom layer designed to pivot upward to allow the welding booth to be lowered onto the pipe, and then pivot downward to allow easy access to the pipe. In one embodiment, each of the one or more fill channel welding procedures may be performed in a different welding booth each having an external welding system.
In one embodiment, root channel welding process 1002 is the first welding process of multi-channel or multi-layer welding method 1000. In one embodiment, root pass welding process 1002 is performed by internal welding system 5004. In one embodiment, the root pass welding process 1002 may be performed by a joint internal welding system 3001 (as will be described in detail below) with on-board welding power.
In one embodiment, root pass welding procedure 1002 may take 1.03 minutes to perform using internal welding system 5004. In one embodiment, the cycle time for the root passage welding process is 4 minutes (this timing is counted from when the tie rod or umbilical 5034 is set to travel automatically). In one embodiment, the total cycle time of the three cycles of the root pass welding procedure (performed by internal welding system 5004) is 13.15 minutes (including 2.30 minutes for the wire spool/wire change procedure) and the average cycle time of the root pass welding procedure (performed by internal welding system 5004) is 4.42 minutes.
In one embodiment, root pass welding process 1002 may be performed by external welding system 7500. In one embodiment, the root pass welding procedure 1002 may be performed by an external welding system 7500 using a purge and verification system 7001. In one embodiment, the root pass welding process 1002 may be performed by an external welding system using a joint fixture. In one embodiment, the root pass welding process 1002 may be performed by an external welding system 7500 using internally disposed clamps 7050, 7052. In one embodiment, the internally disposed clamp may be a standard clamp or a purge clamp (e.g., purge and verification system 7001).
In one embodiment, root pass welding procedure 1002 forms root pass weld layer 1014. In one embodiment, as shown in fig. 1A and 1B, the root channel weld layer 1014 is a first weld bead or weld layer deposited in a multi-pass or multi-layer welding process 1000. In one embodiment, the root channel layer may also be referred to as a root seal bead or a root seal layer. In one embodiment, the root pass welding process 1002 is performed by Gas Metal Arc Welding (GMAW). In one embodiment, the root pass welding process 1002 is performed by Gas Tungsten Arc Welding (GTAW). In one embodiment, the root pass welding process 1002 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 understood by those skilled in the art.
In one embodiment, the hot channel welding process 1004 is a second welding process of the multi-channel or multi-layer welding method 1000. In one embodiment, the hot channel welding process 1004 is performed by an internal welding system 5004. In one embodiment, the hot channel welding process 1004 may be performed by a joint internal welding system 3001 with on-board welding power.
In another embodiment, the hot channel welding process 1004 is performed by an external welding system 7500. In one embodiment, the hot channel welding process 1004 is performed by an external welding system using an internally disposed fixture. In one embodiment, the internally disposed clamp may be a standard clamp or a purge and check clamp. In another embodiment, the hot channel welding process 1004 may be performed by a manual welder. In this embodiment, the pipe end is configured to include a 30 ° bevel angle.
In one embodiment, the hot channel welding process 1004 may take 1.06 minutes when performed using an external welding system (in a welding booth) and in a trench-side position. In one embodiment, the hot channel welding process 1004 may take 58 seconds when performed using an external welding system (in a welding booth) and in a work side position. In one embodiment, the cycle time for the hot aisle welding process is 2.38 minutes (this timing is calculated from the time the hot aisle welding booth is placed on the duct). In one embodiment, the total cycle time of the three cycles of the hot aisle welding process performed by the external welding system in the welding booth was 11.35 minutes, and the average cycle time of the hot aisle welding process performed by the external welding system in the welding booth was 3.45 minutes.
In one embodiment, the hot channel welding process 1004 forms a hot channel weld layer 1016. In one embodiment, as shown in fig. 2, the hot channel solder layer 1016 is a second bead or solder layer deposited in a multi-channel or multi-layer soldering process 1000. In one embodiment, the hot pass welding process 1004 immediately follows the root pass welding process 1002. In one embodiment, the hot pass welding process 1004 is performed by Gas Metal Arc Welding (GMAW). In one embodiment, the hot pass welding process 1004 is performed by Gas Tungsten Arc Welding (GTAW). In one embodiment, the hot channel welding process 1004 is performed by short-circuit gas metal arc welding (GMAW-S). In another embodiment, the hot channel welding process 1004 is performed by other welding processes as understood by those skilled in the art.
In one embodiment, one or more of fill channel welding process 1006a and cap welding process 1006b of fill and cap channel welding process 1006 are performed by external welding system 7500. In one embodiment, the fill and cap pass welding process 1006 may be performed at multiple stations. In another embodiment, the fill and cap pass welding process 1006 can be performed by a manual welder. In this embodiment, the pipe end is configured to include a 30 ° bevel angle.
In one embodiment, one or more fill channel welding processes 1006a are performed after the hot channel welding process 1004 (or after the hot channel welding process 1004). In one embodiment, one or more fill channel welding processes 1006a form a fill channel welded layer 1018. Fill channel weld layer 1018 is configured to fill the weld groove and is substantially flush with the surfaces of pipe segments 1022a and 1022b of pipeline 1024. In one embodiment, the number of fill channel welding processes 1006a in the multi-pass or multi-layer welding method 1000 may vary. In one embodiment, the number of fill channel welding processes 1006a in the multi-pass or multi-layer welding method 1000 may depend on the thickness of the pipe segments 1022a and 1022b of the pipeline 1024 being welded together.
In one embodiment, the fill channel welding process 1006a is performed by Gas Metal Arc Welding (GMAW). In one embodiment, the fill channel welding process 1006a is performed by Gas Tungsten Arc Welding (GTAW). In one embodiment, the fill channel welding process 1006a is performed by pulsed gas metal arc welding (GMAW-P). In another embodiment, the fill channel welding process 1006a is performed by other welding processes as understood by those skilled in the art.
In one embodiment, the facing channel welding process 1006b is the final or final welding process of the multi-channel or multi-layer welding method 1000. In one embodiment, the cap-channel welding process 1006b follows the fill-channel welding process 1006a (or is performed after the fill-channel welding process 1006 a). In one embodiment, as shown in fig. 2, the facing via welding layer 1020 is a bead or weld layer deposited after the fill via welding process 1006 a. In one embodiment, the cover lane welding process 1006b may also be referred to as a cover lane welding process. In one embodiment, the facing channel welding process 1006b forms a facing channel welded layer 1020. In one embodiment, as shown in fig. 2, the facing via weld layer 1020 is a final or final bead deposited in a multi-via or multi-layer welding process 1000. In one embodiment, facing channel weld layer 1020 is configured to be substantially higher than the surfaces of pipe segments 1022a and 1022b of pipeline 1024.
In one embodiment, the facing channel welding process 1006b is performed by Gas Metal Arc Welding (GMAW). In one embodiment, the facing pass welding process 1006b is performed by Gas Tungsten Arc Welding (GTAW). In one embodiment, the facing channel welding process 1006b is performed by pulsed gas metal arc welding (GMAW-P). In another embodiment, the facing channel welding process 1006b is performed by other welding processes as understood by those skilled in the art.
In one embodiment, root channel welding process 1002 may be the only channel welding process of multi-channel or multi-layer welding method 1000 performed by internal welding system 5004, while hot channel welding process 1004 and fill and cap channel welding process 1006 are both performed using external welding system 7500.
In another embodiment, both root pass welding process 1002 and hot pass welding process 1004 of multi-pass or multi-layer welding method 1000 are performed by internal welding system 5004 while fill and cap pass welding process 1006 is performed using external welding system 7500.
In yet another embodiment, the root pass welding process 1002, the hot pass welding process 1004, and the fill and cap pass welding process 1006 are performed using an external welding system 7500. In one embodiment, the purge and inspection fixture is used inside the conduits 1022a, 1022b while the external welding system 7500 performs the root pass welding process 1002, the hot pass welding process 1004, and the fill and cap pass welding process 1006.
Fig. 2G-2I show cross-sectional views of a pipeline 1024 with a welded joint 1026 formed therebetween.
Fig. 2G shows a cross-sectional view of a pipeline 1024 with a welded joint 1026 formed therebetween. For example, the weld joint 1026 of fig. 2G includes a root channel weld layer 1014 and a hot channel weld layer 1016 formed from inside the conduits 1022a, 1022b by an internal welding system 5004, while one or more fill channel weld layers 1018 and cap channel weld layers 1020 are formed from outside the conduits 1022a, 1022b by an external welding system 7500.
The individual weld channel layers (e.g., root channel weld layer 1014, hot channel weld layer 1016, fill channel weld layer 1018, and cap channel weld layer 1020) are also clearly visible in fig. 2. The interface 1032 between the weld material 1034 and the tube material 1036 is readily and clearly discernable in fig. 2. In one embodiment, the shape of the interface 1032 (as shown by line ABCDE) is unique to the pipeline 1024 being welded (e.g., root pass welding process 1002 and/or hot pass welding process 1004) from inside the pipeline 1024.
In one embodiment, when both root pass welding process 1002 and hot pass welding process 1004 of multi-pass or multi-layer welding method 1000 are performed from inside pipeline 1024 by internal welding system 5004, the locations of root pass welding layer 1014 and hot pass welding layer 1016 will be swapped (e.g., when compared to a weld joint where the root pass welding process is performed from inside pipeline 1024 by internal welding system 5004 and hot pass welding process 1004 is performed from outside pipeline 1024 by an external welding system). In one embodiment, as shown in fig. 2 and 2G, the hot channel weld layer 1016 is positioned closer to the inner longitudinal axis a-a of the welded first and second conduits 1022a, 1022b than the root channel weld layer 1014.
In one embodiment, at least a portion 5238 of the hot channel weld layer 1016 of weld material 1034 is disposed closer to the longitudinal axis a-a than the interior faces 5130, 5132 of weld conduits 1022a and 1022b, the at least a portion 5238 being in regions 5240 and 5242 of weld conduits 1022a and 1022b that are immediately adjacent to weld material 1034 on opposite sides of weld material 1034. In one embodiment, as shown in fig. 2 and 2G, when the root pass welding process 1002 and the hot pass welding process 1004 of the multi-pass or multi-layer welding method 1000 are performed from inside the pipeline 1024 by the internal welding system 5004, the necked down region 1028 of the weld joint 1026 further emerges from the inner walls 5130, 5132 of the pipeline 1024.
In one embodiment, the root channel weld layer 1014 is disposed in the interior chamfer surfaces 5228, 5232 of the first and second conduits 1022a, 1022b, and the hot channel weld layer 1016 is disposed on top of the root channel weld layer 1014 (i.e., closer to the interior longitudinal axis a-a). In one embodiment, the internal welding system 5004 is constructed and arranged to perform more than one welding pass from inside the pipeline 1024. In one embodiment, inner welding system 5004 is constructed and arranged to be actuated in a radial direction such that inner welding system 5004 can adjust the height of welding torch 5502 between the two passes (e.g., root pass welding process 1002 and hot pass welding process 1004).
In one embodiment, an additional weld channel layer may be disposed on top of the thermal channel layer 1016 and positioned closer to the inner longitudinal axis a-a of the welded first and second conduits 1022a, 1022b than the thermal channel layer 1016. For example, in one embodiment, the one or more filled-channel welded layers 1018 may be performed by the internal welding system 5004 such that the one or more filled-channel welded layers 1018 are disposed on top of the thermal channel layer 1016 and are positioned closer to the internal longitudinal axis a-a of the welded first and second conduits 1022a, 1022b than the thermal channel layer 1016. For example, in one embodiment, the one or more filled-channel welded layers 1018 and cosmetic-channel welded layers 1020 may be performed by the internal welding system 5004 such that the one or more filled-channel welded layers 1018 and cosmetic-channel welded layers 1020 are disposed on top of the thermal channel layer 1016 and are positioned closer to the internal longitudinal axis a-a of the welded first and second conduits 1022a, 1022b than the thermal channel layer 1016.
In another embodiment, one or more fill channel weld layers 1018 and cosmetic channel weld layers 1020 are disposed in the exterior beveled surfaces 5230, 5234 of the first and second conduits 1022a, 1022b and may be performed from outside the pipeline 1024 by an external welding system 7500.
Fig. 2H shows a cross-sectional view of a pipeline 1024 with a welded joint 1026 formed therebetween. For example, the weld joint 1026 of fig. 2H includes a root channel weld layer 1014 formed from the interior of the conduits 1022a, 1022b by the internal welding system 5004, while the hot channel weld layer 1016, one or more fill channel weld layers 1018, and the facing channel layer 1020 are formed from the exterior of the conduits 1022a, 1022b by the external welding system 7500. In one embodiment, the root passage weld layer 1014 is disposed in the interior chamfers 5228, 5232 of the first and second conduits 1022a, 1022 b. In one embodiment, the hot channel solder layer 1016, one or more fill channel solder layers 1018, and capping channel solder layers 1020 are disposed in the exterior beveled surfaces 5230, 5234 of the first and second conduits 1022a, 1022 b.
Fig. 2I shows a cross-sectional view of a pipeline 1024 with a welded joint 1026 formed therebetween. For example, the weld joint 1026 of fig. 2I includes a root channel weld layer 1014, a hot channel weld layer 1016, one or more fill channel weld layers 1018 and 1020 formed from outside the conduits 1022a, 1022b by an external welding system 7500. In one embodiment, the root channel weld layer 1014, the hot channel weld layer 1016, the one or more fill channel weld layers 1018, and the cap channel weld layer 1020 are disposed in the exterior beveled surfaces 5230, 5234 of the first and second conduits 1022a, 1022 b.
In one embodiment, after the weld joint 1026 is completed, the weld joint 1026 may be inspected during the weld inspection process 1008. In one embodiment, the weld inspection process 1008 is performed after the fill and cap pass welding process 1006. In one embodiment, the weld joint 1026 may be cleaned prior to the weld inspection process 1008. In one embodiment, significant heat may be generated during the welding process (e.g., processes 1002, 1004, and 1006). In one embodiment, the weld inspection process 1008 is performed at an operating temperature that is less than the higher weld temperature. In one embodiment, the weld joint 1026 may be cooled by an internal cooling system 2010 or 6500 (as described in detail below) prior to the weld inspection process 1008. In one embodiment, the weld inspection process 1008 may include any type of non-invasive test/inspection of the weld joint 1026.
In one embodiment, weld inspection process 1008 may include Automated Ultrasonic Testing (AUT). In one embodiment, automated ultrasonic testing of weld joint 1026 may be used for both onshore and offshore pipeline welding applications. In one embodiment, the AUT is configured for use in a high production environment. In one embodiment, the AUT is configured to detect and measure the size of welding flaws.
In one embodiment, the automated ultrasonic testing is performed by an AUT scanner system (e.g., 6801 as shown in fig. 136A). In one embodiment, the AUT scanner system includes an ultrasound sensor system. In one embodiment, the AUT scanner system may be portable. In one embodiment, the AUT scanner system may further include a data acquisition system operatively connected to the ultrasound sensor system. In one embodiment, the ultrasonic sensor system may include an emitter configured to transmit, for example, ultrasonic signals (e.g., wave pulses) into the pipe segments 1022a and 1022b and/or the annular weld 1026 therebetween. In one embodiment, the ultrasonic signals or pulses may be transmitted at a rate of 1Hz to 20,000 Hz. In one embodiment, the frequency of the ultrasonic waves can vary from 0.5MHz to 23 MHz.
In one embodiment, the ultrasonic signal or pulse transmitted through the emitter is configured to reflect from the boundary of the change in density of the annular weld 1026. In one embodiment, the ultrasonic sensor system may include a receiver configured to receive/detect the reflected pulse. In one embodiment, the receiver is configured to measure the intensity of the reflected pulse and generate an electronic signal proportional to the intensity of the reflected pulse. In one embodiment, the emitter and receiver of the ultrasound sensor system may have multiple elements or components. In one embodiment, the emitter of the ultrasound sensor system may be selectively activated to target the ultrasound pulse to a particular location.
In one embodiment, the range of Automated Ultrasonic Testing (AUT) may include time of flight diffraction (ToFD), Phased Array (PA), corrosion mapping, and/or full weld inspection. In one embodiment, when multiple weld profiles are to be evaluated, a time of flight diffraction (ToFD) ultrasonic weld inspection may be used.
In one embodiment, the AUT weld inspection procedure may include a full coverage pulse echo ultrasonic weld inspection. In one embodiment, the pulse-echo ultrasonic inspection technique uses a Phased Array (PA) probe in combination with a ToFD inspection in order to provide very accurate weld defect measurements. In one embodiment, the weld may be divided into separately evaluated zones (zone identification), with the results being re-compiled into a comprehensive weld analysis. In one embodiment, linear and sector scanning may provide excellent inspection of welds. In one embodiment, the ToFD ultrasonic weld inspection may be used to supplement the full coverage pulse echo ultrasonic weld inspection.
In yet another embodiment, the weld inspection process 1008 may include radiographic testing. In one embodiment, the radiographic testing is performed by a radiographic system. In one embodiment, the radiography system includes an emitter configured to transmit X-ray radiation into the tube segments 1022a and 1022b and the annular weld 1026 therebetween. In one embodiment, the intensity of the X-ray radiation may be attenuated by the material of the tube segments 1022a and 1022b and the annular weld 1026 therebetween. In one embodiment, the radiography system includes a receiver configured to measure the intensity of X-ray radiation passing through the material of the tube segments 1022a and 1022b and the annular weld 1026 therebetween.
In one embodiment, the weld inspection process 1008 may include gamma and close range photogrammetry inspection. In one embodiment, the weld inspection process 1008 may include Magnetic Particle Inspection (MPI) or Dye Penetrant Inspection (DPI). In one embodiment, the weld inspection process 1008 may include any other non-invasive test (NDT) such as, but not limited to, guided wave ultrasonic testing, eddy current testing, hardness testing, groove bottom testing (MFL), positive material identification, corrosion mapping surveys, and the like. In one embodiment, non-invasive testing (NDT) may generally refer to any test configured to identify weld defects without damaging the pipe and/or the weld formed therebetween.
Referring to fig. 2G, in one embodiment, as discussed above, each pipe segment 1022a, 1022b includes a metal pipe interior 5244 surrounded by an outer protective coating (e.g., an insulator material) 5246. In one embodiment, the end portions 5248 and 5250 of the pipe segments 1022a, 1022b to be welded leave the metal pipe interior exposed.
In one embodiment, the outer protective coating is applied back to the weld joint 1026 after the weld inspection process 1008. For example, an insulator is applied to the exposed end portions 5248, 5250 of the welded conduits 1022a, 1022b such that the insulator 5246A (as shown in fig. 118) adheres to the exterior surface 5254 of the metal conduit interior 5244, thereby insulating the previously exposed end portions 5248, 5250 of the conduits 1022a, 1022 b.
In one embodiment, to facilitate the application of an external protective coating or insulator, the weld joint 1026 and surrounding portions of the tube sections 1022a and 1022b of the pipeline 1024 are heated to a predetermined coating temperature. In one embodiment, the exposed end portions 5248, 5250 of the conduits 1022a, 1022b are heat welded. In one embodiment, the predetermined coating temperature is the temperature required to apply the outer protective coating or insulator. In one embodiment, the predetermined coating temperature is configured to provide good adhesion or bonding between the external protective coating or insulator and the tubing 1024.
In one embodiment, the heating process 1010 is performed after the weld inspection process 1008. In one embodiment, an induction preheating process may be used to heat the exposed end portions 5248, 5250 of the welded conduits 1022a, 1022b of the wire 1024 in preparation for application of a coating material or insulation.
In one embodiment, the heating process 1010 is performed by a heating system 5304 (shown and explained with reference to fig. 115A and 115B). In one embodiment, the heating system may comprise an electrical heating system. In one embodiment, the heating system may include Ultra High Frequency (UHF) induction coils configured to rapidly heat the exposed end portions 5248, 5250 of the welded conduits 1022a, 1022b of the pipeline 1024 to the desired coating temperature. In one embodiment, the heating system is also configured to regulate the temperature of the exposed end portions 5248, 5250 of the welded conduits 1022a, 1022b of the pipeline 1024 to maintain a suitable coating application temperature. In one embodiment, a heating system may comprise: a heating feedback system configured to enable the heating system to achieve and maintain a desired coating temperature; and a temperature sensor operatively coupled to the feedback system. In one embodiment, the temperature sensor may be a contact or non-contact temperature sensor. In one embodiment, the heating feedback system may include one or more sensors configured to sense other parameters of the heating process, heating time, etc.
In one embodiment, the coating process 1012 is performed immediately after the heating process 1010. In one embodiment, the coating process 1012 is performed in a coating booth (i.e., similar in construction to a welding booth) having coating heads constructed and arranged to apply/spray/provide an insulator/coating/epoxy mixture to the exposed end portions 5248, 5250 of the welded conduits 1022a, 1022b of the pipeline 1024. In one embodiment, the coating head completes the coating process in less than one minute. In one embodiment, the coating head completes the coating process within 50 seconds.
In one embodiment, an insulator/coating is applied to the heated exposed end portions 5248, 5250 of the welded conduits such that the insulator/coating 5246A (as shown in fig. 118) adheres to the exterior surface 5254 of the metal conduit interior, thereby insulating the previously exposed end portions 5248, 5250 of the conduits 1022a, 1022 b.
In one embodiment, a coating is applied to the exterior surfaces or areas of the tube segments 1022a and 1022b surrounding the weld joint 1026 to provide an insulating barrier to prevent or minimize corrosion at the weld area.
In one embodiment, the coating may comprise a polypropylene coating. In one embodiment, the coating may comprise a polyethylene coating. In one embodiment, the coating may comprise a polyurethane coating. In one embodiment, the coating may comprise an insulating (e.g., heat loss) coating. In one embodiment, the coating may comprise a corrosion protection coating. In one embodiment, the coating may comprise a wear-resistant coating. In one embodiment, the coating may include a Fusion Bonded Epoxy (FBE). In one embodiment, the coating may include a Fusion Bonded Epoxy (FBE) plus chemically modified polypropylene (CMPP) or polyethylene (CMPE) two-powder base layer. In one embodiment, a chemically modified polypropylene (CMPP) or polyethylene (CMPE) layer is then followed by a polypropylene (PP) or Polyethylene (PE) tape. In one embodiment, the coating may comprise a multi-component liquid coating (MCL) (e.g., a urethane and epoxy based MCL coating). In one embodiment, the coating may include a Field Joint Coating (FJC).
In one embodiment, the coating may comprise injection molded polypropylene. In this embodiment, the tubing 1024 is preheated to a temperature of 180 ℃ to receive an injection molded polypropylene coating.
In one embodiment, automated equipment may be used to apply the coating material at the weld joint 1026. In one embodiment, the coating delivery system can include an injection molding coating system as shown and described in detail with reference to fig. 117A and 117B. In one embodiment, the coating delivery system can include a flame spray system. In one embodiment, the insulation/coating may be applied to the exposed areas of the solder joints using a nozzle device. In one embodiment, the nozzle arrangement is configured to spray the insulating material onto the exposed area of the pipe at the welding area. In one embodiment, a nozzle arrangement is shown and described with reference to fig. 116A-116B.
In one embodiment, an abrasive blasting procedure may be used to prepare the tubing 1024 for coating. In one embodiment, the abrasive blasting process may be performed before the heating process 1010. In one embodiment, the oxidized pipe weld joint is grit blasted to remove all contaminants.
In one embodiment, a coating system may comprise: a coating feedback system configured to enable the coating system to achieve a desired coating on the tube 1024; and one or more sensors operatively connected to the coating feedback system. In one embodiment, the one or more sensors are configured to sense the following parameters of the coating process-heating time, heating temperature, coating material volume, etc.
In one embodiment, method 1000 may include other processes not shown in fig. 1A. In one embodiment, these other processes of method 1000 are shown in fig. 1B and explained with reference to fig. 1B.
In one embodiment, the method 1000 may include a pipe preparation procedure 1040, a pipe alignment procedure 1042, an optional weld inspection procedure 1044, a repair procedure 1046, a cooling procedure 1048, and a pipeline deployment procedure 1050. In one embodiment, each of these procedures is optional.
In one embodiment, the pipe preparation process 1040 is performed prior to the root pass welding process 1002. In one embodiment, the conduit preparation process 1040 is performed before the conduit alignment process 1042.
In one embodiment, the pipe preparation process 1040 may include a cutting process 1040 a. In one embodiment, the cutting process 1040a is performed for preparing the edges or end portions of the tube segments 1022a, 1022b for welding. In one embodiment, during cutting process 1040a, the tube segments 1022a and 1022b to be welded together are cut to the desired dimensions. In one embodiment, the cutting procedure 1040a may be performed at the manufacturer's location.
In one embodiment, the method may include a stringing process wherein the tubes are dispensed according to a design plan (prior to the tube joining/welding process). In one embodiment, each seam of a pipe section has a specific place in the pipeline. The stringing personnel ensure that each piece of pipe is placed at the location to which it belongs. The inspector checks the designated number of pipes to ensure that the joints are in the correct order.
In one embodiment, the method may include a bending process wherein the conduit is bent to fit the topography of the line corridor. In one embodiment, the pipe is inserted into a bending machine and the mandrel is then positioned in the pipe. The mandrel is constructed and arranged to apply pressure inside the pipe to prevent buckling when bent. The operator positions the pipe and bends it. The pipe is removed from the bender after bending has been performed. After the bending process, each piece of tubing is placed in position.
In one embodiment, the pipe preparation process 1040 may include a beveling process 1040 b. In one embodiment, a beveling process 1040b is performed to prepare the edges or end portions of the tube segments 1022a and 1022b for welding. In one embodiment, during the beveling process 1040b, the end portions of the pipe portions or pipe segments 1022a and 1022b to be welded together are beveled to a desired dimension. In one embodiment, the desired chamfer may be machined into the end portion of the tube segment 1022. In one embodiment, a pipe-to-pipe machine is inserted in the pipe and anchored to the pipe (by raising its internal clamp brake hoop). In one embodiment, the bevel process 1040b may take 10 seconds. In one embodiment, the operator may manually check the resulting bevel using a bevel gauge 5801 shown in FIGS. 2C-2F. Fig. 2C-2E show front, perspective and side views, respectively, of slope gauge 5801, while fig. 2F shows a detailed view of detail a in fig. 2C. In one embodiment, the beveling process 1040a, 1040b may be performed at the manufacturer's location.
In one embodiment, the standard bevel depth for field welding from the inside of the pipe is.050 inches. In one embodiment, the bead is about 3 millimeters high such that the bead protrudes from the surface by 0.05 to 0.07 inches. To make two weld passes (e.g., root pass weld and hot pass weld), in one embodiment, the chamfer may be cut to a depth of 0.150 to 0.170 inches.
In one embodiment, the tube alignment procedure 1042 is performed prior to the root pass welding procedure 1002. In one embodiment, the tube alignment procedure 1042 is performed between the tube preparation procedure 1040 and the root pass welding procedure 1002. In one embodiment, a preheating process may be performed prior to the welding process (i.e., root pass welding process) to heat the tube above 100 ℃ in order to evaporate all moisture from the tube surface.
In one embodiment, referring to fig. 2G, the conduit alignment procedure 1042 can include providing a second conduit 1022a at the second end 1038b of the first conduit 1022b and aligning the ends 1038a, 1038b of the first and second conduits 1022a, 1022b to be welded. In one embodiment, the internal welding system 5004 can include a feedback system (e.g., using the verification detector 5056, the one or more processors 5140, the orientation motors 5030, 5074, the external supports 5330, 6010A, 6010B, the internal clamps 5144, 7050, 7052, as will be explained in detail below) configured to sense whether the ends 1038a, 1038B of the first and second conduits 1022a, 1022B are properly aligned. The term "motor" as used herein broadly refers to any type of electromechanical motor, such as, for example only, an electric motor, a hydraulic motor, a pneumatic motor.
In one embodiment, an optional weld inspection process 1044 may be performed between hot aisle welding process 1004 and fill and cap welding process 1006. In one embodiment, the optional weld inspection procedure 1044 may include radiographic inspection. In one embodiment, the radiographic testing is performed by a radiographic system. In one embodiment, the radiography system includes an emitter configured to transmit X-ray radiation into the tube segments 1022a and 1022b and the root pass weld layer and the hot pass weld layer formed therebetween. In one embodiment, the intensity of the X-ray radiation may be attenuated by the materials of the tube segments 1022a and 1022b and the root pass weld layer 1014 and hot pass weld layer 1016 formed therebetween. In one embodiment, the radiography system includes a receiver configured to measure the intensity of X-ray radiation passing through the material of the tube segments 1022a and 1022b and the root pass weld layer 1014 and the hot pass weld layer 1016 formed therebetween. In another embodiment, the weld inspection procedure 1044 may include gamma and close range photogrammetry inspections.
In one embodiment, the repair procedure 1046 is performed after the weld inspection procedure 1008 and before the heating procedure 1010 and the coating procedure 1012. In one embodiment, the repair process 1046 is configured to repair any weld defects detected during the weld inspection process 1008.
The weld repair procedure referred to herein may be one of various types. In one embodiment, an additional welding operation is performed on top of the previously welded portion to repair any weld defects. In another embodiment, the defective weld may be ground or optionally completely cut off (manually or automatically) prior to performing any subsequent repair welding operations.
In one embodiment, after the heating process 1010 and the coating process 1012, the pipeline 1024 is cooled to a suitable temperature, after which further processing steps may be performed (e.g., after which the joined pipe sections are wound or treated/placed in water or at some other suitable location on land). In one embodiment, the cooling process 1048 is performed after the coating process 1012. In one embodiment, the cooling process 1048 is performed by a cooling system 2010, 2110, 2210, 6500 (as shown in fig. 104-112B and 119-136 and described with reference to fig. 104-112B and 119-136), which cooling system 2010, 2110, 2210, 6500 is configured to remove heat from the welding conduit in order to reduce its temperature to an acceptable temperature for efficient spooling. For example, the pipeline should be below a predetermined temperature (e.g., 50 to 70 ℃) to perform a winding process, an S-lay process, and the like. In one embodiment, the cooling system may be an internal cooling system configured to cool the welded pipe from inside the pipeline 1024.
In one embodiment, the welded pipe may also be air cooled over time. In one embodiment, the welded pipe may be cooled by spraying or pouring water on the outside of the insulation/coating on the pipeline. In one embodiment, the water spraying or casting process may be performed in one or more stations.
In one embodiment, the cooling process 1048 is performed, for example, for a barge welding process, a spool base Tie-in welding process, and a spool base main line welding process. In one embodiment, the onshore main line welding process and the onshore joint welding process may not have separate cooling processes.
In one embodiment, the pipeline deployment/lowering procedure 1050 is performed after the coating procedure 1012. In one embodiment, the pipeline deploy/lower procedure 1050 is performed after the cooling procedure 1048.
In one embodiment, pipeline deployment procedure 1050 may include a reeling procedure 1050a, an S-lay procedure 1050b, or a pipeline lowering procedure 1050 c.
In one embodiment, the spooling process 1050a is configured to spool the pipeline onto a vessel that transports the pipeline to its final destination or location. In one embodiment, the pipeline should be below a predetermined temperature (e.g., 50 to 70 ℃) to perform the winding process 1050 a. In one embodiment, the predetermined temperature (e.g., 50 to 70 ℃) is configured to avoid any damage during the winding process 1050 a.
In one embodiment, the S-lay procedure is an offshore pipelaying procedure with the pipeline lowered to the sea in a horizontal position. In one embodiment, during the S-lay procedure 1050b, the pipeline is pushed off the end of the vessel in an S-curve. In one embodiment, the pipeline should be below a predetermined temperature (e.g., 50 to 70 ℃) to perform the S-lay procedure 1050 b. In one embodiment, the predetermined temperature (e.g., 50 to 70 ℃) is configured to avoid any damage during S-lay procedure 1050 b.
The winding process, the S-lay process and the J-lay process are described in detail with reference to fig. 136B-E.
In one embodiment, the pipeline lowering process 1050c is configured to position/lower a pipeline into a trench that is excavated in advance.
In one embodiment, pipeline welding situations/situations can be classified into five categories, namely, an onshore main line welding process, an onshore joint welding process, a reel base main line welding process, a reel base joint welding process, and a barge welding process.
The onshore main line welding process is shown in fig. 3. An onshore main line welding process is typically performed at ground level and adjacent to a trench excavated in advance, in which the pipeline is located. In one embodiment, the onshore pipeline is welded together in sections, for example up to 1 mile long. Weld stations for onshore welding are adjacent to each other. The pre-welding and post-welding processes of the onshore welding process are separated from the actual welding process itself, so that the pre-welding and post-welding processes can be carried out at their own speeds. After the sections of pipeline are welded together, they are lowered into the trench that was excavated in advance.
The onshore joint welding procedure is shown in figure 4. The onshore joint welding process is typically performed in a trench that is excavated in advance, in which the pipeline is placed. That is, the sections or segments are cut to length and welded together in a trench that is excavated in advance.
The spool-based main line welding process is shown in fig. 5. The bobbin-based main line welding process is typically performed in a factory-like setting. All of the welding processes of the spool base main line occur within a factory-like setting and during the mating assembly line. For example, the pipe is welded, inspected, and coated along a front line to form a pipe rod (e.g., sometimes 7 km long). The pipe sticks are stored until they can be wound onto a vessel for transport to their final destination. I.e. the welded pipe is stored in long sections when the vessel/barge is far from the reel base. The pipeline rods are wound onto large spools on the barge (usually J-lay) and unwound as the barge reaches the operating site.
The bobbin base joint welding process is shown in fig. 6. The spool base joint welding process is used to join the previously assembled pipeline sections or sections together as they are wound onto the vessel/ship that normally transports the pipeline to its final location. The rate of winding is limited by the cooling of this seam which occurs after coating. All the procedures of welding the base joint of the winding shaft are carried out at the same station.
The barge welding process is shown in fig. 7. Barge welding processes are typically performed in a factory-like setting on board a floating vessel. All of the barge welding process steps are typically performed in a factory-like setting and during the mating assembly line. As the pipeline leaves the vessel, the pipeline is deployed in its final position.
Each of these pipeline welding scenarios may have one or more of the welding procedures described with reference to fig. 1A and 1B. One or more of the systems described in this patent application (e.g., internal welding system 5004, joint internal welding system 3001, purge and verification system 7001, external welding system 7500, and internal cooling system 2010) may be used in the operational procedures for these pipeline welding situations.
For example, referring to fig. 3, an onshore main line welding process begins with a pipe preparation process in which an automatic weld-friendly chamfer is machined into each end of the pipe. This may be done by a previous person working a short distance before the welder. After the pipe preparation process, a root pass welding process is performed. In one embodiment, the root passage welding process may be performed by the internal welding system 5004. In another embodiment, the root pass welding procedure may be performed by an external welding system 7500 using internally positioned clamps 7050, 7052. After the root pass welding process, a hot pass welding process is performed. The hot channel welding process can be performed by an external welding system or by internal welding system 5004.
In one embodiment, both the hot tunnel welding process and the root tunnel welding process are performed by the internal welding system 5004. In another embodiment, only the root pass welding procedure is performed by internal welding system 5004 while the hot pass welding procedure is performed by external welding system 7500.
In one embodiment, the fill and cap pass welding process is performed after the hot pass welding process. In one embodiment, the fill and cap pass welding process can be performed by an external welding system 7500. In one embodiment, the fill and cap pass welding process may be performed at multiple stations.
After the filling and facing pass welding process, a welding portion inspection process is performed. For example, ultrasonic inspection, radiographic inspection, or magnetic inspection may be used to inspect the weld area. Any weld defects detected during the weld inspection process are repaired during the weld repair process. The welded pipe is coated with a sintered epoxy coating. A frit epoxy coating is applied to the (heated) exposed end portion of the welded pipe such that the frit epoxy coating adheres to the exterior surface of the pipe interior. The coating process may be performed by an autonomous person who works after the repair person. The pipeline is then lowered into a trench that has been dug in advance. The pipeline lowering process may be performed by autonomous personnel working after the coating personnel.
Referring to fig. 4, the onshore joint welding process begins with a pipeline preparation process. The exact pipe length is not known in advance so the overlap is designed into the onshore joint welding process. Once the pipe is in the trench, a pipe is cut to the correct length and the desired bevel is machined into the end of the pipe. After the pipe preparation process, a root pass welding process is performed.
In one embodiment, the root passage welding process may be performed by the joint internal welding system 3001. In another embodiment, the root pass welding procedure may be performed by a joint fixture system using an external welding system 7500. In another embodiment, the root pass welding procedure may be performed by a manual welder using an externally positioned jig.
After the root pass welding process, a hot pass welding process is performed. In one embodiment, the hot channel welding process may be performed by the joint internal welding system 3001. In another embodiment, the hot channel welding process can be performed by an external welding system 7500. In another embodiment, the hot channel welding process may be performed by a manual welder.
In one embodiment, both the hot channel welding process and the root channel welding process are performed by the joint internal welding system 3001. In another embodiment, only the root pass welding process is performed by the joint inner welding system 3001, while the hot pass welding process is performed by the outer welding system 7500.
The fill and cap pass welding process is performed after the hot pass welding process. In one embodiment, the fill and cap pass welding process can be performed by an external welding system 7500. In another embodiment, the fill and cap channel welding procedure may be performed by a manual welder. The filling and facing channel welding process is performed from the outside of the pipe. After the filling and facing pass welding process, a welding portion inspection process is performed. For example, ultrasonic inspection, radiographic inspection, or magnetic inspection may be used to inspect the weld area. The welding portion inspection process is performed by an autonomous person who works after the welding person. Any weld defects detected during the weld inspection process are repaired during the weld repair process. The repair process is performed by an autonomous person who works after the inspection staff. The welded pipe is coated with a sintered epoxy coating. A frit epoxy coating is applied to the (heated) exposed end portion of the welded pipe such that the frit epoxy coating adheres to the exterior surface of the pipe interior. The coating process may be performed by an autonomous person who works after the repair person.
Referring to fig. 5, the spool base main line welding process begins with a pipe preparation process in which an appropriate bevel is machined into the end of the pipe. After the pipe preparation process, a root pass welding process is performed. In one embodiment, the root passage welding process may be performed by the internal welding system 5004. In another embodiment, the root pass welding process may be performed by the purge and inspection system 7001 using the external welding system 7500. In another embodiment, the root pass welding process may be performed by an internal jig using an external welding system.
After the root pass welding process, a hot pass welding process is performed. In one embodiment, the hot channel welding process can be performed by internal welding system 5004. In another embodiment, the hot channel welding process can be performed by an external welding system 7500.
In one embodiment, both the hot tunnel welding process and the root tunnel welding process are performed by the internal welding system 5004. In another embodiment, only the root pass welding process is performed by internal welding system 5004 while the hot pass welding process is performed by external welding system 7500. In yet another embodiment, the root pass welding process is performed by external welding system 7500 using internal purge clamp 7001 while the hot pass welding process is performed by external welding system 7500.
The radiographic weld inspection process is performed after the hot aisle welding process. The radiographic weld inspection procedure is optional.
The filling and capping pass welding process is performed after the hot pass welding process and the radiographic weld inspection process. In one embodiment, the fill and cap pass welding process may be performed by an external welding system. In one embodiment, the fill and cap pass welding process may be performed at multiple stations.
After the filling and facing pass welding process, a weld inspection process is performed to perform a weld inspection of the welded joint. For example, ultrasonic inspection, radiographic inspection, or magnetic inspection may be used to inspect the weld area. Any weld defects detected during the weld inspection process are repaired during the weld repair process. The welded pipe is coated with an injection molded polypropylene coating. An injection moulded polypropylene coating is applied to the exposed end portions of the welded pipe (pre-heated to 180 ℃) such that the injection moulded polypropylene coating adheres to the outer surface of the pipe interior. The cooling process is performed after the coating process. The tubing may be air cooled over time.
Referring to fig. 6, the spool base joint welding process begins with a pipe preparation process in which an appropriate bevel is machined into the end of the pipe. After the pipe preparation process, a root pass welding process is performed. In one embodiment, the root passage welding process may be performed by the joint internal welding system 3001. In another embodiment, the root pass welding procedure may be performed by purging fixture system 7001 using external welding system 7500. In another embodiment, the root pass welding process may be performed by an internal jig using an external welding system.
After the root pass welding process, a hot pass welding process is performed. In one embodiment, the hot channel welding process may be performed by the joint internal welding system 3001. In another embodiment, the hot channel welding process may be performed by an external welding system.
In one embodiment, both the hot channel welding process and the root channel welding process are performed by the joint internal welding system 3001. In another embodiment, only the root passage welding procedure is performed by the joint internal welding system 3001.
The radiographic weld inspection process is performed after the hot aisle welding process. The radiographic weld inspection procedure is optional.
The fill and cap pass welding process is performed after the hot pass welding process. In one embodiment, the fill and cap pass welding process may be performed by an external welding system. In one embodiment, the fill and cap pass welding process may be performed at multiple stations.
After the filling and facing pass welding process, a weld inspection process is performed to perform a weld inspection of the welded joint. For example, ultrasonic inspection, radiographic inspection, or magnetic inspection may be used to inspect the weld area. Any weld defects detected during the weld inspection process are repaired during the weld repair process. The welded pipe is coated with an injection molded polypropylene coating. An injection moulded polypropylene coating is applied to the exposed end portions of the welded pipe (pre-heated to 180 ℃) such that the injection moulded polypropylene coating adheres to the outer surface of the pipe interior. The cooling process is performed after the coating process. In one embodiment, the pipe may be cooled by pouring or spraying water on the outside surface of the insulation. In another embodiment, the pipe may be cooled by an internal cooling system. In one embodiment, the pipe may be coiled onto the vessel after the cooling process. In one embodiment, the pipe should be below a temperature between 50 and 70 ℃ during the winding process in order to avoid any damage during the winding process. In one embodiment, all of the processes of the spool base joint welding sequence may occur at the same location.
Referring to FIG. 7, the barge welding process begins with a pipe preparation process in which appropriate bevels are machined into the ends of the pipe. After the pipe preparation process, a root pass welding process is performed. In one embodiment, the root passage welding process may be performed by the internal welding system 5004. In another embodiment, the root pass welding procedure may be performed by purging fixture system 7001 using external welding system 7500. In another embodiment, the root pass welding procedure may be performed by an internal jig using an external welding system 7500.
After the root pass welding process, a hot pass welding process is performed. In one embodiment, after the root pass welding process is complete, the pipe is advanced to a hot pass welding process. In one embodiment, the hot channel welding process can be performed by internal welding system 5004. In another embodiment, the hot channel welding process may be performed by an external welding system.
In one embodiment, both the hot tunnel welding process and the root tunnel welding process are performed by the internal welding system 5004. In another embodiment, only the root passage welding process is performed by the internal welding system 5004. The radiographic weld inspection process is performed after the hot aisle welding process. The radiographic weld inspection procedure is optional.
The filling and capping pass welding process is performed after the hot pass welding process and the radiographic weld inspection process. In one embodiment, the fill and cap pass welding process may be performed by an external welding system. In one embodiment, the fill and cap pass welding process may be performed at multiple stations.
After the filling and facing pass welding process, a welding portion inspection process is performed to perform a welding portion inspection. For example, ultrasonic inspection, radiographic inspection, or magnetic inspection may be used to inspect the weld area. Any weld defects detected during the weld inspection process are repaired during the weld repair process. The welded pipe is coated with an injection molded polypropylene coating. An injection moulded polypropylene coating is applied to the exposed end portions of the welded pipe (pre-heated to 180 ℃) such that the injection moulded polypropylene coating adheres to the outer surface of the pipe interior. The cooling process is performed after the coating process. In one embodiment, the pipe may be cooled by pouring or spraying water on the outside surface of the insulation. In one embodiment, the cooling process may be performed at multiple stations. In another embodiment, the pipe may be cooled by an internal cooling system. In one embodiment, the conduit may be pushed away from the end of the vessel in an S-shaped configuration. In one embodiment, the pipeline should be below a temperature between 50 and 70 ℃ during the S-lay procedure in order to avoid any damage during the S-lay procedure.
In one embodiment, an in situ system 5000 for welding two conduits 1022a, 1022b is provided. The term "field system" as used herein is a general term intended to refer to any of the systems and/or subsystems themselves disclosed herein as a whole. For purposes of example only, a "field system" may refer to a combination of an internal inspection system, an external welder, an internal pipe cooler, and an ultrasonic non-invasive testing system along with a remote uLog processing system (e.g., remote computer system 13704). In another example, a "field system" may refer to, for example, an internal welding only system, an internal inspection only system, an internal cooling only system, a joint welder only. That is, "field system" may refer to, for example, only internal welding system 5004, only internal inspection system 7001, only internal cooling system 6500, only splice welder 3001.
As shown in fig. 8, 9, 10-1, 10-2, and 10-3, in one embodiment, each tube segment 1022a or 1022b has a longitudinal axis as shown by arrow a-a. As will be apparent from the discussion below, the field system 5000 is configured to support a plurality of pipe segments 1022a, 1022b and adjust their position and/or orientation until the pipe segments 1022a, 1022b are both aligned such that their longitudinal axes a-a are collinear and one end of each of the pipe segments 1022a, 1022b abut at a joint edge. Fig. 9 illustrates an enlarged detailed view of the field system 5000 of fig. 8 with an edge forming a pipe joint 5002 (also referred to as a "make-up" seam). In one embodiment, the field system 5000 includes an internal welding system 5004 that applies welds from inside the fitted pipe segments 1022a, 1022b to the interior of the joint 5002. To apply the weld to the interior of the seam 5002, the internal welding system 5004 is rolled into the end of one of the pipe segments 1022b, as shown in fig. 10-1. The second tube segment 1022a is then placed and maneuvered until both tube segments 1022a, 1022b are satisfactorily aligned. In one embodiment, the internal welding system 5004 applies a weld (e.g., gas metal arc welding "GMAW") from inside the pipe segments 1022a, 1022b to a face or edge seam of the pipe segments 1022a, 1022b and into the v-shaped opening (other cross-sectional shapes than v-shaped openings may also be used) formed by the beveled/chamfered edges of the two pipe segments 1022a, 1022 b.
Fig. 9A shows a partial cross-sectional view of a pipeline 1024 showing the ideal alignment (along the longitudinal axis a-a of the conduits 1022a, 1022 b) of the welding torch 5502 of the internal welding system 5004 with the internal bevel surfaces 5228 and 5232. In the illustrated embodiment, the conduits 1022a, 1022b are perfectly aligned with each other and do not have any staggers (i.e., height differences between the beveled edges of the conduits 1022a, 1022b after the conduits are aligned).
In one embodiment, field system 5000 may include an external clamp 5302 for clamping the pipes together from the outside (outside the pipes). In one embodiment, the external clamp 5302 has a stem that spans the weld joint and the welding can be performed manually. In one embodiment, external clamp 5302 can be hydraulically operated, or can be mechanically operated (e.g., using a handle). For example, in one embodiment, external clamp 5302 may be a tipton clamp as shown in fig. 7A and 7B.
In one embodiment, the internal welding system 5004 is connected to external structures/systems (i.e., external to the welded conduits 1022a, 1022 b) via an umbilical 5034 (as shown in fig. 10-1). In one embodiment, the external system is a remote uLog processing system. In one embodiment, the umbilical 5034 can be between 40 and 80 feet long (e.g., for a 40 or 80 foot long conduit). In one embodiment, the umbilical 5034 can be referred to as a tie rod. In one embodiment, the drawbar/umbilical 5034 can be fixedly connected to the internal welding system 5004. That is, the drawbar/umbilical 5034 is a permanent part of the internal welding system 5004. In one embodiment, the umbilical 5034 comprises a structural tubular member that protects all of the cables, wiring, and hoses (e.g., connecting the external structure/system and the internal welding system 5004) from damage.
In one embodiment, the umbilical 5034 breaks at the break point DP (as shown in fig. 10-2) as the internal welding system 5004 travels from one pipe (weld) joint to the next. This disconnection facilitates the placement of the new/lead-in pipe segment 1022a in position relative to the first conduit 1022 b. Fig. 10-2 shows the cables, hoses, and cabling at the end of the drawbar/umbilical 5034 disconnected (e.g., connecting the external structure/system and the internal welding system 5004) and a new/lead-in pipe segment 1022a is placed in place with respect to the first conduit 1022 b.
As shown in fig. 10-3, in one embodiment, after the introduction conduit 1002a is placed in position relative to the first conduit 1002b, the umbilical 5034 can protrude/extend from the introduction conduit 1002a distance HD. In one embodiment, umbilical 5034 can protrude/extend from the inlet conduit 1002a distance HD of between 1 and 5 feet.
The umbilical 5034 is generally used to transfer fluid (compressed air), send electrical signals, and/or send communication signals between the external structure/system and the internal welding system 5004. In one embodiment, the joint internal welding system 3001 does not include a tie rod or umbilical.
For example, the umbilical 5034 may include a welding power line configured to deliver power to a welding torch. In one embodiment, umbilical 5034 includes three welding power lines to independently deliver power to three associated welding torches in internal welding system 5004. In one embodiment, the number of welding power lines in the umbilical 5034 can vary and depend on the number of welding torches in the internal welding system 5004.
In one embodiment, the umbilical 5034 may include communication lines configured to communicate with the inspection detector 5056, the inspection camera 5112, and/or other electronic modules of the internal welding system 5004 (e.g., to start or stop welding). In one embodiment, communication with the internal welding system 5004 (including with the verification detector 5056, with the verification camera 5112, and/or with other electronic modules of the internal welding system 5004) may be performed wirelessly. It should be understood that where multiple welding torches are provided, multiple inspection detectors/lasers 5056 may also be provided.
In one embodiment, the umbilical 5034 can include a fluid communication line configured to supply compressed air to the internal welding system 5004. In one embodiment, the umbilical 5034 can include another (separate) power line configured to deliver power to the battery 5116 to recharge it. In one embodiment, a separate power line to recharge the battery 5116 is optional. In one embodiment, the umbilical 5034 may include a separate power line configured to deliver power to one or more electronic modules and/or motors of the internal welding system 5004. In another embodiment, this separate power line is optional.
In one embodiment, the internal welding system 5004 is used for pipes having an inner diameter of 26 to 28 inches, having a wall thickness of 0 to 1 inch. Thus, inner welding system 5004 is configured to fit in a hole between 24 and 28 inches. In one embodiment, the internal welding system 5004 is used for pipes having an inner diameter of 24 inches or less, having a wall thickness of 0 to 1 inch. In one embodiment, the internal welding system 5004 is used with pipes having an outer diameter of 24 inches or less. In one embodiment, the internal welding system 5004 is used for pipes having an outer diameter of 26 to 28 inches.
Fig. 10A illustrates an internal welding system 5004 configured, sized and positioned in a pipe having a 26 inch inner diameter with a 1 inch wall thickness. For example, in one embodiment, the outer diameter of the frame structure of the inner welding system 5004 is 23.32 inches for a pipe having an inner diameter of 26 inches (having a 1 inch pipe wall thickness). For example, for a 26 inch inner diameter pipe (having a 1 inch wall thickness), the outer diameter of the frame structure of the inner welding system 5004 (excluding its wheels) is 23.32 inches.
Fig. 10B illustrates an internal welding system 5004 configured, sized and positioned in a pipe having a 24 inch inner diameter with a 1 inch wall thickness. For example, in one embodiment, the outer diameter of the frame structure of inner welding system 5004 is 21.32 inches for a pipe having an inner diameter of 24 inches (having a 1 inch pipe wall thickness). For example, for a 24 inch inner diameter pipe, the outer diameter of the frame structure of inner welding system 5004 (excluding its wheels) is 21.32 inches.
In one embodiment, the diameter of the frame of the internal welding system 5004 can be a function of the internal welding system's suitability for passing through a pipe bend. In one embodiment, the standard minimum bend radius of the pipe is 30 times D, where D is the outer diameter or outer diameter of the pipe. That is, the radius of the centerline of the pipe is 30 times the outside diameter or outer diameter of the pipe. For example, for a 26 "outside diameter or outer diameter pipe, the minimum bend radius that inner welding system 5004 needs to traverse is 780 inches (i.e., (26 inches) x 30). For example, for a 24 "outside diameter or outer diameter pipe, the minimum bend radius that inner welding system 5004 needs to traverse is 720 inches (i.e., (24 inches) x 30). In one embodiment, the longer the frame of internal welding system 5004 is constructed, the narrower it must be.
In one embodiment, as shown in fig. 10C and 10D, the field system 5000 can include a support 5330 for carrying and moving the first and second conduits 1022a, 1022 b. In one embodiment, the bracket 5330 is configured to provide the second conduit 1022a at the second end of the first conduit 1022b after the frame assembly of the internal welding system 5004 is positioned at the second end 1038b of the first conduit 1022 b. In one embodiment, the mount 5330 may be referred to as an alignment Module (LUM).
In one embodiment, there may be as many stents as are needed to support the conduits 1022a, 1022 b. For example, if conduits 1022a or 1022b are small and flexible, there may be up to four stents spaced along the length of conduits 1022a or 1022 b. If conduit 1022a or 1022b is large and rigid, there may be as few as two stents along the length of conduit 1022a or 1022 b.
In one embodiment, two carriages may be used to carry and move the pipe such that each carriage is positioned at an end of the pipe. In one embodiment, three brackets may be used to carry and move the pipe such that two brackets are positioned at the ends of the pipe and one bracket is positioned at the central portion of the pipe. In one embodiment, the centrally located support is configured to simply provide support and is not configured to articulate. In one embodiment, the standoffs 5330 for the introduction conduit 1022a can all be configured to be actuatable to carry, move and provide the introduction conduit 1022a at the second end of the first conduit 1022b (after the frame assembly of the internal welding system 5004 is positioned at the second end of the first conduit 1022 b), and realign the introduction conduit 1022a in the event that the pre-weld profile data determines that adjustment is needed.
In one embodiment, the support 5330 can include a set of actuator rollers 5332 external to the conduits 1022a, 1022 b. In one embodiment, the rollers 5332 of the rack 5330 can be referred to as outer rotatable members. In one embodiment, outer surfaces 5346 and/or 5348 of first conduit 1022a and/or second conduit 1022b (as shown in fig. 2G) are movably engaged by outer rotatable member 5332 to facilitate adjusting the relative positioning of conduits 1022a, 1022b based on instructions from one or more processors 5140.
In one embodiment, the scaffold 5330 comprises: a stationary frame 5334 configured to be fixedly connected to a surface (e.g., the ground); a first movable frame 5336 configured to be movable to horizontally position the pipe; and a second movable frame 5338 configured to be movable to vertically position the pipe.
In one embodiment, the support 5330 can be hydraulically operated. For example, hydraulic cylinders 5340 positioned on the sides of the support 5330 can be configured to move the second movable frame 5338. In one embodiment, a hydraulic cylinder 5342 positioned below the support 5330 can be configured to move the first moveable frame 5336. In one embodiment, movement of the support 5330 (positioned at both ends of the conduit) can cooperate to adjust linear movement of the conduit 1022a or 1022b in all three directions (up-down, left-right, front-back) and to adjust angular movement of the conduit 1022a or 1022b in both directions (pitch, yaw)).
In one embodiment, the support 5330 is operatively associated with one or more processors 5140. In one embodiment, the cradle 5330 is connected to the one or more processors 5140 wirelessly or using a wired connection such that in the event that the pre-weld profile data determines that an adjustment is needed, the hydraulic cylinders 5340 and 5342 are adjusted based on the pre-weld profile data to move and realign the lead-in conduit 1022 a. In one embodiment, the externally positioned roller 5332 can be operatively connected to the one or more processors 5140 and controlled by the one or more processors 5140 via the first movable frame 5336 and/or the second movable frame 5338.
In one embodiment, support 5300 can be electrically operated. For example, fig. 73 shows brackets 6010A and 6010B that operate electrically. In one embodiment, the rollers of carriages 6010A and 6010B may be driven by motors to move conduits 1022a or 1022B linearly and/or angularly. In one embodiment, the brackets 6010A and 6010B may include motors operatively connected to a lead screw arrangement that enables movement of the first movable frame and/or the second movable frame.
In general, when aligning a tube for a welding process, there may be two types of tube alignment errors, such as an angular tube alignment error and a positional tube alignment error. As shown in fig. 10E, an angular alignment error results in a gap 5344 on one side of the pipe. As shown in fig. 10F, the positional alignment error results in a relative misalignment, i.e., high on one side (e.g., 1022b) and low on the other side (e.g., 1022 a).
In one embodiment, the rack 5330 or the racks 6010A and 6010B may be used in an offshore pipeline alignment and welding process. In offshore pipeline applications, both angular and positional pipe alignment errors can be corrected by sending control signals (to control the associated rollers 5332) from one or more processors 5140 to either the support 5330 or the supports 6010A and 6010B. Accordingly, the one or more processors 5140 are configured to adjust the relative positioning between the conduits (to correct alignment errors thereof) by controlling the support 5330 or the supports 6010A and 6010B. In one embodiment, the one or more processors 5140 are configured to operate the support 5330 to effect relative movement between the first conduit 1022a and the second conduit 1002b based on the pre-weld profile data to alter a joint region 5136 between the conduits 1022a, 1022b prior to the welding operation based on instructions from the one or more processors 5140.
In one embodiment, the conduits 1022a, 1002b can be aligned by a crane and clamp (internal or external). In one embodiment, the clamp may be constructed and arranged to align both conduits 1022a, 1002b horizontally and vertically. In one embodiment, the crane is configured to control both axial position and two angles (pitch and yaw).
In one embodiment, referring to fig. 11, the internal welding system 5004 includes a forward-most portion 5006, a central portion 5008 and a drive portion 5010.
In one embodiment, the frame members of the forwardmost portion 5006, the central portion 5008 and the drive portion 5010 together may be referred to as a frame assembly or frame of the internal welding system 5004. In one embodiment, the frame or frame assembly of the internal welding system 5004 can be configured to support all components of each of the front-most portion 5006, the central portion 5008 and the drive portion 5010. In one embodiment, the frame or frame assembly of the internal welding system 5004 can include a front-most portion frame 5026 (shown in fig. 12), a mid-portion frame 5068 (shown in fig. 23), and a drive portion frame 5278 (shown in fig. 32A). In one embodiment, the frame or frame assembly of internal welding system 5004 is configured to be placed within conduits 1022a, 1022 b.
In one embodiment, the forwardmost portion 5006 is the portion of external cabling, wiring, and hose connections from an external system/structure (external to the pipe to be welded). In one embodiment, the frontmost portion 5006 is configured to house all of the welding support components as described in detail below. In one embodiment, the central portion 5008 is configured to align the tube segments 1022a, 1022b and perform a welding procedure. In one embodiment, the drive portion 5010 is configured to move the internal welding system 5004 from one pipe joint to the next. In one embodiment, the driver portion 5010 is also configured to house batteries, compressed air, and shielding gases needed for the rest of the internal welding system 5004 to operate.
In one embodiment, some of the components of the internal welding system 5004 are positioned such that half of the components are positioned in the forward-most portion 5006 and the remaining half of the components are positioned in the central portion 5008. In one embodiment, some components of internal welding system 5004 are positioned in one of the three portions of internal welding system 5004, but are connected to another of the three portions of internal welding system 5004. For example, one component of the internal welding system 5004 is positioned in the forward-most portion 5006 of the internal welding system 5004 and is connected only to the central portion 5008 of the internal welding system 5004.
Fig. 12 illustrates a detailed view of the front-most portion 5006 of the internal welding system 5004. In one embodiment, the forward-most portion 5006 of the internal welding system 5004 includes a drag coupling 5012, a forward-most electronics module 5014, a front slip ring 5016, a front clamp control valve 5018, a wire feed assembly 5020, a front position sensor 5022, an adjustable swash plate 5024, a forward-most portion frame 5026, a guide pulley 5028, a front rotary motor 5030, and a front rotary union 5032. In one embodiment, frontmost electronic module 5014 may include one or more processors 5014. In one embodiment, the front clamp control valve 5018, the front position sensor 5022, and the front rotation motor 5030 can be operatively connected to the one or more processors 5140.
Fig. 13-22 illustrate views of various components of the front-most portion 5006 of the internal welding system 5004. For example, correspondingly, fig. 13 shows a traction coupling 5012, fig. 14 shows a front rotary union 5032, fig. 15 shows a front slip ring 5016, fig. 16 shows a front-most portion frame 5026, fig. 17 shows an adjustable swash plate 5024, fig. 18 shows a guide pulley 5028, fig. 19 shows a front rotary motor 5030, fig. 20 shows a front clamp control valve 5018, fig. 21 shows a front position sensor 5022, and fig. 22 shows a wire feed assembly 5020.
Fig. 11A shows a view of an umbilical 5034 where the internal welding system 5004 is configured to attach at a first end 5035 of the umbilical 5034 and the operator control system 5039 is configured to attach to a second end 5037 of the umbilical 5034. In one embodiment, the first end 5035 of the umbilical 5034 is connected to the distraction coupling 5012 of the forwardmost portion 5006 of the internal welding system 5004. In one embodiment, communication with the Ulog system (of the internal welding system 5004) is configured to occur through one or more processors or modules in the operator control system 5039. In one embodiment, the operator control system 5039 is positioned outside of the welded conduits 1022a, 1022 b.
In one embodiment, the front-most portion frame 5026 is constructed and arranged to house/support all of the components of the front-most portion 5006 of the internal welding system 5004. In one embodiment, the forward-most portion frame 5026 is constructed and arranged to provide mounting points for all of the components at the front of the internal welding system 5004 and to protect these components from damage. In one embodiment, the front-most portion frame 5026 is constructed and arranged to guide a new pipe segment into alignment with an old/existing pipe segment. In one embodiment, the forward-most portion frame 5026 may be made of steel or any other material as understood by those of skill in the art.
In one embodiment, the front-most frame 5026 is constructed and arranged to have a nose-tapered configuration to enable the internal welding system 5004 to be easily moved into a new tubular segment when joining/welding the new tubular segment with an old/existing tubular segment. In one embodiment, the nose-cone configuration of the leading-most frame 5026 can serve as an alignment structure configured to facilitate alignment of the second conduit 1022b with the first conduit 1022 a. In one embodiment, the nose cone alignment structure is configured to project outwardly from the second end of the first conduit 1022a to facilitate aligning the second conduit 1022b with the first conduit 1022 a.
In one embodiment, referring to fig. 12, the front-most portion frame 5026 comprises a sensor 5352 configured to sense the end of the pipe when the frame of the internal welding system 5004 returns to the opening of the pipe after welding the previous pipe. In one embodiment, the sensor 5352 can be configured to be movable with the frame of the internal welding system 5004. In one embodiment, the sensors 5352 are operatively connected to or associated with the one or more processors 5140.
In one embodiment, sensor 5352 can be a rotary switch. For example, the rotary switch may have a downwardly projecting rod or wire biased into the inner conduit surface and configured to slidingly engage the inner conduit surface until it reaches the conduit and extends downwardly after reaching the end of the conduit to actuate the rotary switch to detect the end of the conduit. For example, when the forward-most portion frame 5026 reaches the end of a pipe (where a portion of the pipe projects outwardly of the pipe for receiving the end of the next pipe to be welded), the wire is configured to extend outwardly from its normal position to detect the end of the pipe. In another embodiment, sensor 5352 can be a linear encoder configured to operatively connect to the wheels/rollers of internal welding system 5004 to determine the distance traveled by internal welding system 5004 and use this information to sense/detect the end of a known pipe length.
In one embodiment, the sensor 5352 is configured to detect a joint region 5136 between the conduits 1022a, 1022 b. In one embodiment, the one or more processors 5140 are configured to operate the drive motors 5124 to move the frame of the internal welding system 5004 through at least one of the conduits 1022a, 1022b until the joint region 5136 is detected by the sensor 5352. In one embodiment, the sensor 5352 is configured to detect when the frame of the internal welding system 5004 is positioned at the joint region between the conduits 1002a, 1022 b. In one embodiment, the sensor 5352 can be a test sensor 5056. In one embodiment, sensor 5352 can be a laser. In one embodiment, the sensor 5352 can be the inspection camera 5112. In one embodiment, the verification detector 5056 and/or the verification camera 5112 are configured to also perform the sensing function of the sensor 5352.
In one embodiment, referring to fig. 12, the end portion 5208 of the forwardmost portion frame 5026 is configured to be connected to a flange portion 5210 of a front clamp 5142 of the central portion 5008 (as shown in fig. 23). In one embodiment, the end portion 5208 of the forwardmost portion frame 5026 is configured to be connected to a flange portion 5210 of the front clamp 5142 of the central portion 5008 using fastening members, such as bolts 5212 (shown in fig. 23).
A front swivel 5032 in the forwardmost portion 5006 is shown in fig. 12 and 14. A rotary union is generally a union or coupling constructed and arranged to allow rotation of two combined/joined members. Rotary unions are constructed and arranged to provide a seal between a stationary supply passage (pipe or tube) and a rotating member (drum, cylinder, or spindle) to allow fluid to flow into and/or out of the rotating member. Fluids commonly used with rotary unions include compressed air and purge gas. Rotary unions typically include a housing, a shaft, a seal, and a bearing. Bearings and seals are assembled around the shaft. The bearings are used to allow rotation of the members (shaft or housing) of the rotary joint. The seal is constructed and arranged to prevent leakage of a fluid medium (e.g., compressed air or purge gas) outside of the rotary union when in operation. The rotary union locks to the inlet valve while rotating to meet the outlet valve. During this time, fluid flows from its source into the rotary union and remains within the rotary union during movement of the union. When the valve openings converge during a rotation, this fluid leaves the rotary union, and for the next rotation, additional fluid flows into the rotary union again.
In one embodiment, front swivel 5032 is configured to allow compressed air to flow therethrough. In one embodiment, front rotary union 5032 (e.g., as described in connection with fig. 25) is constructed and arranged to receive compressed air from rear rotary union 5072 (via, for example, rear slip ring 5080, rotatable hub 5078, and front slip ring 5016). The rear rotary union has substantially the same components and operates in substantially the same manner as the front rotary union 5032 and, therefore, is not shown in the same detail as the front rotary union 5032.
In one embodiment, front rotary union 5032 is constructed and arranged to send a portion of the received compressed air through valve 5204 to front clamp control valve 5018 (to actuate and operate front clamp 5142). In one embodiment, front rotary union 5032 is constructed and arranged to send the remainder of the received compressed air through valve 5204 to a compressor or external air supply tank 5029 (as shown in fig. 70) to recharge the system (e.g., to fill the tank with compressed air). In one embodiment, the remainder of the received compressed air sent to the compressor or external air supply tank 5029 (shown in fig. 70) passes through the front rotary union 5032.
In one embodiment, referring to fig. 70, both valves 5115 and 5117 are configured to close until the refill process begins. During the refilling process, compressed air from the external air supply tank 5029 travels through valves 5115, 5117 and 5204 to the front rotary union 5032, from the front rotary union 5032 to the rear rotary union 5072, and then through valves 5198, 5196, 5194 and 5113 to the compressed air tank 5128 to refill the 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 refilling process.
In one embodiment, the front swivel 5032 in the forwardmost portion 5006 is also configured to allow compressed air to connect from the umbilical 5034 to the wire feed assembly 5020, which wire feed assembly 5020 is rotatably mounted on a rotatable hub 5078 of the central portion 5008.
The front slip ring 5016 in the forwardmost portion 5006 is shown in fig. 12 and 15. Slip rings are electromechanical devices (electrical connectors) that are constructed and arranged to allow the transmission of electrical power and communication signals from a stationary structure to a rotating structure. Slip rings may be used in any electromechanical system that requires unconstrained, continuous rotation in transmitting power and/or data signals. The slip ring comprises a stationary structure (brush) which rubs on the outside diameter of the rotating structure. When the rotating structure rotates, an electric current or an electric signal is conducted through the fixed structure to the rotating structure to be connected. The stationary structure may be a graphite or metal contact (brush) and the rotating structure may be a metal ring. If more than one circuit is required, additional ring/brush assemblies are stacked along the axis of rotation. The brush or ring is stationary and the other component rotates.
In one embodiment, the front slip ring 5016 is configured to allow communication signals to be transmitted from the front-most electronics module 5014 to the wire feed electronics module 5046 of the wire feed assembly 5020. In one embodiment, front slip ring 5016 is also configured to allow transmission of (welding) power from umbilical 5034 and transmission of communication signals to internal welding system 5004.
In one embodiment, as shown in fig. 12 and 17, the adjustable swash plate 5024 is constructed and arranged to improve the alignment of the tube segments 1022a, 1022 b. In one embodiment, the adjustable swash plate 5024 is constructed and arranged to be adjustable to accommodate different conduit sizes. In one embodiment, the adjustable swash plate 5024 is constructed and arranged to protect the central portion 5008 from impact with the incoming pipe segment 1022 b. In one embodiment, the adjustable swash plate 5024 of the internal welding system 5004 is constructed and arranged to be adjustable to extend slightly more than a retracted clip stop collar (i.e., the clip stop collar 5157 in its retracted position) but less than an extended clip stop collar (i.e., the clip stop collar 5157 in its extended position).
In one embodiment, as shown in fig. 12 and 18, the guide wheels 5028 are constructed and arranged to prevent the lead-in pipe segments 1022b from scraping against the sides of the forwardmost portion 5006. In one embodiment, guide pulley 5028 is constructed and arranged to be adjustable to accommodate different conduit sizes. In one embodiment, guide pulley 5028 is a passive member.
In one embodiment, as shown in fig. 12, the front-most electronics module 5014 includes communication connections to an umbilical 1034 and to a front slip ring 5016. For example, in one embodiment, the frontmost electronics module 5014 is configured to transmit power and communication signals to and from the umbilical 5034, and is configured to transmit power and communication signals to and from the front slip 5016.
In one embodiment, front-most electronics module 5014 is also configured to control the operation of front rotary motor 5030 and front clamp control valve 5018. In one embodiment, the front-most electronics module 5014 is further configured to receive a signal from the front position sensor 5022.
The front rotary motor 5030 in the forwardmost portion 5006 is shown in fig. 12 and 19. In one embodiment, front rotary motor 5030 is electronically synchronized with rear rotary motor 5074 positioned in center portion 5008 (described below). In one embodiment, the two rotary motors 5030 and 5074 together are configured to rotate the rotatable hub 5078 of the center portion 5008 while maintaining the front clamp 5142 and the rear clamp 5144 stationary.
In one embodiment, the front rotary motor 5030 can include an offset gear drive (due to packaging constraints). For example, in one embodiment, front rotary motor 5030 comprises a motor having a rotor, a rotary shaft that rotates by the rotor, and an external gear 5021a supported by the rotary motor shaft and having external gear teeth thereon. The external gear 5021a may engage the offset gear 5021b, which offset gear 5021b also has external gear teeth. The opposite end of the offset gear 5021b also has external gear teeth 5021 c. The external gear teeth 5021c of the external/drive gear are constructed and arranged to mesh with internal gear teeth 5023 (shown in fig. 19) formed on an inner circumferential surface on a driven (ring-shaped) gear member 5021 of the wire feed assembly 5020 to transmit torque from the front rotary motor 5030 to the wire feed assembly 5020. In one embodiment, the external gear teeth 5021c of the external/drive gear are constructed and arranged to mesh with internal gear teeth 5023 formed on a driven (ring) gear member 5021 of a wire feed assembly 5020 using a gear train arrangement (see fig. 19) to transmit torque from a front rotary motor 5030 to the wire feed assembly 5020.
In one embodiment, as shown in fig. 12 and 20, front clamp control valve 5018 is configured to receive compressed air from the fixed side of front rotary union 5032.
In one embodiment, the front clamp control valve 5018 is operatively connected to receive control signals from the front end electronics module 5014. In one embodiment, the front clamp control valve 5018 is configured to supply compressed air to actuate and operate the front clamp 5142 when it receives a signal from the front-most electronic module 5014.
In one embodiment, as shown in fig. 12 and 21, the front position sensor 5022 may be a proximity sensor and particularly briefly describe the encoder wheel. In one embodiment, the encoder wheel is constructed and arranged to be rotatably mounted on the wire feed assembly 5020 for rotation with the rotatable hub 5078.
In one embodiment, the front position sensor 5022 is operatively connected to send control signals to the front end electronics module 5014. In one embodiment, the proximity sensor of the front position sensor 5022 may be configured to send a control signal to the front-most electronics module 5014 when the sensor is at a high point on the encoder wheel. In one embodiment, the front-most electronics module 5014 is configured to determine the orientation of the front-most portion 5006 relative to the rest of the internal welding system 5004 (e.g., the rotatable hub 5078) using the signals received from the front position sensor 5022.
In one embodiment, as shown in fig. 12, 22A, and 22B, the wire feed assembly 5020 comprises a wire spool holder 5036, a wire straightener 5038, a wire bowden (guide) tube 5040, a shielding gas control valve 5042, a wire feed system 5044, a wire feed electronics module 5046, and a wire feed assembly frame 5048. In one embodiment, an exemplary wire spool 5272 is shown in fig. 22A. In one embodiment, the wire straightener 5038, the shielding gas control valve 5042, and the wire feed system 5044 may be operatively connected to one or more processors 5140. In one embodiment, the wire feed electronics module 5046 may include one or more processors 5140.
In one embodiment, the wire feed assembly 5020 is constructed and arranged to house a wire spool 5272, a wire spool holder, a wire straightener, a wire feed system, and a shielding gas control valve for each of the three illustrated welding torches 5502 in the central portion 5008 of the internal welding system 5004. In the illustrated embodiment, the wire feed assembly 5020 includes three wire spool holders 5036 associated with the three illustrated welding torches 5502 in the central portion 5008 of the internal welding system 5004, three wire straighteners 5038, three wire bowden (pilot) tubes 5040, three shielding gas control valves 5042, and three wire feed systems 5044. In one embodiment, the number of wire spool holders, wire straighteners, wire Bowden (guide) tubes, shielding gas control valves, wire/electrode wire spools, and wire feed systems in internal welding system 5004 may vary and depend on the number of welding torches.
In one implementationWire spool 5272 has a size of 7(7/8) inches and a weight of 10 pounds. In one embodiment, the size of the electrode or weld line is 0.03 inches. In one embodiment, the welding or welding wire is made of a carbon steel material. In one embodiment, the electrode or weld wire is an ER70S-6 carbon steel MIG weld wire, such as made by the Chicago electric welding system. In one embodiment, the electrode or weld wire is designed for mixing with various shielding gases such as 100% carbon dioxide (CO)2) 75% argon and 25% CO2Or 98% argon and 2% O2The mixtures of (a) and (b) are used together.
In one embodiment, the wire feed assembly 5020 is constructed and arranged to be connected to the rotatable hub 5078 of the central portion 5008 such that the wire feed module 5020 is directly transferred to the rotatable hub 5078 by rotation of the front rotary motor. In one embodiment, the wire feed assembly 5020 is constructed and arranged to fasten (e.g., using a fastening member) to the rotatable hub 5078 of the central portion 5008. In one embodiment, the wire feed assembly 5020 is also constructed and arranged to house the electronics for operating all of the motors in the wire feed assembly 5020 and the rotatable hub 5078.
In one embodiment, the wire feed assembly frame 5048 is constructed and arranged to be hollow so as to allow power, communication signals, shielding gas, wire/electrode, motor control signals, and compressed air to pass therethrough, out of it, and through it.
In one embodiment, as shown in fig. 22, wire spool holder 5036 is constructed and arranged to receive and hold a wire/electrode spool (not shown) for use by internal welding system 5004. In one embodiment, the wire spool holder 5036 can comprise a retainer member 5220, said retainer member 5220 configured to retain a wire/electrode spool therein.
In one embodiment, the retainer member 5220 can be movably positioned on the shaft 5226 of the line cord spool holder 5036 using a locking member 5222 attached to the retainer member 5220. The locking member 5222 can comprise a smaller diameter region and a larger diameter region. In one embodiment, the locking member receiving opening can be formed on the shaft 5226 as having a generally closed circular cross-sectional shape with the side opening 5224 extending outwardly from the shaft 5226. With this configuration, the locking member 5222 is slidably positioned such that the larger diameter region or the smaller diameter region is within the substantially closed circular cross-sectional shape of the locking member receiving opening. When the larger diameter region is positioned in the locking member receiving opening, the shaft 5226 surrounds the larger diameter region, which cannot pass through the lateral opening 5224, thereby locking the retainer member 5220 to the shaft 5226 as a result of the engagement between the locking member 5222 and the locking member receiving opening. Alternatively, with the locking member 5222 positioned such that the smaller diameter region is substantially surrounded by the locking member receiving opening, the retainer member 5220 can be freely removed from the shaft 5226 as the smaller diameter region can pass through the side opening 5224. In another embodiment, the retainer member 5220 can be movably attached to the shaft 5226 of the spool holder 5036 using a retaining screw.
The wire or electrode exiting the wire/electrode spool may have a permanent bend to it. In one embodiment, the wire straightener 5038 is configured to remove the permanent bend and straighten the wire (e.g., by bending the wire in another direction). The straight configuration of the wire helps the wire to more easily pass through the wire bowden (guide) tube 5040. Additionally, providing a straight weld line to weld torch 5502 results in a more consistent weld. In one embodiment, the wire straightener 5038 is optional.
In one embodiment, a wire Bowden tube 5040 is constructed and arranged to guide wire/electrode from a wire feed system 5044 to the welding torch 5502. In one embodiment, a wire Bowden (guide) tube 5040 is attached at both ends thereof. In one embodiment, the wire is wrapped by a wire bowden (guide) tube 5040.
In one embodiment, wire feed system 5044 is constructed and arranged to pull wire from wire spool 5272 through wire straightener 5038 and push wire through wire bowden (guide) tube 5040 to welding torch 5502.
In one embodiment, wire feed system 5044 is configured to be automatically controlled to deliver an appropriate amount of wire to welding torch 5502. In one embodiment, wire feed system 5044 may comprise a motor and two serrated wheels configured to pull wire from wire spool 5272 through wire straightener 5038 and push wire through wire bowden (lead) tube 5040 to welding torch 5502. In one embodiment, the motor of the wire feed system 5004 may include an encoder configured to measure the number of revolutions of the motor. In one embodiment, the motors of the wire feed system 5004 are operatively connected to one or more processors 5140. This information may be used by the one or more processors 5140 to determine how much wire is fed to the welding torch 5502 and to adjust the amount of wire fed to the welding torch 5502. In one embodiment, as rotatable hub 5078 rotates, wire/electrode is fed to torch 5502 via wire feed assembly 5020.
In one embodiment, the shielding gas control valve 5042 is configured to control the flow of shielding gas through the shielding gas line to the welding torch. In one embodiment, each welding torch 5502 has a corresponding shielding gas control valve 5042 connected thereto.
In one embodiment, shielding gas is stored in the drive portion 5010 and is brought through a hose/shielding gas line to the line feed assembly 5020 for distribution to one or more welding torches 5502. In one embodiment, shielding gas control valve 5042 is configured to receive shielding gas from rear rotary union 5072 (e.g., via rear slip ring 5080 and rotatable hub 5078).
In one embodiment, shielding gas control valve 5042 is operatively connected to receive control signals from line feed electronics module 5046. In one embodiment, the shielding gas control valve 5042 is configured to supply shielding gas to the corresponding welding torch upon its receipt of a signal from the wire feed electronics module 5046.
In one embodiment, the wire feed electronics module 5046 is configured to send power and communication signals upstream through the front slip ring 5016 to the frontmost electronics module 5014 and receive power and communication signals upstream from the frontmost electronics module 5014 through the front slip ring 5016. In one embodiment, the wire feed electronics module 5046 is configured to send power and communication signals downstream through the rear slip ring 5080 to the center portion electronics module 5064 and receive power and communication signals downstream from the center portion electronics module 5064 through the rear slip ring 5080.
In one embodiment, the wire feed electronics module 5046 is configured to control all motors and valves attached to the rotatable hub 5078 of the central portion 5008. For example, the wire feed electronics module 5046 is configured to control the wire feed system, axial movement of the welding torch 5502, radial movement of the welding torch 5502, tilting movement of the welding torch 5502, and/or flow and delivery of shielding gas. That is, the wire feed electronics module 5046 is operatively connected to a shielding gas control valve 5042 to control the flow and delivery of shielding gas to the welding torch 5502.
In one embodiment, the wire feed electronics module 5046 is operatively connected to an axial welding torch motor 5550 to control axial movement of the welding torch 5502. In one embodiment, the wire feed electronics module 5046 is operatively connected to the radial welding torch motor 5512 to control radial movement of the welding torch 5502. In one embodiment, the wire feed electronics module 5046 is operatively connected to a tilt welding torch motor 5588 to control the tilting motion of the welding torch 5502. In one embodiment, the axial welding torch motor 5550, the radial welding torch motor, and the tilt welding torch motor 5588 may be referred to individually or collectively as "welding torch motors".
In one embodiment, the thread feed electronics module 5046 is configured to communicate with and control the verification detector 5056 and the verification camera 5112, both rotatably mounted on a rotatable hub 5078. In one embodiment, inspection detector 5056 is carried by a frame assembly of internal welding system 5004. In one embodiment, inspection camera 5112 is carried by the frame assembly of internal welding system 5004.
In one embodiment, the inspection detector 5056 may include an inspection laser, a three-dimensional inspection camera, an inspection ultrasonic sensor system, an inspection capacitance probe, and any other inspection detector as understood by those skilled in the art.
Fig. 23 and 24 show front and cross-sectional views of the central portion 5008 of the internal welding system 5004. In one embodiment, as discussed above, the forwardmost frame 5026 of the forwardmost portion 5006 is connected to the front clamp 5142 of the central portion 5008 and the wire feed assembly 5020 is rotatably connected to the rotatable hub 5078.
In one embodiment, the central portion 5008 of the internal welding system 5004 includes a front clamp 5142 (or first pipe engagement structure 5052), an inspection detector 5056, a welding head assembly or torch module 5500, a rear clamp 5144 (and second pipe engagement structure 5054), a rear clamp control valve 5062, a central portion electronics module 5064, a toe wheel 5066, a central portion frame 5068, an adjustable ramp 5070, a rear swivel 5072, a rear rotary motor 5074, a rear position sensor 5076, a rotary module 5078, and a rear slip ring 5080.
In one embodiment, a front clamp 5142 (or first tube engagement structure 5052), a verification detector 5056, a welding head assembly or torch assembly 5500, a rear clamp 5144 (and second tube engagement structure 5054), a rear clamp control valve 5062, a rear rotary motor 5074, and a rear position sensor 5076 are operatively connected to one or more processors 5140. In one embodiment, the verification camera 5112 is operatively connected to one or more processors 5140. In one embodiment, the central portion electronics module 5064 may include one or more processors 5140. The term "pipe engagement structure" as used herein may refer to a clamp fixedly secured to a pipe surface, or an internal seal configured to create a gas seal against a pipe internal surface, or a combination of both the aforementioned clamp and seal. For example, in one embodiment, the first tubing engagement structure 5052 may be a first clamp 5142, a first seal 5146, or a combination thereof. In one embodiment, the second tubing engagement structure 5054 may be a second clamp 5144, a second seal 5148, or a combination thereof. In one embodiment, the first conduit engagement structure 5052 and the second conduit engagement structure 5054 are carried by a frame assembly of the internal welding system 5004.
Fig. 25-31 illustrate views of various components of the central portion 5008 of the internal welding system 5004. For example, fig. 25 shows a rear rotary union 5072, fig. 26 shows a rear slip ring 5080, fig. 27 shows a center section frame 5068 and an adjustable ramp 5070, fig. 28 shows a toe wheel 5066, fig. 29 shows a rear clamp control valve 5062, fig. 30 shows a front clamp 5142, and fig. 31 shows a rotary module 5078, respectively.
Rear rotary union 5072 in central portion 5008 is shown in fig. 23, 24 and 25. In one embodiment, the structure and operation of rear rotary union 5072 is similar to front rotary union 5032, and thus the structure and operation of rear rotary union 5072 will not be described in detail herein, except for the differences noted below.
In one embodiment, rear rotary union 5072 is configured to allow compressed air and shielding gas (or purge gas) to flow therethrough. In one embodiment, rear rotary union 5072 in center portion 5008 is configured to allow compressed air from compressed air tank 5128 (shown in fig. 32A and 32B) of drive portion 5010 to connect to front rotary union 5032 through rotatable hub 5078 of center portion 5008. In one embodiment, rear rotary union 5072 in central portion 5008 is also configured to connect a shielding gas canister 5114 (shown in fig. 32A and 32B) in drive portion 5010 to shielding gas control valve 5042 in line feed assembly 5020 of forwardmost portion 5006.
In one embodiment, rear rotary union 5072 is constructed and arranged to send a portion of the received compressed air to rear clamp control valve 5062 (to operate rear clamp 5144). In one embodiment, rear rotary union 5072 is constructed and arranged to deliver the remainder of the received compressed air to front rotary union 5032 (e.g., via rear slip ring 5080, rotatable hub 5078, and front slip ring 5016). In one embodiment, the remaining portion of the received compressed air that is sent to front rotary union 5032 passes through rear rotary union 5072.
In one embodiment, front Rotary union 5032 and rear Rotary union 5072 of the present application may be of the type commercially available from Rotary Systems corporation under the designation Series 0122 through Threaded Shaft Unions (Series 0122 Pass Threaded shanks). In another embodiment, the front rotary union and the rear rotary union of the present application may be any rotary union as understood by those skilled in the art.
In one embodiment, the structure and operation of rear slip ring 5080 is similar to front slip ring 5016, and thus the structure and operation of rear slip ring 5080 will not be described in detail herein, except for the differences noted below.
In one embodiment, as shown in fig. 23, 24, and 26, the rear slip ring 5080 in the central portion 5008 is configured to allow communication signals to be transmitted between the line feed electronics module 5046 and the central portion electronics module 5064.
In one embodiment, front slip ring 5016 and rear slip ring 5080 of the present patent application may be of the type commercially available under the designation AC6275, manufactured by Moog corporation. In one embodiment, the front slip ring 5016 and the rear slip ring 5080 of the present patent application may be rated at 50 amps. In another embodiment, the front and rear slip rings of the present patent application may be any rotary union as understood by those skilled in the art.
In one embodiment, as shown in fig. 23 and 24, the central portion electronics module 5064 in the central portion 5008 includes a communications cable to the wire feed assembly 5020 through the rear slip ring 5080 and to the drive portion 5010. In one embodiment, the center portion electronics module 5064 in the center portion 5008 is configured to control the rear rotary motor 5074 and receive signals from the rear position sensor 5076. In one embodiment, the center portion electronics module 5064 in the center portion 5008 is also configured to control the rear clamp control valve 5062.
In one embodiment, as shown in fig. 23, 24, and 27, the center portion frame 5068 is constructed and arranged to house/support all of the components of the center portion 5008 of the internal welding system 5004. In one embodiment, the center section frame 5068 is constructed and arranged to provide mounting points for all components located in the center section 5008 and to protect these components from damage. In one embodiment, the center portion frame 5068 is also constructed and arranged to connect to the drive portion 5010 via a U-joint that allows the internal welding system 5004 to bend in curved conduits. In one embodiment, the center section frame 5068 may be made of steel or any other material as understood by those skilled in the art.
In one embodiment, the end portion 5214 of the center portion frame 5068 is configured to be connected to the flange portion 5216 of the rear clamp 5144. In one embodiment, the end portion 5214 of the center portion frame 5068 is configured to be connected to the flange portion 5216 of the rear clamp 5144 using fastening members (e.g., bolts 5218).
In one embodiment, as shown in fig. 23, 24, and 27, the adjustable swash plate 5070 is constructed and arranged to help center the internal welding system 5004 when the internal welding system 5004 is placed into a pipe. In one embodiment, the adjustable swash plate 5070 is also constructed and arranged to protect the central portion 5008 from impact with the end of the pipe segment. In one embodiment, the adjustable swash plate 5070 is constructed and arranged to be adjustable to accommodate different pipe sizes.
In one embodiment, as shown in fig. 23, 24, and 28, the toe wheels 5066 are constructed and arranged to support the weight of the central portion 5008. In one embodiment, the toe wheel 5066 is constructed and arranged to be spring loaded to protect the inner welding system 5004 from shock impacts as the inner welding system 5004 passes over a weld bead. In one embodiment, the toe wheel 5066 is constructed and arranged to have an adjustable toe angle to assist the internal welding system 5004 in running straight in a pipe. In one embodiment, the toe wheels 5066 are constructed and arranged to be adjustable in height for different pipe sizes. In one embodiment, the toe wheel 5066 is a passive member.
In one embodiment, as shown in fig. 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 rotary union 5072.
In one embodiment, the rear clamp control valve 5062 is operatively connected to receive control signals from the central portion electronics module 5064. In one embodiment, the rear clamp control valve 5062 is configured to supply compressed air to actuate and operate the rear clamp 5144 when it receives a signal from the central portion electronics module 5064.
In one embodiment, as shown in fig. 24, the rear position sensor 5076 may be a proximity sensor and specifically briefly described as an encoder wheel. In one embodiment, the encoder wheel is constructed and arranged to be rotatably mounted on the rotatable hub 5078.
In one embodiment, rear position sensor 5076 is operatively connected to send control signals to central portion electronics module 5064. For example, in one embodiment, the proximity sensor of the rear position sensor 5076 may be configured to send a control signal to the central portion electronics module 5064 when the sensor is at a high point on the encoder wheel. In one embodiment, the center portion electronics module 5064 is configured to determine the orientation of the center portion 5008 relative to the remainder of the internal welding system 5004 (e.g., the rotatable hub 5078) using signals received from the rear position sensor 5076.
The rear rotating motor 5074 in the center portion 5008 is shown in fig. 24. In one embodiment, the rear rotary motor 5074 is electronically synchronized with the front rotary motor 5030 such that the rotary motors 5030 and 5074 together are configured to rotate the rotatable hub 5078 of the center portion 5008 while maintaining the front clamp 5142 and the rear clamp 5144 stationary. In one embodiment, the rotary motors 5030 and 5074 are configured to rotate the welding torch 5502 circumferentially (360 ° rotation) along the joint region 5136. In one embodiment, the rotary motors 5030 and 5074 configured to direct the inspection radiation beam are also configured to drive the welding torch 5502 at least 360 ° relative to the conduit axis a-a to complete a rotary continuous root channel weld.
In one embodiment, front spinning motor 5030 and rear spinning motor 5074 may be referred to as orientation motors. In one embodiment, the front rotation motor 5030 and the rear rotation motor 5074 are operatively associated with one or more processors 5140.
In one embodiment, the rear rotary motor 5074 includes a motor having a rotor, a rotary shaft rotated by the rotor, and a drive gear supported by the rotary shaft and having gear teeth thereon. The gear teeth of the drive gear are constructed and arranged to mesh with gear teeth formed on the driven gear member 5079 of the rotatable hub 5078 to transmit torque from the rear rotary motor 5074 to the rotatable hub 5078.
In one embodiment, the rotatable hub 5078 is constructed and arranged to rotate during a welding, pre-weld scan, and post-weld scan procedure. In one embodiment, a rotatable hub 5078 is positioned between the first clamp 5142 and the second clamp 5144. Because the first clamp 5142 and the second clamp 5144 are not physically connected to each other, the front rotating motor 5030 and the rear rotating motor 5074 at each end of the rotatable hub 5078 are synchronized to prevent the two conduits 1022a, 1022b from moving relative to each other. In one embodiment, the two conduit engagement structures 5142, 5144 can be rotated relative to each other by turning the front and rear rotary motors 5030, 5074, for example, at different speeds and/or in different directions. In one embodiment, the welding torch 5502 and the verification detector 5056 rotate along the junction region 5136 between the conduits 1022a, 1022b (e.g., do not move the conduit engagement structures 5142, 5144) only when the front and rear swivel motors 5030, 5074 are rotating at the same speed and in the same direction.
In one embodiment, the central portion 5077 of the rotatable hub 5078 includes slots/openings through which shield gas hoses, bowden tubes, welding power cables, motor cables, inspection detector cables, and camera cables are configured to pass.
In one embodiment, as shown in fig. 23, 24, and 30, the front clamp 5142 has a hollow configuration. In one embodiment, the opening 5082 through the center of the front clamp 5142 is constructed and arranged to be large enough to allow all required cables and hoses to pass therethrough. In one embodiment, the opening 5082 of the front clamp 5142 is also constructed and arranged to allow structural members needed to support the weight of the front half of the internal welding system 5004 and maintain alignment of the two halves/ pipe sections 1022a, 1022b of the weld joint. In one embodiment, the front clamp 5142 and the rear clamp 5144 are constructed and arranged to mount to the rotatable hub 5078, for example, by angular contact ball bearings 5108, 5098 that are preloaded to provide rigidity.
In one embodiment, the inner surfaces 5130, 5132 of the first and/or second conduits 1022a, 1022b are engaged and manipulated by the first and second clamps 5142, 5144, respectively, to adjust the relative positioning of the conduits based on instructions from the one or more processors 5140. In one embodiment, adjustment of the relative positioning of the conduits 1022a, 1022b is achieved without disengaging the first conduit engagement structure 5144 from the inner face 5132 of the first conduit 1022b and without disengaging the second conduit engagement structure 5142 from the inner face 5130 of the second conduit 1022 a. This can be accomplished because the rotation motors 5030 and 5074 are configured to rotate the conduits 1022a, 1022b without disengaging the conduit engagement structures 5144, 5142, as described herein.
In one embodiment, as shown in fig. 23, 24, and 30, the front clamp 5142 generally includes a piston 5084, a cylinder 5086, a bushing 5088, a clamp brake clevis pin member 5090, a link member 5092, a shaft 5094, a hub 5096, a front bearing 5098, a spider member 5100, a bell housing 5102, a front plate 5104, a rear plate 5106, a rear bearing 5108, and a sleeve 5110. In one embodiment, the rear bearing 5108 and the front bearing 5098 are configured to support a rotatable hub 5078. In one embodiment, the rear clamp 5144 has the same structure, configuration, and operation as described above with respect to the front clamp 5142, and thus the structure, configuration, and operation of the rear clamp 5144 will not be described in detail herein.
In one embodiment, the front clamp 5142 is configured to clamp one of the conduits 1022a, 1022b, and the second clamp 5144 is configured to clamp the other of the conduits 1022a, 1022 b. 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 a second clamp. In one embodiment, the clamps 5142, 5144 of the internal welding system 5004 may be referred to individually or together as a braking system of the internal welding system 5004 that secures the frame of the internal welding system 5004 at a desired location within the conduits 1022a, 1022 b. In one embodiment, the front clamp 5142 and the rear clamp 5144 are radially extending clamps that engage the inner faces 5130, 5132 of the conduits 1022a, 1022b, respectively, to secure the frame of the internal welding system 5004 against movement. The operation of the front and rear clamps 5142 and 5144 will be discussed in detail below.
In one embodiment, the internal welding system 5004 includes a first conduit engagement structure 5052, a second conduit engagement structure 5054, a verification detector 5056, one or more processors 5140, and a welding torch 5502. In one embodiment, the verification detector 5056, the verification camera 5112, the welding torch 5502, and the welding head assembly 5500 are rotatably mounted on a rotatable hub 5078. The structure, configuration, and operation of each of first tube engagement structure 5052, second tube engagement structure 5054, inspection detector 5056, inspection camera 5112, welding torch 5502, and welding head assembly 5500 are described in detail with reference to fig. 30 and 33-59, and their associated description.
Fig. 32A and 32B show detailed side and top views of the drive portion 5010 of the internal welding system 5004. In one embodiment, the drive portion 5010 of the internal welding system 5004 includes a shielding gas tank 5114, a battery 5116, a drive portion electronics module 5118, a pneumatic valve 5120, drive wheels or rollers 5122, a drive motor 5124, a brake 5126, and a compressed air tank 5128. In one embodiment, the pneumatic valve 5120 includes a brake valve 5190 and a drive wheel valve 5192 (both shown in fig. 70). In one embodiment, the drive portion 5010 of the internal welding system 5004 includes a drive portion frame 5278. In one embodiment, the drive section frame 5278 can be made of steel or any other material as understood by those skilled in the art.
In one embodiment, the drive portion electronics module 5118 can include one or more processors 5140. In one embodiment, the pneumatic valve 5120 (brake valve 5190 and drive wheel valve 5192) and the drive motor 5124 are operatively connected to one or more processors 5140.
In one embodiment, the drive portion 5010 can be connected to the central portion 5008 by a universal joint 5123 and a spring member 5125.
In one embodiment, the shielding gas canister 5114 is constructed and arranged to hold shielding gas required by the welding torch 5502. In one embodiment, a hose is constructed and arranged to connect the shielding gas canister 5114 to the rear rotary union 5072 in the central portion 5008.
In one embodiment, the battery 5116 is a lithium ion battery. In one embodiment, the battery 5116 is configured to power all of the electronics of the internal welding system 5004 as well as the electric drive motor 5124. For example, in one embodiment, the battery 5116 is configured to power the central portion electronics module 5064, the frontmost portion electronics module 5014, the driver portion electronics module 5118, and the wire feed electronics module 5046. In one embodiment, a battery 5116 may be operatively connected to the one or more processors 5114.
In one embodiment, the battery 5116 is also configured to power the radial welding torch motor 5512, the oblique welding torch motor 5588, the axial welding torch motor 5550, the motors of the wire feed system 5044, the front and rear rotary motors 5030, 5074, and the drive motor 5124. In one embodiment, the battery 5116 is not configured to supply welding power. In one embodiment, the battery 5116 is configured to deliver power only to the drive portion electronics module 5118 and the drive motor 5124, while power to the remaining motors and electronics modules of the internal welding system 5004 (including the radial welding torch motor 5512, the tilt welding torch motor 5588, the axial welding torch motor 5550, the motors of the wire feed system 5044, the front and rear swivel motors 5030, 5074, the center portion electronics module 5064, the front-most portion electronics module 5014, and the wire feed electronics module 5046) is supplied from an external power source through the puller/umbilical 5034.
In one embodiment, the drive motor 5124 is configured to drive the rollers or wheels 5122 to move the frame assembly of the internal welding system 5004 (including the first conduit engagement structure 5052, the second conduit engagement structure 5054, the welding torch 5502, and the verification detector 5056) along the interior 5130, 5132 of the conduits 1022a, 1022b from the first ends of the conduits 1022a, 1022b to the second ends of the conduits 1022a, 1022 b. In one embodiment, the drive motor 5124 of the drive portion 5010 is configured to move the frame of the internal welding system 5004 down the pipeline 1004 after each weld is completed. In one embodiment, the drive motor 5124 of the drive portion 5010 is configured to accelerate and decelerate the internal welding system 5004 in the pipeline 1004.
In one embodiment, a power source is carried by the frame assembly of the internal welding system 5004 and is configured to power the drive motor 5124. In one embodiment, the drive motor 5124 of the drive portion 5010 is electrically powered. In one embodiment, the drive motor 5124 of the drive portion 5010 is powered by a battery 5116.
In one embodiment, the drive roller 5122 is configured to engage the inner faces 5130, 5132 of one or more of the conduits 1022a, 1022 b. In one embodiment, the drive roller 5122 is operatively connected to a drive motor 5124 of the drive portion 5010. In one embodiment, the drive roller 5122 is configured to be actuated by a pneumatic cylinder 5137, the pneumatic cylinder 5137 being operatively associated with the pneumatic valve 5120 to receive compressed air from the compressed air tank 5128. In one embodiment, the drive roller 5122 is made of an elastomeric or rubber material.
In one embodiment, the drive roller 5122 is configured to enable the internal welding system 5004 to move down the pipeline 1004 after each weld is completed. In one embodiment, the internal welding system 5004 can include a plurality of drive rollers 5122, the drive rollers 5122 being configured to rotatably support a frame or frame assembly of the internal welding system 5004. For example, in one embodiment, the internal welding system 5004 includes four actively driven wheels. I.e. the two drive wheels on each side are 180 deg. apart. In one embodiment, the number of drive wheels may vary. In one embodiment, drive roller 5122 can include tread thereon to increase the traction of internal welding system 5004 as it is driven through a pipeline.
In one embodiment, two of the four drive rollers 5122 can be directly connected to their respective drive motors 5124 and driven by the respective drive motors 5124. In one embodiment, the other two drive rollers 5122 can be connected to and driven by a motor driven drive wheel via a chain 5111.
In one embodiment, the drive roller 5122 is configured and arranged to drive the welding system 5004 inside the conduits 1022a, 1022b until the welding system 5004 is at a desired position. In one embodiment, the drive roller 5122 is constructed and arranged to be pressed against the inside of the pipe by a pneumatic cylinder.
In one embodiment, the brake 5126 is configured to be actuated by a pneumatic cylinder 5133, the pneumatic cylinder 5133 being operatively associated with the pneumatic valve 5120 to receive compressed air from the compressed air tank 5128. In one embodiment, brake 5126 of internal welding system 5004 is for emergency use. For example, the brake 5126 can be used in the event that the drive motor 5124 of the drive portion 5010 is somehow unable to decelerate the internal welding system 5004. For example, brake 5126 may be applied on a hill to prevent internal welding system 5004 from rolling deep into pipeline 1004 or falling out of the pipeline, depending on the direction of inclination. In one embodiment, the brake 5126 is configured to be controlled manually or automatically.
In one embodiment, brake 5126 can also be used to secure the frame of internal welding system 5004 in place within a pipe during a welding procedure, a pre-weld scanning procedure, and/or a post-weld scanning procedure. For example, brake 5126 can be configured to secure the frame of internal welding system 5004 at a desired location within a pipe without movement during a welding process, a pre-weld scanning process, and/or a post-weld scanning process.
In one embodiment, the compressed air tank 5128 is constructed and arranged to hold air for operating the brake 5126, the drive roller 5122, and the front and rear clamps 5142 and 5144. In one embodiment, the compressed air tank 5128 is constructed and arranged to be connected to the umbilical 5034 by both the front rotary union 5032 and the rear rotary union 5072 so that the compressed air tank 5128 can be refilled as needed.
In one embodiment, the pneumatic valve 5120 is constructed and arranged to control air to two pneumatic cylinders configured to engage and operate the brake 5126 and the drive roller 5122, respectively.
In one embodiment, the drive section electronics module 5118 is configured to allow communication signals to be transmitted upstream to the central section electronics module 5064. In one embodiment, the drive section electronics module 5118 is also configured to control the drive motor 5124 and the two pneumatic valves 5120.
In one embodiment, the one or more processors 5140 are configured to operate the drive motors 5124 to move the frame of the internal welding system 5004 through at least one of the conduits 1022a, 1022b until the sensor 5352 detects a joint region 5136 between the conduits 1022a, 1022 b. In one embodiment, the one or more processors 5140 are configured to operate the braking system of the internal welding system 5004 to secure the frame of the internal welding system 5004 in place within the conduits 1022a, 1022b without moving, which positions the verification detector 5056 relative to the joint region 5136 to enable the verification detector 5056 to detect the profile of the joint region 5136 between the conduits 1022a, 1022 b.
Fig. 33 illustrates a view of the central portion 5008 of the internal welding system 5004 positioned inside of the pipe segments 1022a, 1022b, where some components of the central portion 5008 are not shown for clarity. For example, front and rear clamps 5142 and 5144, rotatable hub 5078, horn assembly 5500, inspection detector 5056, and inspection camera 5112 are shown in fig. 33.
In one embodiment, the field system 5000 for welding two pipes includes a computer system 5138 for facilitating welding of pipes. In one embodiment, the computer system 5138 includes one or more processors 5140 communicatively connected to the welding system 5004. In one embodiment, the computer system 5138 and its one or more processors 5140 may be communicatively connected to the welding system 5004 (and its one or more components) by one or more wired or wireless communication links. For example, the wired communication links may include one or more ethernet links, coaxial communication links, fiber optic communication links, or other wired communication links. As another example, the wireless communication link may include one or more Wi-Fi communication links, bluetooth communication links, Near Field Communication (NFC) communication links, cellular communication links, or other wireless communication links. In one embodiment, one or more components of the welding system 5004 can be communicatively connected to each other via one or more of the aforementioned wired or wireless communication links. In one embodiment, it may be advantageous to utilize one or more wireless communication links to communicate one or more processors 5140 or one or more components of the welding system 5004 to one another to reduce the number of communication cables in the welding system 5004 in order to reduce potential cable tangles that may delay operation or damage other components of the welding system 5004. For example, potential cable tangles that occur during rotation of an inspection device (e.g., an inspection laser, inspection camera, or other inspection device), a welding torch, or other component of the welding system 5004 may be reduced in some embodiments by reducing the number of communication cables in the welding system 5004.
In one embodiment, the computer system 5138 and its one or more processors 5140 may be located in the field system 5000. In another embodiment, the computer system 5138 and its one or more processors 5140 may be located remotely from the field system 5000. In one embodiment, one or more processors 5140 can include a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and/or other mechanisms for electronically processing information.
It is to be understood that "one or more processors" as disclosed herein may constitute a single processor that is located onboard and local to the particular system or component in question, off-board and local to the particular system or component in question, or remotely. Further, the connection to the one or more processors may be wired or wireless. Additionally, "one or more processors" may also refer to any combination of on-board and local processors, off-board and local processors, remote processors, or on-board (and local), off-board (and local), and remote processors. When referring to an on-board processor, such a processor refers to a processor that is physically carried by (i.e., physically connected to, and moving with) a particular system or component. When referring to off-board processors, these refer to processors that are local to the worksite and that wirelessly communicate with on-board electronics. Off-board processors may also refer to electronics that are tethered to an on-board system (e.g., by a tie-rod) and are local to the work site. Viewed from another perspective, if the processor moves with the drawbar, it may also be considered an "on-board" processor.
In one embodiment, the first conduit engagement structure 5052 is configured to engage an interior surface 5130 of the first conduit 1022a to enable the first conduit engagement structure 5052 to be secured relative to the first conduit 1022 a. In one embodiment, the second conduit engagement structure 5054 is configured to engage an interior surface 5132 of the second conduit 1022b to enable the second conduit engagement structure 5054 to be secured relative to the second conduit 1022 b.
In one embodiment, a test detector 5056 is positioned between the first tubing engagement structure 5052 and the second tubing engagement structure 5054 and is configured to emit a test radiation beam. In one embodiment, a test detector motor is operatively associated with the test detector 5056 to direct the test radiation beam along the junction region 5136 between the conduits 1022a, 1022 b. In one embodiment, front rotation motor 5030 and rear rotation motor 5074 may be referred to individually or together as a check detector motor. In one embodiment, the front and rear swivel motors 5030, 5074 are configured to rotationally move the verification detector 5056 along the junction region 5136. In one embodiment, the verification detector 5056 is configured to generate a signal based on the profile of the junction region 5136 between the conduits 1022a, 1022 b. In one embodiment, the joint region 5136 is an annular joint region. In one embodiment, the joint region 5136 is in the interior of the conduits 1022a, 1022b at the region of the conduits 1022a, 1022b adjacent to the weld run.
The term "joint region" as used herein refers to the interior surface of a pipe to be welded in and optionally adjacent to the area where the weld material is deposited. The joint region comprises at least a portion of the internal bevel of the two pipes to be welded, or optionally the entire internal bevel if such a bevel is provided. In one embodiment, the land area includes the entire chamfered surface and also extends beyond the chamfered surface (if a chamfer is provided).
In one embodiment, the wheels 5028 on the forward-most portion 5006 of the internal welding system are constructed and arranged to prevent the clamp from dragging on the inner surface of the pipe. The less the wheel 5028 extends out, the easier it is for the internal welding system to fit through the pipe bend. In one embodiment, the wheels 5028 can be adjustable. In one embodiment, the wheels 5028 may not be adjustable. In one embodiment, the spring loaded or toe wheels 5066 at the rear clamp 5144 (as shown in fig. 23) and the adjustable wheels 5276 at the rear of the drive portion 5008 (as shown in fig. 32A) are configured and arranged such that the clamp centerline is about 0.25 inches below the pipe centerline. With this arrangement, when the clip is expanded to conform to the inner surface of the pipe, the expander lifts the clip from the wheel rather than pressing the wheel into the inner wall of the pipe
In some embodiments, a "conduit engagement structure" includes a clamp that fixedly engages a surface of a conduit. The clamp may, for example, include one or more brake hoops or other support structures configured to fixedly engage the pipe surface so as to prevent movement thereof. In another embodiment, a "conduit-engaging structure" includes a seal that sealingly engages an interior surface of a conduit so as to inhibit gas from passing therethrough. Such a seal may include, for example, an inflatable bladder, a resilient structure, or other engineered structure that engages the inner conduit surface to inhibit gas from passing therethrough. This seal may be used in a purge operator to remove oxygen from the area in the pipe to be welded in order to prevent or reduce oxidation due to the welding process. In yet another embodiment, the conduit-engaging structure comprises a combination of clamps and seals, or one or more clamps and/or one or more seals.
In one embodiment, the first tubing engagement structure 5052 includes a first clamp 5142, and the second tubing engagement structure 5054 includes a second clamp 5144.
In one embodiment, the first tube engagement structure 5052 includes a first seal 5146, and the second tube engagement structure 5054 includes a second seal 5148.
In one embodiment, the second seal 5148 and the second clamp 5144 may be referred to as a rear seal 5148 and a rear clamp 5144, respectively. In one embodiment, the first seal 5146 and the first clamp 5142 may be referred to as a front seal 5146 and a front clamp 5142, respectively.
In one embodiment, the first tubing engagement structure 5052 includes a clamp 5142, and the second tubing engagement structure 5054 includes a seal 5148. In one embodiment, the first tubing engagement structure 5052 includes a seal 5146, and the second tubing engagement structure 5054 includes a clamp 5144.
In one embodiment, the first tubing engagement structure 5052 includes a clamp 5142 and a seal 5146, and the second tubing engagement structure 5054 includes a clamp 5144 and a seal 5148. In one embodiment, the first tubing engagement structure 5052 includes a clamp 5142 and a seal 5146, and the second tubing engagement structure 5054 includes a clamp 5144. In one embodiment, the first tubing engagement structure 5052 includes a clamp 5142 and a seal 5146, and the second tubing engagement structure 5054 includes a seal 5148. In one embodiment, the first tubing engagement structure 5052 includes a clamp 5142, and the second tubing engagement structure 5054 includes a clamp 5144 and a seal 5148. In one embodiment, the first tubing engagement structure 5052 includes a seal 5146, and the second tubing engagement structure 5054 includes a clamp 5144 and a seal 5148.
In configurations where there is a seal on one side of the verification detector 5056 and the verification camera 5112 and a clamp on the other (opposite) side of the verification detector 5056 and the verification camera 5112, high pressure purge gas is fed into the region between the clamp and the seal. Purge gas from the area between the clamp and seal can leak through the fine gap between the pipes to be welded and can also be vented from the pipes of the inspection detector 5056 and inspection camera 5112 that are not sealed and only have one side of the clamp. This optional configuration prevents over-pressurization of the region between the clamp and seal (e.g., as compared to an arrangement with two seals, one on either side of the verification detector 5056 and the camera 5112), without the need to provide a regulator that regulates the pressure of the purge gas region and/or a separate over-pressurization relief valve for the region between the clamp and seal. The continuous supply of high pressure purge gas into the region between the clamp and the seal is configured to reduce oxygen in the region near the welding torch during a welding operation.
In another embodiment, the first and second seals may optionally have openings therethrough to prevent over-pressurization of the purge gas chamber formed between the first and second seals. In another embodiment, where an inflatable sealing bladder is provided for sealing, one or both of the seals may be partially inflated to provide a predefined or calculated gap therearound so as to allow flow out of the purge zone at a desired rate.
Where two purge seals 5146, 5148 are provided, an inert gas is introduced into the purge chamber therebetween. However, it should be understood that the purge seals 5146, 5148 need not (and typically do not) produce a perfect seal. The inert gas leaks, for example, through the gap between the two welded conduits 1022a, 1022 b. The inert purge gas may also leak around the seals 5146, 5148, which seals 5146, 5148 need not be perfect. Of course, during the welding operation, the gap between conduits 1022a, 1022b is slowly closed and sealed. Thus, as the weld between conduits 1022a, 1022b occurs, the pressure within the purge chamber between conduits 1022a, 1022b may increase. Thus, a pressure sensor provided within the purge chamber detects the pressure within the purge chamber and generates a signal to one or more processors 5140, which one or more processors 5140 in turn communicate with one or more valves and/or one or more regulators to control or regulate the purge gas pressure within the purge chamber to prevent over-pressurization. The over-pressurization within the purge chamber applies an outwardly directed gas force through the gap between the pipes to be welded that is greater than desired and potentially alters the desired weld results. In various embodiments, only a single seal 5146, 5148 is provided to create a purge chamber that is sealed on only one side. This arrangement still provides a reasonable purge chamber that is largely devoid of oxygen and also prevents any possibility of over-pressurization. In this embodiment, the inert purge gas leaks not only from the gaps between the conduits, but also through the unsealed ends of the conduits, and thus may consume more gas than in the double-sealed embodiment.
In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the pipe axis) between the first clamp 5142 and the second seal 5148. That is, the first clamp 5142 and the second seal 5148 are positioned on axially opposite sides of the inspection detector 5056 and the inspection camera 5112, respectively.
In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the pipe axis) between the first seal 5146 and the second clamp 5144. That is, the first seal 5146 and the second clamp 5144 are positioned on axially opposite sides of the inspection detector 5056 and the inspection camera 5112, respectively.
In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the pipeline axis) between the first clamp 5142 and the second clamp 5144. That is, the first clamp 5142 and the second clamp 5144 are each positioned on axially opposite sides of the inspection detector 5056 and the inspection camera 5112.
In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the pipe axis) between the first seal 5146 and the second seal 5148. That is, the first seal 5146 and the second seal 5148 are positioned on axially opposite sides of the inspection detector 5056 and the inspection camera 5112, respectively.
In one embodiment, the verification detector 5056 and the verification camera 5112 are configured to be positioned axially (relative to the pipeline axis) between the first seal 5146, the first clamp 5142, the second clamp 5144, and the second seal 5148. That is, the first seal 5146 and the first clamp 5142 are positioned axially on one side of the verification detector 5056 and the verification camera 5112, and the second clamp 5144 and the second seal 5148 are positioned axially on the other side of the verification detector 5056 and the verification camera 5112.
In one embodiment, the verification detector 5056 and the verification camera 5112 are configured to be positioned axially (relative to the pipe axis) between the first seal 5146, the first clamp 5142, and the second seal 5148. That is, the first seal 5146 and the first clamp 5142 are positioned axially on one side of the verification detector 5056 and the verification camera 5112, and the second seal 5148 is positioned axially on the other (opposite) side of the verification detector 5056 and the verification camera 5112.
In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the pipe axis) between the first seal 5146, the second seal 5148, and the second clamp 5144. That is, the second seal 5148 and the second clamp 5144 are positioned axially on one side of the verification detector 5056 and the verification camera 5112, and the first seal 5146 is positioned axially on the other (opposite) side of the verification detector 5056 and the verification camera 5112.
In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the pipe axis) between the first seal 5146, the first clamp 5142, and the second clamp 5144. That is, the first seal 5146 and the first clamp 5142 are positioned axially on one side of the verification detector 5056 and the verification camera 5112, and the second clamp 5144 is positioned axially on the other (opposite) side of the verification detector 5056 and the verification camera 5112.
In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (relative to the pipe axis) between the first clamp 5142, the second seal 5148, and the second clamp 5144. That is, the second seal 5148 and the second clamp 5144 are positioned axially on one side of the verification detector 5056 and the verification camera 5112, and the first clamp 5142 is positioned axially on the other (opposite) side of the verification detector 5056 and the verification camera 5112.
In one or more embodiments, because the verification detector 5056 is positioned between the clamps 5142, 5144, it can extract profile data from between the clamps 5142, 5144 after the clamps 5142, 5144 are clamped in place. Thus, the verification detector 5056 may continue to scan and detect the profile of the land area 5136 during the welding operation. This is beneficial for some applications because the joint region 5136 may change slightly while the two conduits 1022a, 1022b are being welded, since the welded connection itself may change the joint region 5136 in other regions that are not being welded. Thus, the verification detector 5056 allows any change in one or more characteristics of the joint region 5136 at the region of the joint region 5136 to be welded to be detected and determined dynamically or "in real time". Furthermore, because the verification detector 5056 is positioned between the clamps 5142, 5144, it is able to extract pre-weld profile data from the joint region 5136 after a clamping force is applied by the clamps 5142, 5144. The clamping force of the clamps 5142, 5144 may itself alter the joint region 5136. For example, the clamping force may slightly alter the distance between the pipe ends and/or the relative height displacement between the pipe ends at some (or all) of the joint regions 5136. In addition, the clamping force applied by the clamps 5142, 5144 may change the roundness of one or both of the pipes (e.g., a first clamp may change the roundness of a first pipe to be welded and/or a second clamp may change the roundness of a second pipe to be welded. in one embodiment, for example, the clamp brake hoops for either clamp 5142, 5144 are provided symmetrically and evenly circumferentially spaced around the inside of the engaged pipes. Due to the possibility of shape changes, the profile of the land area 5136 is not fully determined. Inspection detectors 5136 described herein can be used to determine the profile after the pinch is applied.
In one or more embodiments, because the verification detector 5056 and/or the camera 5112 is positioned between two seals, the verification detector 5056 and/or the camera 5112 is able to extract profile data from between the seals 5146, 5148 after the seals 5146, 5148 are engaged with the inner faces 5130, 5132 of the pipes 1022a, 1022b to be welded. Thus, the verification detector 5056 may continue to scan and detect the profile of the joint region 5136 before, during, and/or after the region between the seals 5146, 5148 is provided or filled with a purge gas welding operation. This is beneficial for some applications because the joint region 5136 can be inspected by the inspection detector 5056 and/or the camera 5112 before, during, and/or after the welding operation without breaking the seals 5146, 5148. If, for example, the verification detector 5056 and/or camera 5112 (along with the one or more processors 5140) determines that a slight modification or additional welding operation to the weld is required, this modification or additional welding operation may be achieved without the need to re-establish a purge chamber (e.g., as compared to an expected arrangement in which a post-weld verification detector and/or camera is located outside of a purge chamber and the verification detector 5056 and/or camera 5112 is introduced to verify the welded joint region 5136 only after the purge chamber is breached). Thus, the verification detector 5056 may be used to scan the joint region 5136 between the conduits 1022a, 1022b to determine the profile of the joint region 5136 between the conduits 1022a, 1022b following a welding operation, and generate post-weld profile data based on the scan, and may obtain this post-weld profile data and optionally effect a corrected or other additional weld based on the post-weld profile data without releasing the clamps 5142, 5144 and/or seals 5146, 5148.
In one embodiment, the clamps 5142, 5144 are configured to rotate. In one embodiment, the grippers 5142, 5144 are configured to rotate in opposite directions to each other.
Further, as described herein, the present system is capable of effecting relative rotation between the first clamp 5142 and the second clamp 5144 after the first clamp 5142 and the second clamp 5144 are clamped to the first pipe interior 5130 and the second pipe interior 5132, respectively. This can be accomplished by one or more orientation motors 5030, 5074 operating one or both of the clamps 5142, 5144 as described herein. This relative rotation of the conduits 1022a, 1022b can be implemented in response to the pre-weld profile data determining that a better rotational match between the conduit ends is available, and can be achieved by relative rotation of one or both of the clamps 5142, 5144. This relative rotation is achieved without loosening the first and second clamps 5142, 5144 and while the verification detector 5056 remains axially positioned between the clamps 5142, 5144. After rotation of the first conduit 1022a and/or the second conduit 1022b, a new profile of the joint region 5136 exists, and the verification detector 5056 can be used again to scan the joint region 5136 for new pre-weld profile data. It should be appreciated that unnecessary downtime may be avoided because neither clamp 5142, 5144 need be released to obtain new pre-weld profile data. During relative rotation of the conduits 1022a, 1022B, it should be understood that in one embodiment, the rollers 5332 of the outer support 5330(6010A, 6010B) may be used (as indicated by one or more processors 5140) to work in conjunction with one or more clamps 5142, 5144 to achieve this relative rotation.
In one embodiment, the clamps 5142, 5144 and seals 5146, 5148 are positioned inside the conduits 1022a, 1022b to form an internally sealed region/zone. In one embodiment, the clamps 5142, 5144 and seals 5146, 5148 are configured to seal opposite sides of a weld to be welded.
In one embodiment, the clamp 5142 and seal 5146 are activated together and the clamp 5144 and seal 5148 are activated together. In one embodiment, the clamps 5142, 5144 and seals 5146, 5148 are controlled by the same valve.
In one embodiment, the seals 5146, 5148 are activated with the clamp 5142. In one embodiment, the seals 5146, 5148 are activated with the clamp 5144. In one embodiment, the clamp 5142 and seal 5146 are independently activated, and the 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 independently of (and separate from) the clamp control system configured to operate both clamps 5142, 5144.
In one embodiment, the clamp 5144 is positioned relative to the end of the conduit 1022 b. In one embodiment, the clamp 5142 and seal 5146 are then activated together. In one embodiment, the clamp 5144 and seal 5148 are activated together when the conduit 1022a is positioned relative to the conduit 1022 b.
In one embodiment, the clamps 5142, 5144 are configured to be movable between a retracted position (as shown in fig. 35B) in which the clamps 5142, 5144 are out of contact with the inner surfaces 5130, 5132 of the conduits 1022a, 1022B, and an extended position (as shown in fig. 35A) in which the clamps 5142, 5144 are configured to exert a central tightening force on the inner surfaces 5130, 5132 of the conduits 1022a, 1022B. In one embodiment, the clamps 5142, 5144 are configured and arranged to engage (contact) the conduits 1022a, 1022b and transmit the force that clamps and molds the conduits 1022a, 1022 b.
In one embodiment, the structure, configuration, and operation of the clamps 5142, 5144 is shown and explained with reference to fig. 30 and fig. 33-42. For example, fig. 33 and 34 show perspective and cross-sectional views of the central portion 5008 of the internal welding system 5004 positioned inside of the pipe segments 1022a, 1022b, wherein both the clamps 5142, 5144 and the seals 5146, 5148 engage the inner surfaces 5130 and 5132 of the pipe segments 1022a, 1022b, and wherein some components of the central portion 5008 are not shown for clarity; fig. 35 illustrates a view of the central portion 5008 of the internal welding system 5004 positioned inside of the pipe segments 1022a, 1022b, wherein only the clamps 5142, 5144 (without seals) engage the inner surfaces 5130 and 5132 of the pipe segments 1022a, 1022b, and wherein some components of the central portion are not shown for clarity; FIG. 36 shows a perspective view of the clamp brake hoop 5157 attached to the clamp brake hoop pin member 5090 positioned in the spider member 5100; FIG. 37 shows a perspective view of the spider member 5100; FIG. 38 shows a perspective view of the clamp brake hoop pin member 5090; and figures 39 and 40 show perspective views of the hub 5096 of a clamp 5142 or 5144 to which the clamp brake hoop pin member 5090 and link member 5092 are connected.
In one embodiment, as shown in fig. 35C, the clamps 5142, 5144 are shown in a retracted position to illustrate how the swash plates 5026, 5070 extend slightly higher. In fig. 35C, welding torch 5502 is shown in its extended position. Typically, the welding torch 5502 only extends after the clamps 5142, 5144 are extended.
In one embodiment, referring to fig. 36, a welding system 5004 can comprise: a plurality of first clip detents 5157, the first clip detents 5157 shown being equally spaced circumferentially from one another on their respective spider members 5100; and a plurality of second clip detents 5157, the second clip detents 5157 being equally spaced circumferentially from one another on their respective spider members 5100.
In one embodiment, the clamp stop 5157 can have different heights for different sized pipes and can be fine-tuned, for example, using shims or any other adjustment means. In one embodiment, the clamp stop hoop 5157 can be a self-centering member. In one embodiment, clamp stop band 5157 of internal welding system 5004 is constructed and arranged to have a radial clearance of about 1 inch from the inner surface of the pipe.
In one embodiment, each clamp stop hoop 5157 includes a tube surface contacting member (or surface) 5156. In one embodiment, the conduit surface contacting member 5156 is constructed and arranged to frictionally engage the inner surfaces 5130, 5132 of the conduits 1022a, 1022b on either side of the joint region 5136 as the clamps 5152, 5154 are extended.
In one embodiment, referring to fig. 30 and 36-38, each clamp stop 5157 is constructed and arranged to be connected to and positioned on its associated clamp stop pin member 5090. In one embodiment, the clamp brake hoop pin member 5090 is constructed and arranged to extend through its corresponding opening 5158 in the spider member 5100. In one embodiment, the openings 5158 in the starwheel member 5100 are configured and arranged to extend generally radially in the starwheel member 5100 to enable the clip brake band pin members 5090 to move radially (e.g., up and down) in the corresponding openings 5158 in the starwheel member 5100. In one embodiment, the spider member 5100 may be any member constructed and arranged to facilitate movement of the clamp brake hoop pin member 5090 such that the clamps 5142, 5144 exert a clamping force on the inner surfaces 5130, 5132 of the conduits 1022a, 1022 b.
In one embodiment, referring to fig. 38, one end 5164 of the clamp brake hoop pin member 5090 is attached to the clamp brake hoop 5157 and the other end 5166 of the clamp brake hoop pin member 5090 is connected to the link member 5092. In one embodiment, the end 5166 of the clamp detent hoop pin member 5090 includes a notch 5168, the notch 5168 being constructed and arranged to receive a link member 5092 therein. In one embodiment, the end 5166 of the clamp brake hoop pin member 5090 further includes an opening 5170, the opening 5170 being constructed and arranged to receive the securing member 5172 to connect the link member 5092 to the end 5166 of the clamp brake hoop pin member 5090.
In one embodiment, referring to FIG. 37, the spider member 5100 may include an opening 5162 that is constructed and arranged to effect a connection between the clamp brake hoop pin member 5090 and the link member 5092. In one embodiment, the opening 5162 of the starwheel member 5100 is also constructed and arranged to enable the link member 5092 to move as the clamps 5142, 5144 move between their retracted and extended positions. In one embodiment, the star wheel members 5100 are attached to respective clamps 5142 or 5144.
In one embodiment, the link member 5092 is an elongated member having an opening formed at an end portion thereof. In one embodiment, the end portions of the link members have a generally circular configuration to enable movement of the link members 5092 as the clamps 5142, 5144 are moved between their retracted and extended positions.
In one embodiment, referring to fig. 30, 39 and 40, one end of the link member 5092 is connected to the clamp brake hoop pin member 5090 and the other end of the link member 5092 is connected to the hub 5096. In one embodiment, each clamp brake band is thus connected to the hub 5096 by its associated clamp brake band pin member 5090 and link member 5092.
In one embodiment, the hub 5096 can include a notch 5174 (as shown in fig. 40), the notch 5174 being constructed and arranged to enable a connection between the link member 5092 and the hub 5096. In one embodiment, the notch 5174 of the hub 5096 is further constructed and arranged to enable the link member 5092 to move within the notch 5174 as the clip is moved between its retracted and extended positions.
In one embodiment, referring to fig. 30, a clamp 5152 or 5154 includes a cylinder 5086, a piston 5084, and a shaft 5094. In one embodiment, the piston 5084 is configured to be axially movable within a cylinder 5086 and the shaft 5094 is fixed to the piston 5084. In one embodiment, shaft 5094 may move with piston 5084.
In one embodiment, the hub 5096 is constructed and arranged to connect to a shaft 5094, which shaft 5094 is moved longitudinally by an axially reciprocating piston 5084 driven by fluid (hydraulic or pneumatic) pressure within a cylinder 5086, for example.
The clamps 5142, 5144 are moved from a retracted position (as shown in fig. 35B) in which the clamps 5142, 5144 are out of contact with the inner surfaces 5130, 5132 of the conduits 1022a, 1022B, to an extended position (as shown in fig. 35A) in which the clamps 5142, 5144 are configured to exert a clamping force on the inner surfaces 5130, 5132 of the conduits 1022a, 1022B, by activating the cylinder 5086 such that the piston 5084 moves axially within the cylinder 5086. In one embodiment, compressed air inlet port 5031 (shown in fig. 30) passes from front rotary union 5032 through front clamp control valve 5018. Compressed air entering port 5031 pushes piston 5084 forward to move clamps 5142, 5144 to their extended positions.
That is, axial movement of piston 5084 results in axial movement of shaft 5094, which is connected to piston 5084. In one embodiment, axial movement of the shaft 5094 in turn causes axial movement of the hub 5096. In one embodiment, axial movement of the hub 5096 is translated through its link members 5092 into radial movement of the clamp brake hoop pin members 5090. Thus, a radial clamping force is generated by the fluid pressure of the compressed air acting on the piston 5084, which piston 5084 drives a link member 5092 that translates axial movement of the piston 5084 (via the shaft 5094 and hub 5096) into radial movement of the clamp brake hoop 5157.
In one embodiment, the size of the air cylinder, the fluid pressure applied, and the size of the various components of the clamps 5142 and 5144 can be varied to control the clamping force exerted by the clamps on the inner surfaces 5130, 5132 of the conduits 1022a, 1022 b.
In one embodiment, the seals 5146, 5148 have a generally circular or annular configuration to allow a portion of the central portion (e.g., the front clamp 5142 or the rear clamp 5144) to pass therethrough. In one embodiment, the seals 5146, 5148 are constructed and arranged as radially expandable members. In one embodiment, the seals 5146, 5148 are constructed and arranged to connect to pneumatic or hydraulic lines that communicate fluid to the seals 5146, 5148 to inflate them. When the seals 5146, 5148 are inflated, they are constructed and arranged to engage the inner surfaces 5130, 5132 of the conduits 1022a, 1022b, respectively, to form a chamber 5150 therebetween. In one embodiment, the seal 5146 engages the inner surface 5130 of the conduit 1022a upon inflation, and the seal 5148 engages the inner surface 5132 of the conduit 1022b upon inflation. In one embodiment, the seals 5146, 5148 engage on opposite sides of the joint region 5136 upon inflation. In one embodiment, chamber 5150 is a closed volume that can be referred to as a purge gas chamber. In one embodiment, the chamber 5150 is constructed and arranged to receive a purge gas therein.
In one embodiment, the internal welding system 5004 may include a purge gas canister configured to provide a purge gas between the inflated first seal 5146 and the inflated second seal 5148 to reduce oxygen from between the inflated first seal 5146 and the inflated second seal 5148 during the welding operation. In one embodiment, the purge canister may be positioned in the drive portion 5010 of the internal welding system 5004. In one embodiment, the purge gas is configured to prevent oxidation during the welding process. In one embodiment, the purge gas is an inert gas. In one embodiment, the purge gas may include argon, helium, nitrogen, or a combination thereof. In one embodiment, the purge gas may include argon and CO2Combinations of (a) and (b).
In one embodiment, the purge gas is pumped into the internal seal area formed between the inflated first seal 5146 and the inflated second seal 5148. By making the sealed inner region free of oxygen, oxidation that may be generated by high temperatures occurring during the welding process may be prevented.
In one embodiment, the internal welding system 5004 may include an oxygen sensor 5176 and a pressure sensor 5178. In one embodiment, the oxygen sensor 5176 and the pressure sensor 5178 are operatively connected to one or more processors 5140. In one embodiment, the oxygen sensor 5176 and the pressure sensor 5178 are constructed and arranged to be positioned on the rotatable hub 5078. In another embodiment, the oxygen sensor 5176 and the pressure sensor 5178 are constructed and arranged to be positioned on the spider member 5100 (e.g., between the clamps).
In one embodiment, the oxygen sensor 5176 is configured to measure the oxygen content of the gas in the purge chamber 5150 and send oxygen content data to the one or more processors 5140 that is indicative of the oxygen content of the gas in the purge chamber 5150. In one embodiment, the one or more processors 5140 are configured to receive oxygen content data, compare the received oxygen content data to its predetermined oxygen content value, and generate an oxygen excess signal if the oxygen content data is greater than the predetermined oxygen content value. In one embodiment, based on the oxygen excess signal, the internal welding system 5004 may be configured to open the valve structure to allow purge gas (from the purge gas source/canister) to flow into the purge chamber 5150 until the measured oxygen content falls below a predetermined oxygen content value. In one embodiment, based on the oxygen excess signal, internal welding system 5004 can be configured to stop the welding process.
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 to the one or more processors 5140 that is indicative of the pressure of the inert gas in the purge chamber 5150. In one embodiment, the one or more processors 5140 are configured to receive pressure data, compare the received pressure data to its predetermined pressure value, and generate an overpressure signal if the pressure data is greater than the predetermined pressure value. In one embodiment, based on the overpressure signal, internal welding system 5004 may be configured to open the vent valve structure to release pressure in purge chamber 5150 until the measured pressure drops below a predetermined pressure value. In one embodiment, based on the overpressure signal, the internal welding system 5004 may be configured to stop the welding process.
In one embodiment, the seals 5146, 5148, the purge gas canister, the purge gas chamber 5150 formed between the seals 5146, 5148, the oxygen sensor 5176 that monitors the gas in the purge gas chamber 5150, and the pressure sensor 5178 are all optional.
In one embodiment, referring to fig. 33, the internal welding system 5004 includes a verification camera 5112 configured to be positioned between the first pipe engagement structure 5052 and the second pipe engagement structure 5054. In one embodiment, the inspection camera 5112 is constructed and arranged to be rotatably mounted on the rotatable hub 5078 and connected to said rotatable hub 5078.
In one embodiment, the verification camera 5112 is operatively connected to one or more processors 5140. In one embodiment, the inspection camera 5112 is configured to send camera inspection data to the one or more processors 5140 before, after, or during the welding operation.
In one embodiment, the camera inspection data may generally include images of the weld joint captured by the inspection camera 5112. In one embodiment, inspection camera 5112 is configured to capture images of the weld joint during or after the welding operation.
In one embodiment, the camera inspection data may generally include images of the joint region 5136 between the conduits 1022a, 1022b captured by the inspection camera 5112. In one embodiment, the inspection camera 5112 is configured to capture images of the joint region 5136 between the conduits 1022a, 1022b prior to or during a welding operation.
In one embodiment, inspection camera 5112 may be any device configured to capture/view a weld seam or joint region 5136 between conduits 1022a, 1022 b. In one embodiment, the camera device 5112 may be a two-dimensional (2D) camera for visually inspecting a weld joint or joint region 5136 between the conduits 1022a, 1022 b.
In one embodiment, the inspection camera 5112 may be a two-dimensional (2D) Charge Coupled Device (CCD) color camera. In one embodiment, the one or more processors 5140 associated with the inspection camera 5112 may be configured to analyze the images captured by the inspection camera 5112 to detect any defects present in the weld joint. In one embodiment, a visual signal may be delivered to an external operator display based on the analysis. For example, the 2D camera may be a color camera, and the color change may indicate the weld defect to the operator. In one embodiment, the perceived change in profile may also indicate a weld defect.
In one embodiment, the inspection camera 5112 is configured to obtain thermal images of the weld joint/area (e.g., various color regions of the metal). This thermal image is then analyzed to determine what temperature has been reached by different areas of the weld joint/zone.
In one embodiment, the image provided by inspection camera 5112 may be a color image. In one embodiment, the one or more processors 5140 associated with the inspection camera 5112 may be configured to analyze the color of each pixel of the received image to determine the temperature associated with that pixel.
In another embodiment, the image provided by inspection camera 5112 can be a grayscale image. In one embodiment, one or more processors 5140 associated with inspection camera 5112 may be configured to analyze the intensity or brightness of each pixel of the received image to determine the temperature associated with that pixel. In one embodiment, the one or more processors 5140 associated with the inspection camera 5112 may be configured to analyze the properties of the pixels of the received image to determine if the temperature is outside a threshold or predetermined temperature range (and is relatively very high or relatively very low), and or if there is a large temperature difference between adjacent pixels. In one embodiment, an abnormal temperature or temperature difference may indicate the occurrence of a weld defect.
For example, in one embodiment, the image may be analyzed to determine whether a region or regions of the weld joint/region have reached a relatively very high or relatively very low temperature. In one embodiment, the image may be analyzed to determine if one or more regions of the weld joint/area have a temperature difference/change. In one embodiment, the temperature of each of the weld joints/regions is determined and the determined temperature of each of the weld joints/regions is compared to a threshold or predetermined temperature range to determine whether a region or regions of the weld joint/region have reached a relatively very high temperature and/or whether a region or regions of the weld joint/region have a temperature difference/variation.
In one embodiment, inspection camera 5112 is configured to follow welding torch 5502 such that an operator may inspect the weld whenever the weld is produced by welding torch 5502.
In various embodiments, the inspection detector includes a laser, a 3D camera, ultrasound, and a capacitance probe. In the case of using a laser, the type of laser may be a laser displacement sensor. In one embodiment, the laser may be an LK-G5000 series ultra high speed/high accuracy laser displacement sensor manufactured by Keyence corporation. In one embodiment, the laser may be an intelligent laser sensor, such as the intelligent laser sensor SLS-050 manufactured by Meta Vision Systems, Inc.
In one embodiment, the inspection detector may include an emitter for emitting the inspection radiation beam and a receiver for receiving the inspection signal from the reflected radiation. In one or more embodiments, the receiver of the detector includes a sensor that detects the reflected radiation and generates a signal based on the reflected radiation. The signals are received by one or more processors. In one embodiment, the signal contains data and information corresponding to the three-dimensional profile of the joint area between the pipes to be welded, and can be used to detect, for example, the relative height of the adjacent pipe surfaces at the area to be welded, the relative spacing between the pipes, any non-uniformity in the adjacent surfaces to be welded (e.g., at the slopes thereof). Furthermore, because the inspector detector scans along the entire joint between the pipes, it can determine the specific joint profile at any particular scanned area. This information may be used by one or more processors to control the operation of the welding torch to provide customized/specialized welding that is specifically tailored to the structural profile of the pipe to be welded at its joint region.
In one embodiment, the system 5000 may include housings 5852, 5854 (shown in fig. 31) that are configured to house and protect the verification detector 5056 and the verification camera 5112, respectively, from hot welding sparks (spatter) and/or other debris that may fly toward the verification detector 5056 and/or the verification camera 5112 during a welding operation.
In one embodiment, the housings 5852, 5854 of the inspection detector 5056 and/or the inspection camera 5112 may be made of a polycarbonate material. In one embodiment, portions of the housings 5852, 5854 may be configured to be movable to facilitate cleaning (e.g., removal of weld spatter or other weld debris therefrom) or repair. In one embodiment, the portion of housing 5852, 5854 may comprise a camera lens shield or an inspection detector lens shield. In one embodiment, the portions of the housings 5852, 5854 of the inspection detector 5056 and/or the inspection camera 5112 may be configured to be disposable such that the portions of the housings 5852, 5854 may be easily replaced when they become clogged with weld spatter or other weld debris. For example, in one embodiment, the inspection camera 5112 may include a (rectangular) polycarbonate member in front of its lens that can be replaced when clogged/obscured by weld spatter or other weld debris.
In one embodiment, the pre-weld, dynamic, and post-weld tests may be performed by the test detector 5056. In one embodiment, pre-weld inspection, dynamic inspection, and post-weld inspection may be performed by inspection detector 5056 and inspection camera 5112.
In one embodiment, the test detector 5056 includes an emitter 5180 for emitting a test radiation beam and a receiver 5182 for receiving a test signal from reflected radiation. In one embodiment, the test detector 5056 emits radiation toward the land area 5136. In one embodiment, the receiver 5182 of the inspection detector 5136 is configured to receive radiation reflected from the surface of the joint region 5136 and generate an electronic signal based thereon. In one embodiment, the receiver or sensor 5182 of the inspection detector 5056 is configured to sense the reflected signal to detect the 3D topography of the weld joint/region. The inspection detector 5056 may be referred to herein interchangeably as an inspection laser.
In one embodiment, the inspection detector 5136 includes a plurality of inspection detectors that emit radiation toward the joint region 5136. In one embodiment, each inspection detector can include a receiver for receiving radiation reflected from the surface of the joint region 5136 and generating an electronic signal based thereon.
In one embodiment, the verification detector 5056 may include a laser displacement sensor. In one embodiment, the verification detector 5056 may include a complementary metal-oxide-semiconductor (CMOS) sensor. In one embodiment, the inspection detector 5056 may include a high definition ernostatr type lens. In one embodiment, one or more processors 5140 associated with the inspection detector 5056 are configured to detect the location of reflected light on the RS-CMOS sensor using triangulation.
In one implementation, the verification detector 5056 may receive its power from the line feed electronics module 5046. In one embodiment, the wire feed electronics module 5046 is configured to receive its power from the battery 5116 in the drive portion 5010 through the rear slip ring 5080. Thus, the verification detector 5056 receives its power from the battery 5116 in the drive portion 5010 through the rear slip 5080 and the wire feed electronics module 5046. This may be the case when the cables, hoses, and/or lines to the drawbar/umbilical 5034 are disconnected from the system 5004, for example when the system 5004 travels from one weld joint to the next.
In another embodiment, the test detector 5056 may receive its power directly from the umbilical/tie 5034. For example, when a cable, hose, and/or line to the drawbar/umbilical 5034 is connected to the system 5004, the check detector 5056 may receive its power directly from the umbilical/drawbar 5034.
It should be understood that in some embodiments, power to the verification detector 5056 and/or the camera 5112 and communication from the verification detector 5056 and/or the camera 5112 may be required. This power and/or communication of the verification detector 5056 and/or the camera 5112 may occur using components that are external to the pipe-engaging structure (e.g., external to the clamps 5142, 5144 and/or seals 5146, 5148), such as one or more processors 5140 and/or a power source. In some embodiments, where power and/or communication occurs through hardwired (as opposed to wireless) communication and/or power lines, such hardwired may take into account rotation by the rotatable hub 5078, for example, to reduce or prevent hardwired twisting and/or tangling. Thus, in one example as described herein, a hard-wired (which may transmit information and/or power) may be provided with: (i) a movable portion that moves with the verification detector 5056 as the verification detector 5056 directs the verification beam along the junction region under the rotational force of one or more orientation motors; and (ii) a fixed portion that remains fixed during movement of the movable portion. The hardwired fixed and rotating parts may be connected by said slip ring providing a joint between the hardwired movable and fixed parts to enable signals to pass from the movable part to the fixed part. It should be understood that a single hard-wired line (e.g., having multiple discrete lines) or multiple hard-wired lines (separate lines for power and communication) may be used. Furthermore, if on-board power is provided to the inspection detector, only the communication line may pass through the slip ring. If wireless communication with the inspection detector is provided, only the power line may pass through the slip ring. If on-board power and wireless communication is provided, hard-wired communication need not be provided.
Similar to that described with respect to hardwired communication lines, it may also be desirable to provide inert gas to an axial location between the conduit engaging structures (e.g., between clamps and/or seals) through a gas pressure line or tube for carrying pressurized inert gas. It may also be desirable to reduce twisting and/or tangling of the pneumatic lines that may otherwise occur during rotation of the rotatable hub 5078. Thus, the pneumatic line may be provided with a fixed portion connected with a source of inert gas and a movable portion extending into the rotatable hub, the movable portion being coupled to the fixed portion by a rotary union. The rotary union allows relative rotation between the fixed and movable pneumatic parts.
In one embodiment, a test detector 5056 may be operatively associated with the test motor to direct the radiation beam along the junction region 5136 between the conduits 1022a and 1022 b. In one embodiment, the verification detector 5056 and the verification motor may be operatively associated with one or more processors 5140. In one embodiment, first rotating motor 5030 and second rotating motor 5074 may be interchangeably referred to together as a check motor.
In one embodiment, the verification detector 5056 is configured to detect a characteristic of the junction region 5136 between the conduits 1022a, 1022 b. In one embodiment, the characteristics of the joint region 5136 may include the gap between the conduits 1022a, 1022 b. In one embodiment, the characteristics of the joint region 5136 may include an axial offset (e.g., high/low) between the conduits 1022a, 1022 b. In one embodiment, the characteristics of the joint region 5136 can include the geometry at each weld location. In one embodiment, the characteristics of the joint region 5136 may include a notch, gauge, or any irregularity of the conduits 1022a, 1022 b. In one embodiment, the characteristics of the joint region 5136 can include the roundness of the conduits 1022a, 1022 b. In one embodiment, the characteristics of the joint region 5136 may include the profile of the slope of the conduits 1022a, 1022b (after alignment of the conduits). In one embodiment, the characteristics of the joint region 5136 can include various color regions of the metal of the weld seam/region. For example, these color regions are analyzed to determine what temperature has been reached by different regions of the solder joint/region.
In one embodiment, for example, the verification detector 5056 may be configured to detect a characteristic of the junction region 5136 between the conduits 1022a, 1022b prior to the welding torch 5502 being activated to secure/weld the conduits 1022a, 1022b to one another. For example, the characteristics of the joint region 5136 may include the conduit bevel geometry, the gap between the inner abutting ends of the conduits 1022a, 1022b (after conduit alignment), the gap between the bevels of the conduits 1022a, 1022b (after conduit alignment), and the like. In one embodiment, the verification detector 5056 may be configured to detect a characteristic of a region of the joint 5136 between the conduits 1022a, 1022b at a region thereof prior to deposition of the weld material thereon, for example, during a welding operation. For example, the characteristics of the joint region 5136 may include the height difference between the beveled edges of the pipe after it is aligned. In one embodiment, the characteristics of the joint region 5136 can include a difference in elevation between adjacent edges of the pipe (e.g., at its inner chamfered portion). In one embodiment, the verification detector 5056 may be configured to detect a characteristic of the joint region 5136 between the conduits 1022a, 1022b, for example, after a welding operation. For example, the characteristics of the joint area 5136 may include characteristics of the formed weld bead, weld shape parameters such as mismatch, bead concavity, and re-entrant angle.
In one embodiment, the one or more processors 5140 are configured to operate the verification detector 5056 and the motors 5030, 5074 to scan the junction region 5136 between the conduits 1022a, 1022 b.
In one embodiment, the one or more processors 5140 are configured to interact with the verification detector 5056 to scan the joint region 5136 between the conduits 1022a, 1022b to determine the profile of the joint region 5136 between the conduits 1022a and 1022b prior to the welding process and generate pre-weld profile data based thereon.
The term "profile" as used herein is a general term for the physical properties of the joint area to be welded between pipes. The term "profile data" refers to data corresponding to a profile that can be derived from a joint region. This data may be obtained, for example, by scanning the joint area using an inspection detector, such as a laser. The profile data may include multiple types of information about the profile, such different types of information being referred to herein as "characteristics".
In one embodiment, the one or more processors 5140 are configured to interact with the verification detector 5056 to scan the joint region 5136 between the conduits 1022a, 1022b to determine the profile of the joint region 5136 and generate dynamic profile data at the region of the joint 5136 between the conduits 1022a and 1022b prior to deposition of welding material thereon during a welding process. In one embodiment, the one or more processors 5140 are configured to generate a welding signal to control the welding torch 5502 based on the dynamic profile data. The dynamic profile data is described in detail below. The term "dynamic" as used herein also means or refers to "real-time," which means that the one or more processors use the sensing or detection to control the welder during the course of the current welding operation. Of course, because the inspection detector, welding torch, lags behind the inspection detector/inspection laser by the defined amount, some buffering (or slight time delay) occurs between the receipt of profile data and the use of such profile data by the one or more processors to control the welding torch.
In one embodiment, the one or more processors 5140 are configured to interact with the verification detector 5056 to scan the joint region 5136 between the conduits 1022a, 1022b to determine the profile of the joint region 5136 between the conduits 1022a and 1022b after the welding process and generate post-weld profile data based thereon. The post-weld profile data is described in detail below.
In one embodiment, verification detector 5056 is configured to work in conjunction with welding torch 5502 of welding system 5004 to sense joint seam profiles and/or weld material profiles in order to apply weld material to edge seams in the proper location and quantity. In one embodiment, the inspection detector 5056 is configured to survey a weld and send signals to one or more processors 5140 of the articulating horn 5502 to control the movement of the horn 5502 around the entire edge seam. Specifically, welding torch 5502 is configured to follow inspection detectors as the weld head control system continuously receives weld profile information from the edge joint. This information is then used to continuously adjust the welding torch 5502 to achieve the desired weld configuration/profile.
In one embodiment, internal welding system 5004 may include a check detector/welding torch 5502. In one embodiment, internal welding system 5004 includes three welding torches 5502 and three associated verification detectors 5056. In another embodiment, internal welding system 5004 may include two inspection detectors/welding torches 5502. In one embodiment, the number of inspection detectors used in the internal welding system 5004 may vary.
In one embodiment, the field system 5000 of the present patent application is an intelligent internal inspection system that places internal automation (including an inspection camera 5112, an inspection detector 5056, and a welding head or torch 5502) between spaced fixtures 5142, 5144 and seals 5146, 5148. In one embodiment, the field system 5000 of the present patent application is an intelligent internal inspection system that places an inspection camera 5112 and an inspection detector 5056 between spaced fixtures 5142, 5144 and seal arrangements 5146, 5148. In one embodiment, the field system 5000 of the present patent application is an intelligent internal inspection system that places internal automation (including an inspection camera 5112, an inspection detector 5056, and a welding head or torch 5502) between spaced fixtures 5142, 5144.
In one embodiment, the welding system is attached to the rear of the alignment fixture, thereby being an inline analysis tool that minimizes downtime associated with the use of third party tools. In one embodiment, both inspection camera 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. Because the color of the weld indicates to what temperature the material is raised during the welding process, the information obtained by inspection camera 5112 helps determine whether the weld is being performed correctly. In one embodiment, the inspection detector 5056 is configured to analyze the profile of the weld. In one embodiment, the inspection detector 5056 in conjunction with a two-dimensional (2D) Charge Coupled Device (CCD) color camera 5112 is configured to perform root inspection directly after the root pass welding process and the hot pass welding process. In one embodiment, the welding system 5004 is configured to provide root passage weld layer profiles and 2D raw color images showing color anomalies and any geometric defects of the root passage weld layer. In one embodiment, the welding system 5004 is configured to create a permanent record of the root pass weld layer profile and the visual image that can be stored and played back in the user's electronic device (e.g., laptop).
In one embodiment, the inspection performed by the inspection detector 5056 in conjunction with the color camera 5112 may be used as a reference for an AUT weld inspection. In one embodiment, the inspection performed by the inspection detector 5056 in conjunction with the color camera 5112 may be used as a "pass, fail" (pass/fail test (or check)) for root channel welds and hot channel welds. In one embodiment, if a root defect is found, all of the channels may be cut and prepped in the same station after deposition, well before defect marking occurs, thus avoiding significant waste of production time.
In one embodiment, the internal welding system 5004 includes a feedback system configured to be operatively connected to a plurality of sensors and one or more processors 5140. In one embodiment, the one or more processors 5140 are configured to analyze data provided by a plurality of sensors. In one embodiment, one of the plurality of sensors includes a temperature sensor configured to provide an indication of the temperature of the weld joint and/or to monitor the temperature during the welding process. In one embodiment, one of the plurality of sensors includes a welding material sensor configured to monitor welding material usage during a welding procedure. In one embodiment, one of the plurality of sensors may include a sensor configured to monitor a speed and time of the welding process.
Fig. 41 illustrates a front perspective view of horn assembly 5500, while fig. 42 and 43 illustrate a rear perspective view of horn assembly 5500. Fig. 44-46 show a left side perspective view, a right side perspective view, and a cross-sectional view of welding horn assembly 5500 in which some of the components of welding horn assembly 5500 are not shown for clarity.
In one embodiment, in the embodiment shown, the central portion 5008 may have three welding torches 5502. In another embodiment, the central portion 5008 can have two welding torches 5502. In yet another embodiment, the central portion 5008 may have only one welding torch 5502. In one embodiment, the number of welding torches may vary.
In one embodiment, welding tip assembly 5500 comprises a welding torch 5502 and a welding torch housing assembly 5504. In one embodiment, welding torch 5502 includes a welding tip 5503. In one embodiment, welding head assembly 5500 (welding torch 5502 and welding torch housing assembly 5504) is carried by a frame or frame assembly of internal welding system 5004.
In one embodiment, welding torch 5502 is constructed and arranged to feed or direct consumable wire 5507 into a welding region/zone. Consumable electrode wire 5507 is supplied from a source (e.g., a wire reel or a wire spool) through a wire feed system 5044. In one embodiment, the welding torch 5502 is constructed and arranged to be connected to a power supply (e.g., a constant voltage power supply). In one embodiment, an arc is formed between consumable wire 5507 and conduits 1022a, 1022b, which heats conduits 1022a, 1022b, causing them to melt and join. In one embodiment, shielding gas is fed through welding torch 5502 along with consumable wire 5507, which shields the welding process from contaminants in the air. In one embodiment, the shielding gas is fed through a welding torch nozzle, which may include a gas cup 5505, to the welding area/zone. In one embodiment, electrode 5507 may extend beyond the end of gas cup 5505.
In one embodiment, shielding gas stored in the drive portion 5010 is brought through a hose/shielding gas line to the line feed assembly 5020 for distribution to one or more welding torches 5502. In one embodiment, shielding gas control valve 5042 is configured to receive shielding gas from rear rotary union 5072 (e.g., via rear slip ring 5080, rotatable hub 5078, and front slip ring 5016). In one embodiment, the shielding gas control valve 5042 is configured to control the flow of shielding gas through the shielding gas line to the welding torch 5502. In one embodiment, each welding torch 5502 has a corresponding shielding gas control valve 5042 connected thereto. In one embodiment, shielding gas control valve 5042 is configured to supply shielding gas to a corresponding welding torch 5502 when it receives a signal from wire feed electronics module 5046.
In one embodiment, welding torch 5502 is configured to be carried by a frame assembly of internal welding system 5004 and is configured to produce a weld at an end of a second end of first conduit 1022 a. In one embodiment, the welding torch 5502 is configured to be positioned internally within the first conduit 1022a and/or the second conduit 1022b to provide an internal welding operation. In one embodiment, the internally positioned welding torch 5502 is mounted to a rotatable hub 5078 (positioned on said rotatable hub 5078) and connected to the rotatable hub 5078.
In one embodiment, the welding torch 5502 may have at least three degrees of freedom. In one embodiment, the freedom of articulation makes the welding torch 5502 very effective and efficient at filling the joint profile optimally and where needed.
Degrees of freedom generally refer to the free movement of the welding torch 5502 in three dimensions. Translational movement or displacement generally refers to linear movement or displacement along three mutually perpendicular X, Y and Z axes.
In one embodiment, the term position as used herein generally refers to translational movement or displacement. In one embodiment, the position may be relative or absolute.
In one embodiment, the coordinate system may include: a Y-axis aligned substantially parallel to the longitudinal axis a-a (shown in fig. 8) of conduits 1022a, 1022 b; an X axis perpendicular to the Y axis; and a Z axis aligned perpendicular to the Y axis and substantially parallel to a radial axis R-R (shown in fig. 8) of conduits 1022a, 1022 b. For example, translational movement along the X-axis generally refers to forward and reverse movement. Translational movement along the Y-axis generally refers to left-to-right movement. Translational movement along the Z-axis generally refers to upward and downward movement.
Rotational movement or displacement generally refers to rotation about these same three mutually perpendicular X, Y and Z axes. Rotation about three mutually perpendicular X, Y and Z axes is commonly referred to as yaw (Z), pitch (Y) and roll (X). For example, rotational movement about the X-axis typically refers to left or right side tilting movement. Rotational movement about the Y-axis generally refers to forward or (backward) reverse tilt movement. Rotational movement about the Z-axis is generally referred to as left turn or right turn movement.
In one embodiment, the term orientation as used herein generally refers to rotational movement or displacement. In one embodiment, the orientation may be relative or absolute.
In one embodiment, the at least three degrees of freedom may include two translational movements of welding torch 5502 along two of three mutually perpendicular X, Y, and Z axes and one rotational movement of welding torch 5502 about one of the same three mutually perpendicular X, Y, and Z axes.
In one embodiment, two translational movements of welding torch 5502 along two of the three mutually perpendicular X, Y, and Z axes may include an upward and downward movement of welding torch 5502 and a side-to-side (e.g., left-to-right) movement of welding torch 5502. In one embodiment, the upward and downward movement of welding torch 5502 may be referred to as a radial movement of welding torch 5502 (i.e., substantially parallel to radial axis R-R of conduits 1022a, 1022 b), and the side-to-side (left-to-right) movement of welding torch 5502 may be referred to as an axial movement of welding torch 5502 (i.e., substantially parallel to longitudinal axis a-a of conduits 1022a, 1022 b).
In one embodiment, a rotational movement of welding torch 5502 about one of the same three mutually perpendicular X, Y, and Z axes may comprise a forward or (backward) reverse tilt movement of welding torch 5502.
In one embodiment, the welding torch 5502 is mounted for movement about a pivot point P (shown in fig. 54, 56, and 58) at or adjacent to the welding tip 5503 of the welding torch 5502 such that a weld pool created at the welding tip 5503 is substantially coincident with the pivot point P. In one embodiment, pivot point P is positioned forward of welding tip 5503. For example, in one embodiment, welding torch 5502 is designed to pivot about a pivot point P (shown in fig. 54, 56, and 58) at which wire 5507 is in contact with conduits 1022a, 1022 b. In one embodiment, welding torch 5502 is mounted for movement such that it articulates about an axis adjacent to welding torch tip 5503. In one embodiment, the axis passes through pivot point P and is substantially parallel to the longitudinal axis a-a of conduits 1022a, 1022 b.
In one embodiment, the welding torch 5502 is operatively connected to one or more welding torch motors 5596. In one embodiment, the one or more welding torch motors 5596 and welding torch 5502 are configured to be positioned within the interior of the first conduit 1022a and/or the second conduit 1022 b. In one embodiment, one or more welding torch motors 5596 are configured to move the welding torch 5502 relative to the first and second conduit engagement structures 5052 and 5054 after the first and second conduit engagement structures 5052 and 5054 are secured relative to the first and second conduits 1022a and 1022b, respectively.
In one embodiment, the one or more processors 5140 are configured to control the one or more welding torch motors 5596 to control the position and orientation of the welding torch 5502. For example, as will be described in detail below, one or more of the welding torch motors 5596 may include: a radial welding torch motor 5512 configured to control the radial position and orientation of the welding torch 5502; an axial welding torch motor 5550 configured to control the axial position and orientation of the welding torch 5502; and a tilt welding torch motor 5588 configured to control the tilt position and orientation of the welding torch 5502.
In one embodiment, the motors 5030 and 5074 are configured to move the welding torch 5502 circumferentially about the joint region 5136 and also to move the verification detector 5056 about the joint region 5136 simultaneously with the welding torch 5502. In one embodiment, the welding torch 5502 follows the verification detector 5056. In one embodiment, the front and rear swivel motors 5030, 5074 are configured to rotate the rotatable hub 5078 and to rotate the welding torch 5502, the verification detector 5056, and the verification camera 5112, all positioned on the rotatable hub 5078 and connected to the rotatable hub 5078. In one embodiment, the front rotational motor 5030 and the rear rotational motor 5074 are interchangeably referred to as circumferential weld torch motors.
In one embodiment, the one or more processors 5140 are operatively connected with the one or more orientation motors 5030 and 5074 to rotate the first clamp 5142 relative to the second clamp 5144 based on instructions from the one or more processors 5140 to rotate the first conduit 1022a relative to the second conduit 1022 b.
In one embodiment, the motors 5030 and 5074 are configured to move the welding torch 5502 circumferentially about the joint region 5136 and are also configured to move the verification detector 5112 about the joint region 5136 simultaneously with the welding torch 5502. In one embodiment, the welding torch 5502 follows the inspection camera 5112. In one embodiment, the inspection camera 5112 follows the welding torch 5502.
In one embodiment, the motors 5030 and 5074 are configured to move the welding torch 5502 circumferentially about the joint region 5136, and are further configured to move both the verification camera 5112 and the verification detector 5056 about the joint region 5136 concurrently with the welding torch 5502. In one embodiment, the welding torch 5502 follows both the verification detector 5056 and the verification camera 5112. In one embodiment, the welding torch 5502 follows the verification detector 5056 and precedes the verification camera 5112.
In one embodiment, the motors 5030 and 5074 are configured to drive the welding torch 5502 in a first rotational direction during root pass welding and to drive the welding torch 5502 in a second direction (opposite the first direction) during hot pass welding.
In one embodiment, the motors 5030 and 5074 are configured to drive the welding torch 5502 at least 360 ° relative to the conduit axis a-a (as shown in fig. 8) to complete a rotationally continuous root channel weld. In one embodiment, 360 ° rotation of the welding torch 5502 relative to the conduit axis a-a (about the interior surface of the conduit) is possible because the welding torch 5502 is mounted on a rotatable hub 5078 (i.e., configured to rotate axially).
In one embodiment, the one or more welding torch motors 5596 are configured to move the welding torch 5502 longitudinally within the conduits 1022a, 1022b (as shown in fig. 48 and 49) toward and away from the inner surfaces 5130, 5132 of the conduits 1022a, 1022b (as shown in fig. 33). In one embodiment, the one or more welding torch motors 5596 are configured to move the welding torch 5502 at an angle relative to the weld (as shown in fig. 56 and 58). In one embodiment, the motors 5030 and 5074 are configured to move the welding torch 5502 circumferentially along the joint region 5136.
In one embodiment, horn assembly 5500 comprises: a radial positioning system 5506 configured to enable radial movement of the welding torch 5502; an axial positioning system 5508 configured to enable axial movement of the welding torch 5502; and a tilt positioning system 5510 configured to enable tilting movement of the welding torch 5502.
In one embodiment, the torch housing assembly 5504 is constructed and arranged to enclose a welding torch 5502, a radial positioning system 5506, an axial positioning system 5508, and a tilt positioning system 5510 therein. In one embodiment, the torch housing assembly 5504 is configured to protect the components of the welding torch 5502 and the various components of its positioning systems 5506, 5508, and 5510 from the welding heat and spatter.
In one embodiment, the torch housing assembly 5504 may comprise a base member 5509 and two side housing members 5511 and 5513. For example, the base member 5509 may be coupled to the side housing members 5511 and 5513 using any suitable fastening mechanism (e.g., fastener member 5527). In one embodiment, the torch housing assembly 5504 may include a first lateral housing member 5522 and an opposing second lateral housing member 5523 constructed and arranged to connect the side housing members 5511 and 5513 to each other at top end portions thereof. For example, the first and second lateral housing members 5522, 5523 may be coupled to the side housing members 5511, 5513 using any suitable fastening mechanism (e.g., fastener member 5525).
In one embodiment, referring to fig. 41-46, the welding torch 5502 is mounted for movement by a radial positioning system 5506 such that the welding tip 5503 is configured to move toward and away from the welding faces 5130, 5132 of the conduits 1022a, 1022 b. In one embodiment, the one or more processors 5140 are configured to control the one or more welding torch motors 5512 to adjust the radial distance of the welding tip 5503 from the joint region 5136 from within the conduits 1022a, 1022 b.
In one embodiment, the one or more processors 5140 are configured to control the one or more welding torch motors 5512 to move the welding tip 5503 radially away from the joint region 5136 after root pass welding so as to contain weld material deposited in the root pass welding and provide hot pass welding (closer to the longitudinal axis a-a) from within the conduits 1022a, 1022b on top of the root pass welding.
In one embodiment, the one or more processors 5140 configured to control the one or more welding torch motors may be part of the wire feed electronics module 5046.
In one embodiment, the radial positioning system 5506 is configured to enable the welding torch 5502 to move radially to track changes in the shape of the conduit, to adjust the welding tip-to-work piece (e.g., conduit) distance for multiple passes (e.g., root pass welding process and hot pass welding process), and to retract away from the conduits 1022a, 1022b as the internal welding system travels.
In one embodiment, radial positioning system 5506 is configured to provide 1.25 inches of radial travel for welding torch 5502. In one embodiment, the welding torch 5502 may be moved between a normal, non-raised configuration and a raised configuration by the radial positioning system 5506. As shown in fig. 43, the welding torch 5502 is raised (to its raised configuration) by the radial positioning system 5506 such that the welding torch 5502 is positioned at the correct/desired/predetermined distance from the conduits 1022a, 1022b for the welding procedure.
In one embodiment, the radial positioning system 5506 may comprise a linear actuator. In one embodiment, the radial positioning system 5506 may include a radial welding torch (electric) motor 5512, a lead screw 5514, and a lead nut 5516. In one embodiment, the motor 5512 is configured (e.g., mechanically coupled) to rotate the lead screw 5514. In one embodiment, the motor 5512 is configured to rotate in a clockwise or counterclockwise direction to cause the welding torch 5502 to raise or lower substantially parallel to a radial axis R-R (shown in fig. 8) of the conduits 1022a, 1022 b. In one embodiment, the motor 5512 is configured to be directly coupled to rotate the lead screw 5514. In another embodiment, the motor 5512 is configured to be indirectly coupled to rotate the lead screw 5514, such as through a series of gears or a gearbox.
In one embodiment, the lead screw 5514 includes threads machined on its outer surface and extending along its length. In one embodiment, the lead nut 5516 is constructed and arranged to be threaded onto the lead screw 5514 and includes complementary threads machined on its inner surface.
In one embodiment, the radial positioning system 5506 includes two front vertical guide members 5518 and 5520 positioned parallel to the lead screw 5514 and on either side of the lead screw 5514. In one embodiment, the front vertical guide rod members 5518 and 5520 are each connected on one end thereof to the base member 5509 of the torch housing assembly 5504 and on the other end thereof to the first cross housing member 5522. In one embodiment, 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 to connect the front vertical guide rod members 5518 and 5520 to the base member 5509 of the torch housing assembly 5504. In one embodiment, end portions of the front vertical guide members 5518 and 5520 are received in openings formed in the first lateral housing member 5522 to connect the front vertical guide members 5518 and 5520 to the first lateral housing member 5522.
In one embodiment, an end portion of the lead screw 5514 (opposite its end portion connected to the motor 5512) is constructed and arranged to pass through an opening 5534 in the first lateral housing member 5522.
In one embodiment, the radial positioning system 5506 includes two rear vertical guide rod members 5600 and 5602 positioned parallel to the lead screw 5514 and two front vertical guide rod members 5518 and 5520. In one embodiment, the rear vertical guide rod members 5600 and 5602 are each connected on one end thereof to a bottom member 5509 of the torch housing assembly 5504 and on the other end thereof to a second lateral housing member 5523. In one embodiment, end portions of the rear vertical guide rod members 5600 and 5602 are received in openings formed in the bottom member 5509 of the torch housing assembly 5504 to connect the rear vertical guide rod members 5600 and 5602 to the bottom member 5509 of the torch housing assembly 5504. In one embodiment, end portions of the rear vertical guide rod members 5600 and 5602 are received in openings formed in the second lateral housing member 5523 to connect the rear vertical guide rod members 5600 and 5602 to the second lateral housing member 5523.
In one embodiment, the radial positioning system 5506 also includes one lateral radial positioning member 5524 and two vertical radial positioning members 5526. In one embodiment, two vertical radial positioning members 5526 are connected to two end portions of the lateral radial positioning member 5524. In one embodiment, the lateral radial positioning member 5524 and the two vertical radial positioning members 5526 of the radial positioning system 5506 are configured to be movable during radial movement of the welding torch 5502.
In one embodiment, the lateral radial positioning members 5524 may have protruding end portions 5528 configured to engage with notches or protruding end portion receiving openings 5530 of two vertical radial positioning members 5526. In one embodiment, after the protruding end portions 5528 of the lateral radial positioning member 5524 are received in the notches or protruding end portion receiving openings 5530 of the two vertical radial positioning members 5526, the lateral radial positioning member 5524 and the two vertical radial positioning members 5526 may then be fixedly connected to each other using any suitable fastening mechanism (e.g., fastener member 5532).
In one embodiment, the lateral radial positioning member 5524 includes openings to receive the front vertical guide rod members 5518 and 5520 therethrough. This configuration allows the lateral radial positioning member 5524 to be slidable to adjust the position on the front vertical guide rod members 5518 and 5520. In one embodiment, the lead screw 5514 is configured to pass through a central opening 5536 of the lateral radial positioning member 5524.
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 radial positioning members 5604 and 5606 and the two vertical radial positioning members 5526 of the radial positioning system 5506 are configured to be movable during radial movement of the welding torch 5502.
In one embodiment, each trailing radial positioning member 5604 and 5606 has an end portion configured to engage with an end portion of its corresponding vertical radial positioning member 5526. In one embodiment, after the end portions of the trailing radial positioning members 5604 and 5606 are engaged with the end portions of the two vertical radial positioning members 5526, each trailing radial positioning member 5604 and 5606 may then be fixedly coupled to its corresponding vertical radial positioning member 5526 using any suitable fastening mechanism (e.g., fastener member 5608).
In one embodiment, posterior radial positioning members 5604 and 5606 include openings to receive posterior vertical guide rod members 5600 and 5602, respectively, therethrough. This configuration allows rear radial positioning members 5604 and 5606 to be slidable to adjust the position on rear vertical guide rod members 5600 and 5602.
In one embodiment, the lead nut 5516 is configured to interlock with a portion of the lateral radial positioning member 5524 such that the lead nut 5516 is prevented from rotating with the lead screw 5514. That is, the lead nut 5516 is constrained from rotating with the lead screw 5514, and thus the lead nut 5516 is configured to travel up and down the lead screw 5514. In one embodiment, the lead nuts 5516 interlock and are positioned in the central opening 5536 of the lateral radial positioning member 5524. In one embodiment, the lead screw 5514 is configured to pass through an opening of the interlock lead nut 5516.
In one embodiment, two vertical radial positioning members 5526 are connected to each other using a front lateral support member 5610 and a rear lateral support member 5612. For example, the forward lateral support member 5610 is constructed and arranged to be connected to forward and bottom portions of the two vertical radial positioning members 5526 using any suitable fastening mechanism (e.g., fastener member 5614). The rear lateral support member 5612 is constructed and arranged to be connected to the rear and bottom portions of the two vertical radial positioning members 5526 using any suitable fastening mechanism (e.g., fastener member 5616).
In one embodiment, the welding assembly 5500 further includes two vertical positioning members 5538 and a top positioning member 5540. In one embodiment, two vertical positioning members 5538 are each connected to an end portion of the top positioning member 5540. In one embodiment, the end portions of the top positioning member 5540 may each have an L-shaped configuration. In one embodiment, the corresponding connection portions of the two vertical positioning members 5538 may comprise a complementary shaped configuration configured to engage with the L-shaped configuration of the end portion of the top positioning member 5540. In one embodiment, after the L-shaped configuration of the end portion of the top positioning member 5540 engages the complementary shaped configuration of the corresponding connecting portion of the two vertical positioning members 5538, the top positioning member 5540 and the two vertical positioning members 5538 may then be fixedly connected to each other using any suitable fastening mechanism (e.g., fastener member 5542).
In one embodiment, axial positioning system 5508 is configured to enable welding torch 5502 to move axially to maintain welding torch 5502 in a welding slope as welding torch 5502 travels around a pipe and to allow welding torch 5502 to oscillate within a welding slope if it is desired to completely fill the slope.
Fig. 47 shows welding torch 5502 positioned in a normal centered axial position. In one embodiment, axial positioning system 5508 is configured to provide +/-1 inch of axial travel for welding torch 5502. For example, as shown in fig. 48 and 49, welding torch 5502 is moved to +1 inch of axial travel and-1 inch of axial travel, respectively, by axial positioning system 5508 such that welding torch 5502 is positioned at the correct/desired/predetermined distance from the pipe for welding.
Fig. 50 and 51 show left side perspective and exploded views of welding head assembly 5500, wherein some of the components of welding head assembly 5500 are not shown for clarity. Fig. 52 shows a bottom perspective view of the top positioning member 5540 of the weld head assembly. Fig. 53 illustrates a top elevation view of horn assembly 5500, where some of the components of horn assembly 5500 are not shown for clarity.
In one embodiment, referring to fig. 50-53, axial positioning system 5508 may be a linear actuator. In one embodiment, the axial positioning system 5508 may include an axial welding torch (electric) motor 5550, a lead screw 5552, and a lead nut 5554. In one embodiment, the structure, configuration, and operation of each of the motor 5550, lead screw 5552, and lead nut 5554 of the axial positioning system 5508 are similar to the motor 5512, lead screw 5514, and lead nut 5516 of the radial positioning system 5506, and therefore, are not described in detail herein. In one embodiment, the lead nut 5554 is driven along the threads as the lead screw 5552 is rotated by the motor 5550.
In one embodiment, the axial positioning system 5508 includes two horizontal guide members 5556 and 5558 positioned parallel to the horizontally positioned lead screw 5552 and positioned on either side of the horizontally positioned lead screw 5552. In one embodiment, each of the horizontal guide members 5556 and 5558 is connected at both ends thereof to a top positioning member 5540. In one embodiment, end portions of the horizontal guide members 5556 and 5558 are received in openings formed in the top positioning member 5540 to connect the horizontal guide members 5556 and 5558 with the top positioning member 5540. In one embodiment, at least one end portion of each of the horizontal guide members 5556 and 5558 includes a protruding member 5560 configured to be received in a corresponding protruding member receiving portion 5562 formed in an opening of the top positioning member 5540 to secure the horizontal guide members 5556 and 5558 with the top positioning member 5540.
In one embodiment, welding head assembly 5500 includes a welding torch frame 5564 configured to receive welding torch 5502 therein. In one embodiment, the welding torch frame 5564 includes three horizontally extending openings 5566, 5568, and 5570 and one vertically extending opening 5572 formed therein. In one embodiment, the horizontal guide members 5556 and 5558 are configured to pass through openings 5566 and 5570, respectively, of the welding torch frame 5564. In one embodiment, the horizontally positioned lead screw 5552 is configured to pass through an opening 5568 of the welding torch frame 5564. In one embodiment, the welding torch 5502 is configured to pass through an opening 5572 of a welding torch frame 5564. In one embodiment, the welding torch frame 5564 may include a support portion 5574, the support portion 5574 configured to support a portion of the welding torch 5502 when the welding torch 5502 is received in the opening 5572 of the welding torch frame 5564.
In one embodiment, a portion 5584 of the welding torch frame 5564 is configured to engage a portion 5586 of the welding torch 5502 to prevent any rotation of the welding torch 5502 when the welding torch 5502 is received in the opening 5572 of the welding torch frame 5564.
In one embodiment, the motor 5550 is configured (e.g., mechanically coupled) to rotate the lead screw 5552. In one embodiment, the motor 5512 is configured to rotate in a clockwise or counterclockwise direction to cause left or right side movement of the welding torch 5502 substantially parallel to the axial axis a-a (shown in fig. 8) of the conduits 1022a, 1022 b. In one embodiment, the motor 5550 is configured to be indirectly coupled to rotate the lead screw 5552, for example, through a series of gears 5576, 5578, and 5580. That is, the motor 5550 includes an output shaft 5582, and the motor 5550 is operatively connected to the lead screw 5552 through gears 5576, 5578, and 5580 that engage the output shaft 5582 of the motor 5550. In one embodiment, the gear 5576 is connected to an output shaft 5582 of the motor 5550, the gear 5580 is connected or attached to the lead screw 5552, and the gears 5576 and 5580 are coupled to each other by the gear 5578. By coupling the motor 5550 to the lead screw 5552 through gears 5576, 5578 and 5580, the lead screw 5552 rotates when the motor 5550 operates. In another embodiment, the motor 5550 is configured to be directly coupled (i.e., without a gear arrangement) to rotate the lead screw 5552.
In one embodiment, the lead nut 5554 is configured to interlock with a portion of the welding torch frame 5564 such that the lead nut 5554 is prevented from rotating with the lead screw 5552. That is, the lead nut 5554 is constrained from rotating with the lead screw 5552, and thus the lead nut 5554 is configured to travel/move side-to-side (i.e., substantially parallel to the axial direction Y-Y as shown in fig. 53) with the lead screw 5552. In one embodiment, the lead nuts 5554 interlock and are positioned in the opening 5568 of the welding torch frame 5564. In one embodiment, the lead screw 5552 is configured to pass through an opening of the interlock lead nut 5554.
In one embodiment, the tilt positioning system 5510 is configured to enable the welding torch 5502 to change its tilt angle in the plane of travel to account for changes in the direction of welding relative to the direction of gravity. In one embodiment, the tilt angle of welding torch 5502 may be changed to accommodate gravity. In one embodiment, the tilt angle of the welding torch 5502 may be adjusted to compensate for the different orientations due to gravity. In one embodiment, the angular orientation of the welding torch 5502 is controlled based on the profile of the joint area. In one embodiment, the tilt angle of the welding torch 5502 may be adjusted based on dynamic weld profile data. In one embodiment, the tilt angle of welding torch 5502 may be adjusted to accommodate and/or compensate for other welding conditions (i.e., not just gravity) based on dynamic weld profile data.
Because the welding torch is able to articulate during the welding operation, the gravitational forces acting on the weld pool can be taken into account as the welding torch rotates about the fixed pipe. Specifically, the angle of the welding torch may be changed by at least one welding torch motor (i.e., the tilted welding torch motor 5588) based on whether the welding torch is operating against gravity traveling up or as gravity traveling down. One or more motors (e.g., tilt welding torch motor 5588) may also change the welding angle within the plane of rotation based on a particular position within the upward or downward travel of the welding torch. It should be appreciated that because the welding torch may articulate for some embodiments, it may be better angled to accommodate gravity and need not be disposed in a fixed position based on an assumption that, for example, the welding torch travels only downward with gravity. In some embodiments, as described above, the present application contemplates that welding may be accomplished while the welding torch is moved up (against gravity) or down (with gravity). Further, the welding torch may be articulated based on different rotational positions (e.g., a welding operation performed at 10 degrees from top dead center may have slightly different requirements than a weld performed at 90 degrees from top dead center due to, for example, gravity applied to the weld pool and the tendency of the weld pool to adhere differently to the interior surface of the pipe at different locations on the pipe to be welded).
In one embodiment, the motors 5030 and 5074 of the pilot check detector 5056 also rotate the welding torch 5502 circumferentially about the plane of rotation to produce a weld along the joint region 5136. In one embodiment, the tilt positioning motor 5588 angularly articulates the welding torch 5502 generally within a plane of rotation. In one embodiment, the angular orientation of welding torch 5502 is controlled based on the position of the torch. In one embodiment, the welding torch 5502 is configured to pivot about a plane of rotation along a weld joint.
In one embodiment, welding torch 5502 may be configured such that welding torch 5502 may include a different torch tilt angle for each 90 ° rotation. For example, in one embodiment, welding torch 5502 may include an inclination angle 1 when performing a welding procedure in portion boundary 1 from the 2 o 'clock position to the 5 o' clock position, welding torch 5502 may include an inclination angle 2 when performing a welding procedure in portion boundary 2 from the 5 o 'clock position to the 8 o' clock position, welding torch 5502 may include an inclination angle 3 when performing a welding procedure in portion boundary 3 from the 8 o 'clock position to the 11 o' clock position, and welding torch 5502 may include an inclination angle 4 when performing a welding procedure in portion boundary 4 from the 11 o 'clock position to the 2 o' clock position. In one embodiment, welding torch 5502 may be configured such that welding torch 5502 may include a different torch tilt angle for each 30 ° rotation. In one embodiment, welding torch 5502 may be configured such that welding torch 5502 may include a different torch tilt angle for each 60 ° rotation. In one embodiment, welding torch 5502 may be configured such that welding torch 5502 may include a different torch tilt angle for each 120 ° rotation. In one embodiment, welding torch 5502 may be configured such that welding torch 5502 may include different torch tilt angles for any desired degree of rotation.
In one embodiment, welding torch 5502 may be configured to have a continuously variable torch tilt angle to compensate for or accommodate a continuously varying orientation of the welding torch due to gravity. In one embodiment, welding torch 5502 may be configured to progressively change the torch tilt angle based on the position of the welding torch (i.e., the position of the welding torch along the circumferential weld).
Figure 54 illustrates welding torch 5502 positioned in a normal, non-tilted position. In one embodiment, the tilt positioning system 5510 is configured to provide an angular tilt of +/-5 ° for the welding torch 5502. For example, as shown in fig. 55 and 56, the welding torch 5502 is moved to an angular tilt of +5 ° by the tilt positioning system 5510 such that the welding torch 5502 is positioned at a correct/desired/predetermined distance from the pipe for welding. As shown in fig. 57 and 58, welding torch 5502 is accordingly moved to an angular tilt of-5 ° by tilt positioning system 5510 such that welding torch 5502 is positioned at a correct/desired/predetermined distance from the conduit for welding. In another embodiment, the tilt positioning system 5510 is configured to provide an angular tilt of +/-7 ° for the welding torch 5502. In one embodiment, the tilt positioning system 5510 is configured to provide an angular tilt of less than +/-5 ° to the welding torch 5502.
In one embodiment, the circumferential arc between the pivot point P and the point of impingement PI of the test radiation beam on the joint region (as shown in fig. 56 and 58) remains substantially constant during the welding process. In one embodiment, the one or more processors 5140 learn a constant arc distance between pivot point P (e.g., welding tip) and the verification point PI such that the one or more processors 5140 are configured to control the articulation and pivotal movement of the welding torch 5502 based on the pre-weld profile verification data.
The configuration of welding torch 5502 that enables welding torch 5502 to pivot about pivot point P allows the angle of welding torch 5502 to be changed while welding without affecting the speed at which welding torch 5502 travels. This is particularly useful, for example, for welding systems having multiple welding torches. In one embodiment, the welding torch does not change its angle at the same time, in which case it is beneficial to change the torch angle without any adverse effect on the other welding torches.
In one embodiment, the tilt positioning system 5510 includes a tilt welding torch motor 5588, a guide rail member 5544, and a guide roller 5546. In one embodiment, rail member 5544 is configured to engage guide roller 5546 to facilitate angular positioning of welding torch 5502. In the illustrated embodiment, guide rollers 5546 can include two upper guide rollers and two lower guide rollers. In one embodiment, the tilt positioning system 5510 includes a rail member 5544 and its four associated guide rollers 5546 positioned on opposite sides of the welding torch assembly 5500.
In one embodiment, the guide rollers 5546 are constructed and arranged to connect to their corresponding vertical positioning members 5538. In one embodiment, each vertical radial positioning member 5526 is configured to connect with a corresponding rail member 5544 using any suitable fastening mechanism (e.g., fastener member 5548). This configuration connects each vertical radial positioning member 5526 to a corresponding vertical positioning member 5538 through the engagement of a corresponding guide rail member 5544 and guide roller 5546.
In one embodiment, motor 5588 is configured (e.g., mechanically coupled) to rotate gear 5590. In one embodiment, the motor 5588 is configured to rotate in a clockwise or counterclockwise direction to cause the welding torch 5502 to make a forward or backward tilting movement. In one embodiment, motor 5588 is configured to be coupled to rail member 5544, for example, via gear 5590. That is, the motor 5588 includes an output shaft 5592, and the gear 5590 is connected to the output shaft 5592 of the motor 5588. By coupling the motor 5588 to the rail member 5544 through the gear 5590, the rail 5544 moves when the motor 5588 operates.
In one embodiment, guide rail member 5544 is configured to guide upper guide roller 5546 and lower guide roller 5546. In one embodiment, upper and lower guide rollers 5546, 5546 are biased against guide rail members 5544 such that upper and lower guide rollers 5546, 5546 are configured to cause movement of a corresponding vertical positioning member 5538 (connected thereto) and thereby enable welding torch 5502 to change its tilt angle in the plane of travel.
In one embodiment, two opposing vertical positioning members 5538 are connected to each other by a top positioning member 5540 such that movement of one of the vertical positioning members 5538 (i.e., caused by the motor 5588) causes similar movement of the other of the vertical positioning members 5538. The configuration of the two horizontal guide members 5556 and 5558 connected at both ends thereof to the top positioning member 5540 also facilitates the transfer of movement from one of the vertical positioning members 5538 to the other.
The operation of the radial positioning system 5506 is discussed in detail below. When the lead screw 5514 is rotated by the motor 5512, the lead nut 5516 is driven along the thread. In one embodiment, the direction of movement of the lead screw nut 5516 is dependent on the direction of rotation of the lead screw 5514 caused by the motor 5512.
Because the lead nut 5516 is interlocked in the opening 5536 of the lateral radial positioning member 5524, the lateral radial positioning member 5524 is configured to travel/move (up or down) on the lead screw 5514 with the lead nut 5516. The slidable engagement between the lateral radial positioning member 5524 and the front vertical guide members 5518 and 5520 also facilitates this (up or down) travel/movement of the lateral radial positioning member 5524.
Additionally, because the lateral radial positioning member 5524 is connected to the two vertical radial positioning members 5526, movement (up or down) of the lateral radial positioning member 5524 causes movement (up or down) of the two vertical radial positioning members 5526.
The two vertical radial positioning members 5526 are also connected to two rear radial positioning members 5604 and 5606. Movement (up or down) of the two vertical radial positioning members 5526 causes movement (up or down) of the two rear radial positioning members 5604 and 5606 on the rear vertical guide rod members 5600 and 5602. The slidable engagement between the rear radial positioning members 5604 and 5606 and the rear vertical guide rod members 5600 and 5602 also facilitates the travel/movement (up or down) of the two vertical radial positioning members 5526.
As discussed above, each vertical radial positioning member 5526 is connected with a corresponding vertical positioning member 5538 through engagement of the corresponding guide rail member 5544 and guide roller 5546. Thus, movement (up or down) of each vertical radial positioning member 5526 also causes movement (up or down) of its corresponding vertical positioning member 5538. Because the two vertical positioning members 5538 are fixedly connected to the top positioning member 5540, movement (up or down) of the two vertical positioning members 5538 causes movement (up or down) of the top positioning member 5540.
Because the welding torch 5502 is coupled to the top positioning member 5540 by the horizontal lead screw 5552, the two horizontal guide rod members 5556 and 5558, and the welding torch frame 5564, movement of the top positioning member 5540 (up or down) also causes movement of the welding torch 5502 (up or down). Thus, welding torch 5502 is mounted for movement by radial positioning system 5506 such that welding tip 5503 is configured to move toward and away from the welding surface of conduits 1022a, 1022 b.
The operation of the axial positioning system 5508 is discussed in detail below. When the lead screw 5552 is rotated by the motor 5550 via gears 5576, 5578 and 5580, the lead nut 5554 is driven along the threads. In one embodiment, the direction of movement of the lead nut 5554 is dependent on the direction of rotation of the lead screw 5552 caused by the motor 5550.
Because the guide nut 5554 interlocks in the opening 5568 of the welding torch frame 5564, the welding torch frame 5564 is configured to travel/move (edge-to-edge) with the guide nut 5554. The slidable engagement between the welding torch frame 5564 and the horizontal guide members 5556 and 5558 also facilitates this (side-to-side) travel of the welding torch frame 5564. The slidable engagement between the two horizontal guide members 5556 and 5558 and the welding torch frame 5564 also facilitates (side-to-side) travel of the welding torch frame 5564 (and welding torch 5502). In one embodiment, the amount of axial movement of the welding torch frame 5564 is limited by an elongated opening 5594 in the top positioning member 5540.
The operation of the tilt positioning system 5510 is discussed in detail below. As gear 5590 is rotated by motor 5588, rail member 5544 is driven along the gear teeth. In one embodiment, the direction of movement of track member 5544 is dependent upon the direction of rotation of gear 5590 caused by motor 5588.
In one embodiment, upper and lower guide rollers 5546, 5546 biased against guide rails 5544 are configured to cause movement/tilting of corresponding vertical positioning members 5538 (connected to guide rollers 5546).
In one embodiment, the configuration of two opposing vertical positioning members 5538 connected to each other by a top positioning member 5540 is such that movement of one of the vertical positioning members 5538 (i.e., caused by the motor 5588) causes similar movement of the other of the vertical positioning members 5538. The configuration of the two horizontal guide members 5556 and 5558 connected at both ends thereof to the top positioning member 5540 also facilitates the transfer of movement from one of the vertical positioning members 5538 to the other.
This movement enables the welding torch 5502 (connected to the two horizontal guide members 5556 and 5558 by the welding torch frame 5564) to change the angle of inclination of the welding torch 5502 in the plane of travel as the vertical positioning member 5538 and the top positioning member 5540 (along with the two horizontal guide members 5556 and 5558) move/tilt.
As noted herein, the welding torch is mounted for movement in a manner such that when it is driven by the tilting welding torch motor 5588, the welding torch articulates or pivots about a point at or slightly forward of the tip of the welding torch. For example, the welding torch tip may articulate about a point disposed in a weld pool created by the welding torch tip during a welding operation. Thus, the position of the weld pool does not change relative to the radius drawn for the weld pool, despite the fact that the welding torch may be articulated by tilting the welding torch motor. Thus, the arc length between the weld pool and the point at which the radiation beam emitted from the inspection laser impinges on the inner surface of the pipe to be welded (e.g., at the joint area) remains constant as the orientation motor rotates the welding torch and the inspection laser, regardless of the articulation of the welding torch by the tilt welding torch motor. And because the speed and orientation motors are also controlled and known by the one or more processors, knowing the fixed arc length and calculating the detected weld profile at the upcoming area in front of the welding tip based on the processor, the one or more processors can control the welding parameters at a particular area of the joint area. In one embodiment, the orientation motor is provided with an angular encoder operatively connected to the one or more processors to enable the one or more processors to determine the rotational position of the motor and thus the clamp and the pipe. In another embodiment, signals from a test detector (e.g., a test laser) are used to detect movement of the welded pipe, where such signals are used by one or more processors that know the fixed arc length to control the welding torch at the appropriate position corresponding to the determined position of the welding torch. In another embodiment, the point at which the welding torch is articulated need not be at a position in front of or at the welding tip, and the arc length between the weld pool and the point at which the inspection laser beam impinges on the joint area need not remain constant. Rather, one or more processors that receive positional information of the welding torch tip from the one or more welding torch motors and/or the inspection detector are used to calculate in real time ("dynamically") the actual position of the welding tip relative to the pipe based on profile data received from the inspection detector in order to control the one or more welding torch motors to position the welding torch tip in a desired position.
As noted herein, the welding torch is mounted for movement or driving in a generally radial direction along a longitudinal axis of the welding torch tip toward or away from an interior surface of the welded pipe by one or more motors. It should be understood that because the longitudinal axis of the welding torch (e.g., through its welding torch tip) may not be aligned with the radius of the pipe being welded (as taken from the central axis) or the radius of the rotatable central hub due to the fact that the welding torch is generally angled in the forward welding direction (and articulated by the tilting welding torch motor 5588), when referring to the "radial" movement of the welding torch and its tip toward and away from the interior surface of the pipe (e.g., the joint area), such radial movement is used in the context described above. For example, such radial movement of the welding torch may be considered to refer to longitudinal movement of the welding torch along the welding torch tip axis. Because the welding torch is mounted for movement by at least one welding torch motor, and specifically radial welding torch motor 5512, to enable the torch tip to move toward and away from the weld surface, the welding tip may move further away from the joint area after each weld pass to accommodate build-up of welding material. After the first and second pipe engaging structures are secured relative to the pipe, the welding torch may be used to complete a full root weld pass, which is the first weld (e.g., one full 360 degree weld) applied between the pipe ends. After the root pass is completed, the weld tip may be moved (retracted) slightly away from the interior surface of the pipe (and specifically away from the applied root pass weld material) so that a second weld pass (also referred to as a "hot" pass weld) may be performed using the weld tip at an appropriate distance from the root pass weld material.
In one embodiment, the one or more processors 5140 operate the motors 5030 and 5074 and the one or more welding torches 5502 to create a full circumferential weld along the joint region 5136 by rotating the one or more welding torches 5502 in a single rotational direction along the joint region 5502 until the full circumferential weld is completed.
In one embodiment, the one or more welding torches 5502 comprise a plurality of welding torches. In one embodiment, at least one of the plurality of welding torches welds in an upward rotational direction while at least another of the plurality of welding torches welds in a downward rotational direction.
In one embodiment, the welding tip is configured to point in a welding direction. In one embodiment, the welding torch is always pointed in the direction of travel. That is, basically, the welding tip is directed substantially in the direction of travel. In one embodiment, the welding torch tilt angle is slightly higher when welding torch 5502 is performing an up-hill welding procedure (where welding torch 5502 is welding in an upward rotational direction), and is slightly lower when a down-hill welding procedure (where welding torch 5502 is welding in a downward rotational direction).
In one embodiment, the internal welding system is configured to perform a downhill welding procedure (i.e., welding in a downward rotational direction) when a short arc welding procedure is used.
In one embodiment, when the internal welding system is configured to perform an up-hill welding process (i.e., welding in an upward rotational direction), the productivity and quality of the weld may be improved. In one embodiment, the uphill welding process is configured to provide the option of welding both sides of the pipe simultaneously, rather than performing the downhill welding process on each side in sequence. For example, this may be a multiple welding torch operation and have multiple weld overlaps. Alternatively, this may provide the option of welding 360 ° in one continuous pass to produce a weld with only one overlap. In one embodiment, customer requirements and pipe size may dictate which method is used.
In one embodiment, welding may be performed using as many welding torches as the welding torch can fit within the pipe unless there is a quality requirement to have only one weld overlap joint. In one embodiment, internal welding system 5004 may include four welding torches, six welding torches, or eight welding torches, where half of the welding torches perform welding in a downward rotational direction and the other half of the welding torches perform welding in an upward rotational direction. In one embodiment, half of the welding torches are configured to perform a clockwise welding procedure and the other half of the welding torches are configured to perform a counterclockwise welding procedure. In one embodiment, the four welding torches of internal welding system 5004 may be positioned 90 ° apart from each other and configured to each rotate 90 °. In one embodiment, the six welding torches of internal welding system 5004 may be positioned 60 ° apart from each other and configured to each rotate 60 °. In one embodiment, eight welding torches of internal welding system 5004 may be positioned 45 ° apart from each other and configured to each rotate 45 °. In one embodiment, internal welding system 5004 may include two welding torches positioned 180 ° apart from each other and configured to each rotate 180 °. In one embodiment, internal welding system 5004 may include a welding torch configured to rotate 360 °.
The ability to weld in both the upward and downward directions can increase the welding operation speed (weld throughput time) and also improve the weld quality (by taking into account gravity at different locations). Additionally, where multiple welding torches are provided, welding may occur simultaneously up and down (e.g., multiple circumferentially spaced welding torches moving in the same rotational direction and applying welding material simultaneously), with at least one welding torch moving up while at least one other welding torch moves down. This is time efficient, for example, compared to performing downhill welding on each side of the pipe in turn. Alternatively, in one embodiment, a single welding torch may be used to perform a single 360 degree weld to provide an overlapping continuous weld with no welded portions. This overlap occurs when more than one welding torch is used, and the end of each weld joint portion from the following welding torch needs to be connected to and slightly overlap the open end of the weld joint portion applied by the welding torch preceding the following welding torch. Thus, continuous 360 degree internal welding may be useful for some applications where it may be desirable to avoid welding overlap portions (which make the weld path less uniform at the overlap point).
In one embodiment, all of the welding torches are directed in a forward welding direction. In other words, they point slightly in the direction of the weld, so that the welding torch tip "pushes" the weld instead of following it. This is true whether the welding torch is positioned internally, as in some embodiments, or externally, as in other embodiments described herein. This is illustrated with reference to an internal welder, as shown in FIG. 56A. In one embodiment, the welding torch tip is directed at an angle θ (e.g., a "lead-in angle") between 3 degrees and 7 degrees. The lead-in angle θ is defined as the angle measured between a line (radius) R from the axial center of the welding pipe to the welding torch tip (or weld pool), as shown in fig. 56A (line R can also be considered as a radius taken from the axial center of the rotating hub 5078 to the torch tip or weld pool) and a line passing through the longitudinal axis a of the welding torch tip. In the illustration of fig. 56A, the welding torch is rotationally moved in a counterclockwise direction (as depicted by arrow D). This lead-in angle θ may be changed by operation of the tilting welding torch motor 5588 as the welding torch is moved circumferentially around the interior of the pipe by the orientation motor. It is expected that lead-in angle θ is slightly higher (e.g., 6 degrees) when the welding torch is traveling upward, and slightly lower (e.g., 4 degrees) when traveling downward. Further, in one embodiment, lead-in angle θ may be continuously varied throughout the travel of a particular welding torch. In another embodiment, the pipe may be divided into sectors, wherein the weld angle θ varies based on the sectors. For example, when considering a full 360 degree movement to correspond to the hour hand on a clock, the duct may be divided into various o' clock sectors: 2-5, 5-8, 8-11 and 11-2. The one or more motors are operable by the one or more processors to change at the sector boundary.
As can be seen from fig. 56A, the welding is carried out in the depicted depiction in the counterclockwise direction. For welding in the clockwise direction, the one or more processors 5140 sends a signal to the one or more torch motors causing the gear 5590 to rotate and the welding torch 5502 to pivot (e.g., about point P) causing an axis through the torch (line a) to move on the opposite side of the radial line R. Thus, the angle θ will be negative for a clockwise weld. This enables the welding torch to point in a forward direction ("pushing" the weld pool) while welding in a clockwise direction.
In one embodiment, as shown in fig. 60A-63, an internal welding system 5004 can include a welding torch WT, a camera C and two inspection detectors L1And L2. In one embodiment, the welding torch WT and the camera C are separated by an angle of 180. In one embodiment, the angle between the camera and the welding torch WT may vary.
In one embodiment, two test detectors L1And L2May be a lead inspection detector configured to precede the welding torch WT during a welding procedure and also provide pre-weld data. In one embodiment, two test detectors L 1And L2Can be a follow-up check detector configured to follow the welding torch WT during a welding procedure and provide post-weld data.
In one embodiment, the test detector L1And the welding torch WT is separated by an angle of 20 deg.. In one embodiment, the test detector L2And the welding torch WT is separated by an angle of 20 deg.. In one embodiment, the test detector L2Angle and checking detector L with welding torch WT1The angle to the welding torch WT may vary.
In one embodiment, the test detector L2Angle and checking detector L with welding torch WT1The angle to the welding torch WT may be adjustable. For example, in one embodiment, when L1If it is a leading test detector, then the test detector L1An angle of 20 DEG or less with the welding torch WT and follow the inspection detector L2The angle to the welding torch WT is greater than 20. In one embodiment, when L2If it is a leading test detector, then the test detector L2An angle of 20 DEG or less with the welding torch WT and follow the inspection detector L1The angle to the welding torch WT is greater than 20.
In one embodimentAs shown in fig. 60A, the detector L is inspected1Is positioned at its starting position. In one embodiment, referring to FIG. 60B, when the welding torch WT is positioned at the beginningWTAt this time, the welding torch WT starts the welding process. In one embodiment, the welding torch WT is configured to be in a clockwise direction (as indicated by arrow T) during a welding procedure1Indicated) travel. In one embodiment, referring to FIG. 61, when the welding torch WT comes to a stopWTWhen the welding torch WT ends the welding process. In one embodiment, when the welding torch WT is at arrow T1In the indicated clockwise direction from the beginningWTGo to stopWTWhile, the weld bead WB1Formed by a welding torch WT. In one embodiment, as shown in FIGS. 60B and 61, at torch WT at arrow T1In the indicated clockwise direction from the beginningWTGo to stopWTIn the process, the welding torch WT follows the inspection detector L1. After the welding process, the welding torch WT is in a counterclockwise direction (i.e., with arrow T)1In the opposite direction) so that the inspection detector L is moved2Is positioned again at the beginning of its starting positionWTTo (3).
In one embodiment, referring to FIG. 62, when the welding torch WT is positioned at the beginning WTAt this time, the welding torch WT starts the welding process. In one embodiment, the welding torch WT is configured to be in a counterclockwise direction (as indicated by arrow T) during a welding procedure2Indicated) travel. In one embodiment, referring to FIG. 63, when the welding torch WT comes to a stopWTWhen the welding torch WT ends the welding process. In one embodiment, the welding torch WT starts when it is in the counterclockwise direction indicated by arrow T2WTGo to stopWTWhile, the weld bead WB2Formed by a welding torch WT. In one embodiment, as shown in FIGS. 62-63, at the welding torch WT at arrow T2From the beginning in the indicated counterclockwise directionWTGo to stopWTIn the process, the welding torch WT follows the inspection detector L2. After the welding process, the welding torch WT is in a clockwise direction (i.e., opposite to arrow T)2In the opposite direction) Is moved so that the laser L1Is positioned again at the beginning of its starting positionWTTo (3).
In one embodiment, as shown in fig. 64-69, the internal welding system 5004 may include two welding torches WT1And WT2A camera C and a test detector L. In one embodiment, the inspection detector L and the welding torch WT are1At an angle of 20 deg. apart. In one embodiment, the inspection detector L and the welding torch WT are 2At an angle of 20 deg. apart. In one embodiment, inspection detector L and camera C are separated by an angle of 180.
In one embodiment, as shown in fig. 64, the inspection detector L is positioned at its start position. In one embodiment, referring to FIG. 65, when welding torch WT is welded1Is positioned at the beginningWT1While in operation, the welding torch WT is welded1The welding process is started. In one embodiment, the welding torch WT is comprised of a plurality of welding torch heads1Is configured to be in a clockwise direction (as indicated by arrow T) during the welding process1Indicated) travel. In one embodiment, referring to FIG. 66, the welding torch WT is welded while the welding torch WT is being welded1Arrival stopWT1Welding torch WT1And finishing the welding process. In one embodiment, as shown in FIG. 66, the welding torch WT is welded while the welding torch WT is being welded1At the arrow T1In the indicated clockwise direction from the beginningWT1Go to stopWT1While, the weld bead WBWT1By welding torches WT1And (4) forming. In one embodiment, as shown in FIGS. 64-66, at the welding torch WT1At the arrow T1In the indicated clockwise direction from the beginningWT1Go to stopWT1In the process of (1), welding torch WT1Following the check detector L. After the welding process, the welding torch WT is welded1In the counterclockwise direction (i.e., with arrow T)1In the opposite direction) so that the inspection detector L is positioned at its start position again, as shown in fig. 67.
In one embodiment, referring to FIG. 68, when welding torch WT is welded2Is positioned at the beginningWT2While in operation, the welding torch WT is welded2The welding process is started. In one embodiment of the process of the present invention,welding torch WT2Is configured to be in a counterclockwise direction (as indicated by arrow T) during the welding process2Indicated) travel. In one embodiment, referring to FIG. 69, when welding torch WT is welded2Arrival stopWT2Welding torch WT2And finishing the welding process. In one embodiment, the welding torch WT is welded while the welding torch WT is being welded2Starting in the counterclockwise direction as indicated by the arrow T2 shown in fig. 69WT2Go to stopWT2While, the weld bead WBWT2By welding torches WT2And (4) forming. In one embodiment, as shown in FIGS. 68-69, at welding torch WT2At the arrow T2From the beginning in the indicated counterclockwise directionWT2Go to stopWT2In the process of (1), welding torch WT2Following the check detector L. After the welding process, the welding torch WT is welded2In the clockwise direction (i.e. with arrow T)2In the opposite direction) so that the inspection detector L is positioned at its start position again, as shown in fig. 64 and 67.
In one embodiment, internal welding system 5004 may include a welding torch and an inspection detector. In one embodiment, the angle between the inspection detector and the welding torch may be 20 ° or less. In one embodiment, the inspection detector and the welding torch may be separated by an arc length AL of 3 inches (as shown in fig. 64). In one embodiment, the inspection detector and the welding torch may be separated by an arc length AL of 4 inches. In one embodiment, the angle between the inspection detector and the welding torch is 19 °. In one embodiment, the angle between the inspection detector and the welding torch is 16 °. In one embodiment, the angle between the inspection detector and the welding torch is 14 °. In one embodiment, the angle between the inspection detector and the welding torch is 12 °.
Fig. 70 illustrates a schematic diagram showing compressed air flowing through the internal welding system 5004, wherein some components of the internal welding system 5004 are not shown for the sake of clarity and to better illustrate other components and/or features of the internal welding system 5004.
Referring to fig. 70, a compressed air tank 5128, a brake cylinder 5133, a drive wheel cylinder 5137, a brake valve 5190, and a drive wheel valve 5192 are shown in the drive portion 5010 of the internal welding system 5004. A rear rotary union 5072, a rear clamp control valve 5062, a rear clamp 5144, and a front clamp 5142 are shown in central portion 5008 of internal welding system 5004. Front swivel union 5032 and front clamp control valve 5018 are shown in the forwardmost portion 5006 of internal welding system 5004.
In one embodiment, the compressed air tank 5128 has two separate fluid communication lines connected by a valve 5113. In one embodiment, compressed air tank 5128 is in fluid communication with brake valve 5190 (and brake cylinder 5133), drive wheel valve 5192 (and drive wheel cylinder 5137), rear clamp control valve 5062 (and rear clamp 5144), rear rotary union 5072, front rotary union 5032, front clamp control valve 5018 (and front clamp 5142), and compressor 5029 via a fluid communication line.
The compressed air stored in the compressed air tank 5128 is sent to the valve 5194 through a fluid line. A portion of the compressed air received through the valve 5194 is sent to the stopper valve 5190, and the remaining portion of the compressed air received through the valve 5194 is sent to the valve 5196. The brake valve 5190 is in fluid communication with the brake cylinder 5133 via lines 5198 and 5199. In one embodiment, the brake valve 5190 is configured to supply compressed air to actuate the brake cylinder 5133 when it receives a signal from the drive section electronics module 5118. The compressed air operates the brake cylinder 5133, and by the operation thereof, the brake cylinder 5133 provides a braking force to the driving roller 5122. In one embodiment, the brake cylinder 5133 and brake valve 5190 can be referred to as a braking system configured to secure the frame of the internal welding system 5004 at a desired location within the conduits 1022a, 1022b without moving. In one embodiment, a braking system configured to secure the frame of the internal welding system 5004 at a desired location within the conduits 1022a, 1022b without movement may include a wheel/roller lock. In one embodiment, the wheel/roller lock is configured to prevent one or more of the rollers 5122 so that the frame of the internal welding system 5004 is fixed from moving. In one embodiment, the braking system may further include a motor lock. In one embodiment, the motor lock is configured to prevent rotation of the drive motor 5124, which drive motor 5124 drives the roller 5122 for movement of the frame of the internal welding system 5004.
A portion of the compressed air received through the valve 5196 is sent to the driving wheel valve 5192, and the remaining portion of the compressed air received through the valve 5196 is sent to the valve 5198. The drive wheel valve 5192 is in fluid communication with the drive wheel cylinder 5137 via lines 5200 and 5201. In one embodiment, the drive wheel valve 5192 is configured to supply compressed air to actuate the drive wheel cylinder 5137 when it receives a signal from the drive section electronics module 5118. The compressed air operates the driving wheel cylinder 5137, and by the operation thereof, the driving wheel cylinder 5137 provides a driving force to the driving roller 5122. In one embodiment, the drive wheel cylinder 5137 can be operatively connected to an axle having a drive roller 5122 thereon. In one embodiment, the drive wheel cylinder 5137 can be operatively connected to the axle by one or more gear arrangements.
In one embodiment, both drive wheel cylinder 5137 and brake cylinder 5133 are retracted when internal welding system 5004 is loaded into a pipe. In one embodiment, the drive wheel cylinder 5137 is retracted only when the internal welding system 5004 is being removed from the pipeline. In one embodiment, the drive wheel cylinder 5137 is extended to accelerate or decelerate (the travel of) the internal welding system 5004 in the pipe.
A portion of the compressed air received through valve 5198 is sent to rear rotary union 5072 and the remaining portion of the compressed air received through valve 5198 is sent to rear clamp control valve 5062. The rear clamp control valve 5062 is in fluid communication with the rear clamp 5144 via lines 5202 and 5203. In one embodiment, fluid communication line 5202 is used for extension of the clamp 5144 and fluid communication line 5203 is used for retraction of the clamp 5144. In one embodiment, the rear clamp control valve 5062 is configured to supply compressed air to actuate and operate the rear clamp 5144 when it receives a signal from the central portion electronics module 5064.
The compressed air output through rear rotary union 5072 is sent to front rotary union 5032. The compressed air output through front rotary union 5032 is sent to valve 5204. A portion of the compressed air received through the valve 5204 is sent to the front clamp control valve 5018 and the remaining portion of the compressed air received through the valve 5204 is sent to the compressor 5029. In one embodiment, the compressor 5029 is configured to recharge the system with received compressed air (e.g., to fill the tank with compressed air).
Front clamp control valve 5018 is in fluid communication with front clamp 5142 via lines 5206 and 5207. In one embodiment, fluid communication line 5206 is used for extension of the leading clamp 5142 and fluid communication line 5207 is used for retraction of the leading clamp 5142. In one embodiment, the front clamp control valve 5018 is configured to supply compressed air to actuate and operate the front clamp 5142 when it receives a signal from the front-most electronic module 5014.
Fig. 71 illustrates a schematic diagram showing the flow of power (including welding power), communication data, and control data through the internal welding system 5004, wherein some components of the internal welding system 5004 are not shown for the sake of clarity and to better illustrate other components and/or features of the internal welding system 5004.
Referring to fig. 71, the front-most electronics module 5014, the front rotary motor 5030, the front position sensor 5022, the front clamp control valve 5018, the front slip ring 5016, the wire feed electronics module 5046 of the wire feed assembly 5020, the wire feed system 5044, and the shielding gas control valve 5042 are shown in the front-most portion 5006 of the internal welding system 5004. A rotatable hub 5078, a welding torch 5502, a verification detector 5056, a verification camera 5112, front and rear clamps 5142 and 5144, a rear slip ring 5080, a center portion electronics module 5064, a rear position sensor 5076, a rear clamp control valve 5062, and a rear spin motor 5074 are shown in the center portion 5008 of the internal welding system 5004. A battery 5116, a drive portion electronics module 5118, a brake valve 5190, a drive wheel valve 5192, and a drive motor 5124 are shown in the drive portion 5010 of the internal welding system 5004.
In one embodiment, welding power is received by internal welding system 5004 from umbilical 5034. In one embodiment, welding power from umbilical 5034 is supplied to welding torch 5502 through front slip ring 5016.
In one embodiment, the battery 5116 of the drive portion 5010 is configured to supply power to all of the electronic modules in the internal welding system 5004, including the front most electronic module 5014, the wire feed electronic module 5046, the central portion electronic module 5064, and the drive portion electronic module 5118. In one embodiment, the battery 5116 of the drive portion 5010 is configured to supply power to all electric drive motors in the internal welding system 5004, including the front rotary motor 5030, the motor of the wire feed system 5044, the rear rotary motor 5074, the drive motor 5124, the axial welding torch motor 5550, the radial welding torch motor 5512, and the tilt welding torch motor 5588.
In one embodiment, power from the battery 5116 is supplied directly to the rear slip ring 5080, the center portion electronics module 5064, and the drive portion electronics module 5118. In one embodiment, power from the battery 5116 is supplied to the front slip ring 5016 through the rear slip ring 5080. That is, the power of the battery 5116 is transmitted from the rear slip ring 5080 to the front slip ring 5016. In one embodiment, power from the battery 5116 is supplied from the front slip ring 5016 to the front most electronic module 5014 and the wire feed electronic module 5046.
In one embodiment, power for the battery 5116 is supplied to the front rotary motor 5030 from the front-most electronics module 5014 and to the motor of the wire feed system 5044 from the wire feed electronics module 5046. In one embodiment, power from the battery 5116 is supplied to the rear-rotating motor 5074 from the central-portion electronics module 5064. In one embodiment, power from the battery 5116 is supplied to the drive motor 5124 from the drive section electronics module 5118. In one embodiment, power for the battery 5116 is supplied from the wire feed electronics module 5046 to the axial welding torch motor 5550, the radial welding torch motor 5512, and the tilt welding torch motor 5588.
In one embodiment, the battery 5116 is also configured to supply power to the inspection camera 5112 and the inspection detector 5056. For example, power from the battery 5116 is supplied to the inspection camera 5112 and the inspection detector 5056 from the line feed electronics module 5046.
In one embodiment, the battery 5116 is also configured to supply power to the front position sensor 5022 and the rear position sensor 5076. For example, power of the battery 5116 is supplied from the frontmost electronic module 5014 to the front position sensor 5022, and from the central portion electronic module 5064 to the rear position sensor 5076.
In one embodiment, the battery 5116 is also configured to supply power to the front clamp control valve 5018, the shielding gas control valve 5042, the rear clamp control valve 5062, the brake valve 5190, and the drive wheel valve 5192. For example, power of the battery 5116 is supplied from the frontmost electronic module 5014 to the front clamp control valve 5018, from the wire feed electronic module 5046 to the shielding gas control valve 5042, from the central portion electronic module 5064 to the rear clamp control valve 5062, and from the drive portion electronic module 5118 to the brake valve 5190 and the drive wheel valve 5192.
In one embodiment, the internal welding system 5004 is configured to receive communication signals via the umbilical 5034 and to send the communication signals to an external computer system (e.g., having one or more processors). In one embodiment, the received communication signals may travel from the umbilical 5034 to the front most electronics module 5014, then through the front slip ring 5016 to the wire feed electronics module 5046, then through the rear slip ring 5080 to the center portion electronics module 5064, and then to the drive portion electronics module 5118.
In one embodiment, the communication signals may travel from the drive portion electronics module 5118 (in the opposite direction from the received signals), then to the central portion electronics module 5064, then through the rear slip ring 5080 to the wire feed electronics module 5046, then through the front slip ring 5016 to the front most electronics module 5014, and to the umbilical (and to an external computer system having one or more processors).
In one or more embodiments described herein, and as may be appreciated from fig. 71, the one or more processors 5140 are operatively associated with a test detector 5056 (e.g., a test laser (or optionally multiple test detectors 5056 where more than one is provided)) via one or more hardwired communication lines 5056a that transmit signals from the test laser 5056 to the one or more processors 5140. The hard-wired communication line includes: (i) a movable portion 5056b that moves with the inspection detector 5056 as the inspection laser directs the inspection beam along the junction region; and (ii) a fixed portion 5056c, which remains fixed during movement of the movable portion 5056 b. The system also includes the previously described front slip ring 5016 (which can be considered to be part of a hardwired communication line from one perspective), which front slip ring 5016 provides an interface between a portion of the movable portion 5056b and a portion of the fixed portion 5056c of the communication line to enable signals to pass from the movable portion 5056b to the fixed portion 5056 c.
It should be understood that one or more hardwired communication lines 5056a (including movable and fixed portions thereof) are also (or alternatively in the case of test detectors 5056 being provided with wireless communication for communicating with one or more processors) configured to transmit power to the test detectors 5056 through the slip ring 5016.
The slip ring 5016 includes an outer stator 5016a and an inner rotor 5016b (see fig. 26). The inner rotor 5016b and the stator 5016a have a bearing 5016k therebetween. The stator 5016a is fixedly mounted relative to the center frame 5068 (see fig. 23 and 24) while the rotor 5016b is connected with the rotatable hub 5078 at its center axis (see, e.g., fig. 24). When the rotatable hub 5078 is driven to rotate, the rotor 5016b rotates with the hub. The stator 5016a is connected to a fixed portion 5056c of the hardwired communication line, and the rotor 5016b is connected to a movable portion 5056b of the hardwired 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 passageway 5016d therethrough. Passage 5016d allows other conduits or lines to pass therethrough, and in particular, for example, a pneumatic line from a forward swivel union (such as an external compressed air line that is connected to compressed air tank 5128).
As can be appreciated, in some embodiments, the hardwiring between the verification detector 5056 and the one or more processors 5140 may also travel through other components. For example, as shown in fig. 71, a communication line from the test detector 5056 may travel through the line feed electronics 5046 before being received by the slip ring 5016.
Slip ring 5016 allows movable portion 5056b of the communication line to move with rotatable hub 5078 as hub 5078 rotates during scanning operations of inspection detector 5056, during pre-weld scanning of the joint area between the pipes prior to welding operations, and during dynamic scanning of the joint area between the pipes during welding operations.
It should also be understood that the slip ring 5016 is also configured to couple the communication connection between the one or more processors 5140 and the inspection camera 5112 and provide power to the inspection camera 5112. This can be accomplished via the same one or more hardwired communication lines 5056 a. The one or more processors 5140 are configured to receive camera inspection data from the inspection camera 5112 before, after, or during the welding operation. As the camera scans the junction region, the movable portion 5056b moves with the camera (and movable hub 5078), and the fixed portion 5056c remains fixed during movement of the movable portion 5056b in communication with the camera 5112.
It should also be understood that the same slip ring 5016 (and/or slip ring 5080) is configured to transfer power to other components that may rotate with the rotatable hub 5078. For example, as shown in fig. 35B, a welding power line 5502k for providing welding power to the welding torch 5502 and a power and command line 5550k for controlling and powering one or more welding torch motors 5550, 5512, 5588 (for controlling the welding torch) are each lines configured to pass through the slip ring 5016. For example, for illustrative purposes, in fig. 26 and 35B, the fixed portion of the hardware power line for the welding power line 5502k is labeled 5112c and the movable portion of the welding power line is labeled 5112B. It is understood that they may alternatively be represented by additional lines shown into the same slip ring 5016 or shown connected with a separate slip ring.
Similarly, a hardwired communication line 5550k may be provided through the slip ring 5016 to provide commands (and control) as well as power to the torch motors 5550, 5512, 5588. For simplicity and without redundancy, the movable portion 5550m of this hard-wired 5550k is shown in fig. 35B but not in fig. 26. It should be understood that this fig. 26, as well as fig. 71, is used to illustrate how slip ring 5016 (or another slip ring) may be used to transmit power and communications to welding torch 5502 when welding torch 5502 is rotating with a rotatable hub 5078 and when welding torch 5502 is powered and controlled to produce a weld during a welding operation.
As shown in fig. 35B (and several other figures), the rotatable hub 5078 has a generally hollow cylindrical portion 5078 a. The middle of the cylindrical portion at a region generally axially aligned with the welding torch, laser and camera has a plurality of openings or slots 5078b therethrough. Opening 5078b allows movable power lines and communication lines from slip ring 5016 (and optionally slip ring 5080) to pass radially outward from interior 5078c of rotatable hub 5078 to the exterior of hub 5078 for connection with a welding torch, laser and camera.
It should be understood that while the rotatable hub 5078 shown and described herein has a generally cylindrical configuration, the hub may have a different shape. The rotatable hub may have any tubular shape (e.g., having a hollow square or triangular configuration, for example only). Further, the rotatable hub is also interchangeably referred to as a "rotatable frame".
As shown and described above, the verification detector 5056 is mounted on the exterior of a tubular hub having opposite ends and a radial opening 5078b therebetween. The movable portion 5056b of the power and communication lines extending from the front slip ring 5016 and the line feed electronics module 5046 extend through the interior 5078c of the tubular hub 5078, through the radial opening 5078b and connect with one or more test detectors 5056.
As can also be appreciated from fig. 24 and 35B, the gas pressure line 5032a carrying the shielding gas (inert gas) passes through the rear rotary union 5072, through the opening 5080d in the slip ring, and travels through the hollow interior 5078c of the rotatable hub 5078 to one of the shielding gas valves 5042 (see fig. 72) mounted in a line feed electronics module 5046 (see fig. 71) mounted on the rotatable hub 5078 for rotation therewith. After connection with the shielding gas valve 5042, the gas pressure line 5032a (which is a movable line that moves with rotation of the rotatable hub 5078) rotates back and extends again through the hollow interior 5078c of the rotatable hub 5078 (thus, two lines 5032a are shown in fig. 24). The gas pressure wire 5032a passes through one or more of the openings 5078b to be directed near the tip of the welding torch 5502. The pneumatic line 5032a shown in fig. 35B includes a movable portion of the pneumatic line that rotates as the rotatable hub 5078 rotates.
Fig. 25 is a partial cross-sectional view of front rotary union 5032, said front rotary union 5032 having substantially the same construction as rear rotary union 5072. Front swivel union 5032 is used to deliver compressed air from an external source 5029 to an on-board compressed air tank 5128. The forward rotary union includes a stator 5032d and a rotor 5032 e. Rotor 5032e is mounted on stator 5032d via ball bearing 5032 f. The stator 5032d is fixed with respect to the central frame 5068, and the rotor 5032e is coupled to a movable portion 5072d of the pneumatic line, an opposite end of the movable portion 5072d being connected with the rotor of the rear rotary union 5072. The movable portion 5072d of the pneumatic line passes through the central passageway 5016d of slip ring 5016 for introduction to the interior 5078c of rotatable hub 5078 and then to the rotor of rear rotary union 5072.
It should be understood that while front slip ring 5016 is shown in fig. 26 and front rotary union 5032 is shown in fig. 25, the same configuration for each applies to rear rotary union 5072 and rear slip ring 5080.
The manner in which the movable portion of the pneumatic line passes through the central passageway 5016d of slip ring 5016 can be further understood from the cross-sectional view of fig. 24, which 24 illustrates this property in the context of how this applies to rear slip ring 5080 and rear rotary union 5072. Specifically, rear rotary union 5072 has an outer stator 5072a and an inner rotor 5072 b. The rotor 5072b receives compressed air from a rotatable air pressure supply line 5072d (see fig. 24 and 70; it is to be understood that fig. 70 is a schematic view and that line 5072d is drawn schematically in fig. 70, but through the inner portion 5078c of the rotatable hub as shown in fig. 24). The rotatable supply line 5072d is connected at its opposite end to the rotor of the forward rotary union 5032. Specifically, external supply tank 5029 first passes compressed air through the stator of front rotary union 5032 and then exits through the rotor of front rotary union 5032. The rotor of front rotary union 5032 is operatively connected to rotatable hub 5078 so as to be rotatable therewith. A rotatable supply line 5072d passes from the rotor of forward rotary union 5032 to the rotor 5072b of aft rotary union 5072. The compressed air passes through the stator 5072a of the rear rotary union to a fixed air pressure supply line 5072f extending therefrom. The fixed air pressure supply line 5072f is connected by a valve to the compressed air tank 5128, and the tank 5128 periodically receives compressed air from the external supply tank 5029 when the compressed air tank 5128 is depleted. As shown in fig. 24, a rotatable supply line 5072d passes from the rotor 5072b through a central opening 5080d in the aft slip ring 5080. A movable pneumatic supply line 5072d is then passed through a passageway 5078c in the rotatable hub 5078 for connection with the front rotary union 5032.
As can be seen in fig. 24, the aft slip ring 5080 has an inner rotor 5080r, an outer stator 5080s, and a bearing 5080m therebetween.
As can also be appreciated from fig. 24, 72, the rear rotary union 5072 also has another securing line 5072g, which securing line 5072g receives shielding gas from a shielding gas tank 5262, described in more detail later. The shielding gas passes from the stator 5072a to the rotor 5072b and then out of the rotor through the movable gas pressure line 5032 a. The movable pneumatic line 5032a passes through an opening 5080d in the slip ring and into a passageway 5078 c. The pneumatic line 5032a moves with the rotation of the rotatable hub 5078. The opposite end of the gas pressure line 5032a is connected to a shielding gas valve 5042 and then turned back (thus, two lines 5032a are shown in fig. 24) and threaded to the welding torch 5502. Upon traveling to the welding torch 5502, the movable gas pressure wire 5032a passes through an opening 5078b in the movable hub 5078, as can be appreciated from fig. 72.
Although not described in detail herein, it should be understood that the provision of shielding gas through the rear rotary union 5072 also applies to the passage of purge gas from the purge gas tank 7070 through the rear rotary union 7072, as shown in fig. 94, which is described later.
In fig. 25, front swivel 5032 is shown with two inlet and outlet ports. As shown, only one of the ports is used for delivering compressed air through the pneumatic line (the fixed portion 5032c and the movable portion 5072 d). The other ports are non-functional with the front rotary union, but both ports are used with the rear rotary union 5072, as understood from the above description.
It should also be understood that in some embodiments, wireless communication may be provided to/from the inspection detector, the camera, and/or the welding torch, in which case the slip ring may be bypassed for use for certain functions.
In one embodiment, the communication signals may not traverse the entire communication path between the umbilical cable 5034 and the drive section electronics module 5118, and may travel between particular devices/modules of the communication path.
In one embodiment, all of the electronic modules in the internal welding system 5004 (including the frontmost electronic module 5014, the wire feed electronic module 5046, the central portion electronic module 5064, and the drive portion electronic module 5118) may each include memory, secondary storage, and one or more processors configured to perform system control. In one embodiment, all of the electronic modules in the internal welding system 5004 can be configured to receive, process, store, retrieve, and transmit signals (sensors or controls) and data. In one embodiment, these electronic modules may contain other components. For example, various circuits (e.g., such as power supply circuitry, signal conditioning circuitry, solenoid driver circuitry, and/or any other circuitry known in the art) may be incorporated into the electronic module. In one embodiment, all of the electronic modules in the internal welding system 5004 may be configured to transmit control signals for directing the operation of devices operatively connected thereto, and to receive data or other signals (sensors) from devices operatively connected thereto.
For example, the front-most electronics module 5014 is operatively coupled to the front rotary motor 5030, the front position sensor 5022, and the front clamp control valve 5018. In one embodiment, the front-most electronics module 5014 is configured to transmit control signals to control the operation of the front rotary motor 5030 and the front clamp control valve 5018 and to receive sensor signals from the front position sensor 5022.
In one embodiment, the wire feed electronics module 5046 is operatively coupled to the shielding gas control valve 5042, the motor of the wire feed system 5044, the axial weld torch motor 5550, the radial weld torch motor 5512, and the tilted weld torch motor 5588. In one embodiment, the wire feed electronics module 5046 is configured to transmit control signals to control the operation of the shielding gas control valve 5042, the motor of the wire feed system 5044, the axial weld torch motor 5550, the radial weld torch motor 5512, and the tilt weld torch motor 5588.
In one embodiment, the mid-section electronics module 5064 is operatively coupled to a rear rotation motor 5074, a rear position sensor 5076, and a rear clamp control valve 5062. In one embodiment, the mid-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.
In one embodiment, the drive portion electronics module 5118 is operatively coupled to the drive motor 5124, the brake valve 5190, and the drive wheel valve 5192. In one embodiment, the drive section electronics module 5118 is configured to transmit control signals to control the operation of the drive motor 5124, the brake valve 5190, and the drive wheel valve 5192.
Fig. 72 illustrates a schematic diagram showing a flow of shielding gas through internal welding system 5004, wherein some components of internal welding system 5004 are not shown for the sake of clarity and to better illustrate other components and/or features of internal welding system 5004.
In one embodiment, the inert/shielding gas supply line is configured to direct inert/shielding gas from the inert/shielding gas source 5262 to the area between the first clamp 5142 and the second clamp 5144 and toward the area of the welding torch 5502 to which the welding tip 5503 is attached to reduce oxygen near the welding tip 5503 during a welding operation.
Referring to fig. 72, a shielding gas canister 5262 is shown in the drive portion 5010 of the internal welding system 5004. In one embodiment, the high pressure regulator 5264 can be positioned in the drive portion 5010 of the internal welding system 5004. In one embodiment, the high pressure regulator 5264 can be positioned in the central portion 5008 of the internal welding system 5004. In one embodiment, a rear rotary union 5072, a weld torch 5502, a rotatable hub 5078, front and rear clamps 5142, 5144, and front and rear clamps 5142, 5144 are shown in central portion 5008 of internal welding system 5004. In one embodiment, the leading seal 5146 and the trailing seal 5148 can be positioned in the central portion 5008 of the internal welding system 5004. A shielding gas valve 5042 is shown in the forward-most portion 5006 of the internal welding system 5004.
In one embodiment, protective gas tank 5262 is configured to be maintained at a pressure of 500-. Shielding gas tank 5262 is in fluid communication with rear rotary union 5072 via a fluid communication line. In one embodiment, shielding gas tank 5262 is in fluid communication with rear rotary union 5072 via valve 5266 and high pressure regulator 5264. In one embodiment, the high pressure regulator 5264 is configured to automatically shut off the flow of purge gas at a pressure of 75 pounds. That is, the high pressure regulator 5264 is generally configured to reduce the pressure in the shielding gas tank 5262 to about 75 pounds of the fluid communication line downstream of the high pressure regulator 5264 and from the rear rotary union 5072 to the shielding gas valve 5042.
In one embodiment, rear rotary union 5072 is in fluid communication with shielding gas valve 5042 via a fluid communication line. In one embodiment, shielding gas stored in shielding gas tank 5262 is sent to rear rotary union 5072 through a fluid communication line, and then from rear rotary union 5072 to shielding gas valve 5042 through a fluid communication line. In one embodiment, each shielding gas control valve 5042 is configured to control the flow of shielding gas to the corresponding welding torch 5502 through shielding gas line 5268. In one embodiment, each welding torch 5502 has a corresponding shielding gas control valve 5042 connected thereto. In one embodiment, shielding gas control valve 5042 is operatively connected to receive control signals from line feed electronics module 5046. In one embodiment, the shielding gas control valve 5042 is configured to supply shielding gas to the corresponding welding torch when it receives a signal from the wire feed electronics module 5046.
In one embodiment, the driver portion 5010 of the internal welding system 5004 may include a purge gas tank, a shielding gas tank 5262, and a compressed air gas tank. In one embodiment, shielding gas from the shielding gas tank 5262 is used only to supply shielding gas to the welding torch 5502. In one embodiment, a separate purge gas canister may be configured to fill and maintain the purge gas in the purge gas chamber. In one embodiment, compressed air is used to inflate the seals 5146 and 5148 and expand the clamps 5142 and 5144.
In one embodiment, the driver portion 5010 of the internal welding system 5004 may include a compressed air gas tank and a purge/shielding gas tank. That is, the shielding gas tank and the purge gas tank are the same. In one embodiment, compressed air from a compressed air gas canister is used to inflate the seals 5146 and 5148 and expand the clamps 5142 and 5144. In one embodiment, seals 5146 and 5148 are optional in internal welding system 5004. In one embodiment, the shielding gas to the welding torch 5502 and the purge gas to the purge gas chamber are supplied through the same gas tank with the purge/shielding gas. In one embodiment, supplying the purge gas to the purge gas chamber is optional.
In one embodiment, the driver portion 5010 of the internal welding system 5004 may include only a purge/shielding gas canister (i.e., no compressed air gas canister). This may be the case for smaller internal welding systems. In one embodiment, the purge/shield gas tank is configured to supply purge/shield gas to the welding torch 5502, to supply purge/shield gas to the purge gas chamber, and to supply purge/shield gas to inflate the seals 5146 and 5148 and expand the clamps 5142 and 5144. In one embodiment, seals 5146 and 5148 are optional in internal welding system 5004. In one embodiment, supplying the purge gas to the purge gas chamber is optional.
Fig. 72A, 72B, and 72C show close-up views of an internal welding torch used in prior art systems and internal welding system 5004, respectively, with the tubes having a gap and radially offset (staggered) alignment. For example, as shown in fig. 72A, conduits 1022A, 1022b have a 1 mm gap and radial offset (stagger).
As shown in fig. 72B, in the prior art system, the raised edge of the pipe protects the left side of the weld groove, resulting in a reduction in weld 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 after a welding procedure) and to offset and/or tilt its internal welding torch 5502 based on the received weld profile data to achieve full weld penetration. Thus, weld profile data from internal welding system 5004 may be used to make better welds.
In one embodiment, the one or more processors 5140 are configured to receive profile data from the field system 5000 relating to the welding of the joint region 5136 between the first and second conduits 1022a, 1022 b. In one embodiment, the relevant profile data is based on a scan of the joint region 5136 between the conduits 1022a, 1022 b. In one embodiment, one or more processors 5140 are configured to compare one or more characteristics of the relevant profile data to one or more predefined profile characteristics to generate a response to field system 5000. In one embodiment, the one or more processors 5140 are configured to transmit the response to the field system 5000 to cause the field system 5000 to perform one or more operations based on the response. In one embodiment, the one or more processors 5140 are configured to transmit a signal to the field system 5000 to stop a welding-related procedure, change or develop a welding protocol, save or further analyze the profile data of the joint region 5136, save or further analyze the pre-weld profile data, save or further analyze the post-weld profile data, confirm or modify a version thereof, and/or the like.
In one embodiment, one or more processors 5140 are operatively associated with the verification detector 5056 to determine the profile of the junction region 5136 between the conduits 1022a, 1022 b. In one embodiment, the welding torch 5502 is configured to produce a weld at the joint region 5136 between the conduits 1022a, 1022b based on the profile of the joint region 5136 between the conduits 1022a, 1022 b. In one embodiment, the welding torch (e.g., of the external welding system 7500) is configured to produce a weld between the conduits 1022a, 1022b based on the profile of the joint area 5136 between the conduits 1022a, 1022 b.
In one embodiment, the one or more processors 5140 are configured to receive inspection data from the inspection detector 5056 before, after, or during a welding operation. In one embodiment, the one or more processors 5140 are configured to receive camera inspection data from the inspection camera 5112 before, after, or during a welding operation. In one embodiment, the one or more processors 5140 are configured to receive inspection data from the inspection detector 5056 and camera inspection data from the inspection camera 5112 before, after, or during the welding operation.
In one embodiment, the inspection camera 5112 is configured to scan the welded joint region 5136 after the welding operation. In one embodiment, the inspection camera 5112 is configured to send signals to the one or more processors 5140 based on the scanning. In one embodiment, the one or more processors 5140 are configured to determine characteristics of the welded joint region 5136 based on signals from the inspection camera 5112.
In one embodiment, the one or more processors 5140 are configured to analyze the data to automatically detect undercuts or other shape deviations.
In one embodiment, if the characteristic of the joint region 5136 is greater than a predetermined threshold, it can be referred to as an undesirable characteristic of the joint region 5136. In one embodiment, if the characteristic of the joint region 5136 is greater than a predetermined threshold and the difference between the characteristic and the predetermined threshold falls within a predetermined acceptable/allowable range, it is determined that the undesirable characteristic of the joint region 5136 does not require correction. In one embodiment, if the characteristic of the joint region 5136 is greater than a predetermined threshold and the difference between the characteristic and the predetermined threshold does not fall within a predetermined acceptable/allowable range, it is determined that the undesirable characteristic of the joint region 5136 requires correction.
In one embodiment, if the characteristic of the joint region 5136 is less than a predetermined threshold, it can be referred to as an undesirable characteristic of the joint region 5136. In one embodiment, if the characteristic of the joint region 5136 is less than a predetermined threshold and the difference between the characteristic and the predetermined threshold falls within a predetermined acceptable/allowable range, it is determined that the undesirable characteristic of the joint region 5136 does not require correction. In one embodiment, if the characteristic of the joint region 5136 is less than a predetermined threshold and the difference between the characteristic and the predetermined threshold does not fall within a predetermined acceptable/allowable range, it is determined that the undesirable characteristic of the joint region 5136 requires correction.
In one embodiment, if the characteristics of the joint region 5136 are not within a predetermined range, it may be referred to as an undesirable characteristic of the joint region 5136. In one embodiment, if the characteristics of the joint region 5136 are not within the predetermined range and fall within the acceptable/allowable range, it is determined that the undesirable characteristics of the joint region 5136 do not require correction. In one embodiment, if the characteristics of the joint region 5136 are not within the predetermined range and do not fall within the acceptable/allowable range, it is determined that the undesirable characteristics of the joint region 5136 do not require correction.
In one embodiment, the one or more processors 5140 are configured to receive electronic signals (e.g., generated by a receiver of the inspection detector 5136) to determine whether undesirable characteristics of the joint region 5136 should be corrected. In one embodiment, in response to detecting one or more undesirable characteristics of the junction region 5136, the one or more processors 5140 are configured to send instructions to the motors 5030, 5074 that control the axial rotational position of one of the conduits to cause the motors 5030, 5074 to rotate one of the conduits 1022a, 1022b relative to the other of the conduits 1022a, 1022b to correct the undesirable characteristics. In one embodiment, the motors 5030, 5074 are configured to move the radially extending clamps 5142, 5144.
In one embodiment, the welding torch 5502, which is operatively connected to the one or more processors 5140, is configured to perform a welding operation to weld the conduits 1022a, 1022b together in response to the one or more processors 5140 detecting that no undesirable features are present.
In one embodiment, the one or more processors 5140 are configured to interact with the verification detector 5056 to scan the joint region 5136 between the conduits 1022a, 1022b to determine the profile of the joint region 5136 between the conduits 1022a, 1022b prior to a welding operation and generate pre-weld profile data based thereon. In one embodiment, the one or more processors 5140 are configured to interact with the verification detector 5056 to scan the entire joint region 5136 between the conduits 1022a, 1022b to generate pre-weld profile data prior to applying weld material to weld the two conduits 1022a, 1022b together. In one embodiment, the one or more processors 5140 are configured to interact with the verification detector 5056 to scan the joint region 5136 to obtain pre-weld profile data after the first clamp 5142 and the second clamp 5144 are engaged with the first conduit 1022a and the second conduit 1022b, respectively.
Additionally or alternatively, the one or more processors 5140 are configured to interact with the inspection camera 5112, an x-ray radiographic inspection device, a gamma ray inspection device, an ultrasonic inspection device, a magnetic particle inspection device, an eddy current inspection device, or other inspection device to scan the joint region 5136 between the pipes 1022a, 1022b to determine the profile of the joint region 5136 prior to the welding operation.
The pre-weld scanning/verification procedure is the same for the joint internal welding system 3001 and the purge and verification system 7001, and therefore will not be described again with respect to the joint internal welding system 3001 and the purge and verification system 7001.
In various embodiments, "pre-weld" profile data as described herein refers to data obtained from an inspection detector (such as, for example, by an inspection laser) that scans the joint area between two pipes to be welded before a welding torch is activated to secure the pipes to each other. This pre-weld profile data is transmitted to one or more processors to determine whether the pipe is sufficiently aligned before any weld material is deposited into the joint region. In one embodiment, if a misalignment is detected, for example, as determined by the one or more processors to be outside of an acceptable misalignment value, the one or more processors are configured to send a signal to a bracket engaged with the exterior surface of the pipe. One or both of the brackets may be adjusted based on an output signal from the pre-weld profile data to adjust the relative positioning between the pipes so as to bring the alignment of the joint area within acceptable misalignment values.
It will be appreciated that, given slight inconsistencies in the pipe structure, absolute perfect alignment is often (and often) not achieved. However, this perfect alignment is not required as long as the alignment is within tolerances for good welding.
In one embodiment, the pre-weld profile data may include pipe ovality/roundness data. In one embodiment, the tube ovality/roundness data may include a location and size of a minimum inner diameter, a location and size of a maximum inner diameter, a tube average wall thickness, a location and size of a minimum wall thickness, and/or a location and size of a maximum wall thickness. In one embodiment, the tube ovality/roundness data may include a comparison between each of the location and size of the minimum inner diameter, the location and size of the maximum inner diameter, the location and size of the minimum wall thickness, and the location and size of the maximum wall thickness to their respective predetermined values. In one embodiment, the pipe ovality/roundness data may include a comparison between each of the pipe average inner diameter and the pipe average wall thickness and their respective predetermined values. In one embodiment, the tube ovality/roundness data may include the inner diameter deviation of the tube at all locations on the circumference of the tube based on the comparison.
In one embodiment, the pre-weld profile data may include pipe bevel profile data. In one embodiment, the pipe bevel profile data may include pipe bevel geometry. In one embodiment, the pipe bevel profile data may include a comparison between each of a size and a shape of the pipe bevel, a blunt (land) thickness of the pipe bevel, a bevel angle of the pipe bevel, an offset of the pipe bevel, and a root angle of the pipe bevel to their respective predetermined values. In one embodiment, the pipe bevel profile data may include pipe bevel deviations at all locations of the pipe circumference based on the comparison.
In one embodiment, the pre-weld profile data may include weld joint fit-up and alignment data. In one embodiment, the weld joint fit-up and alignment data may include data regarding the gap between the inner abutting ends of the pipe (after pipe alignment). In one embodiment, the weld joint fit-up and alignment data may include data regarding the gap between the bevels of the pipe (after pipe alignment). In one embodiment, the weld joint fit-up and alignment data may include a location and size of a minimum gap, a location and size of a maximum gap, and/or an average gap. In one embodiment, the weld joint fit-up and alignment data may include a comparison between the location and size of the minimum gap and the location and size of the maximum gap and their respective predetermined values. In one embodiment, the weld joint fit-up and alignment data may include a comparison between the average gap and its corresponding predetermined value. In one embodiment, the weld joint fit-up and alignment data may include gap deviations at all locations of the pipe circumference based on the comparison. In one embodiment, the weld joint fit-up and alignment data may include a minimum height difference between the pipes (i.e., acceptable alignment), and the like.
In one embodiment, the one or more processors 5140 are configured to interact with the verification detector 5056 to scan the joint region 5136 after the first and second clamps 5142 and 5144 are engaged with the first and second conduits 1022a and 1022b, respectively. In one embodiment, one or more processors 5140 are configured to operatively connect with a first pipe joint structure 5052 and a second pipe joint structure 5054. In one embodiment, the one or more processors 5140 are configured to operate the first conduit engagement structure 5052 and/or the second conduit engagement structure 5054 based on the pre-weld profile data to modify a joint region 5136 between the conduits 1022a, 1022b prior to the welding operation.
In one embodiment, the one or more processors 5140 are configured to alter the joint region 5136 between the conduits 1022a, 1022b prior to the welding operation by driving the first conduit engagement structure 5052 and/or the second conduit engagement structure 5054 to alter the roundness (or ovality) of the first conduit 1022a and/or the second conduit 1022b based on the pre-weld profile data. For example, in one embodiment, the one or more processors 5140 are configured to alter the joint region 5136 between the conduits 1022a, 1022b prior to a welding operation by selectively actuating one or more of the clamp braking hoops 5157 of the clamps 5142 and/or 5144 to alter the roundness of the first and/or second conduits 1022a, 1022b based on the pre-weld profile data.
In one embodiment, the one or more processors 5140 are configured to alter the joint region 5136 between the conduits 1022a, 1022b prior to a welding operation by driving the first conduit engagement structure 5052 and/or the second conduit engagement structure 5054 to rotate and/or axially move the first conduit 1022a and/or the second conduit 1022b based on the pre-weld profile data. In one embodiment, the one or more processors 5140 are configured to modify the joint region 5136 between the conduits 1022a, 1022b prior to a welding operation by rotating one conduit 1022a or 1022b relative to the other conduit 1022a or 1022 b.
In one embodiment, the one or more processors 5140 are configured to develop a welding protocol based on the pre-weld profile data. In one embodiment, the welding protocol includes a welding speed and welding torch position protocol.
In one embodiment, the one or more processors 5140 are configured to operate the cradle 5330 (as shown in fig. 10A and 10B) or 6010A and 6010B (as shown in fig. 73) based on the pre-weld profile data for providing the incoming conduit 1022a at the second end of the conduit 1022B (after the frame assembly of the internal welding system 5004 is positioned at the second end of the conduit 1022B) in order to modify the joint region 5136 between the conduits 1022a, 1022B prior to the welding operation. In one embodiment, the one or more processors 5140 are configured to control externally positioned rollers 5332 of support 5330 based on the pre-weld profile data for providing lead-in conduit 1022a at the second end of conduit 1022b (after positioning the frame assembly of internal welding system 5004 at the second end of first conduit 1022 b).
In one embodiment, the one or more processors 5140 are configured to operate the stent 5330 (as shown in fig. 10A and 10B) or 6010A and 6010B (as shown in fig. 73) based on the pre-weld profile data to generate relative movement between the first conduit 1022a and the second conduit 1022B to modify the joint region 5136 between the conduits 1022a, 1022B prior to the welding operation. In one embodiment, outer surfaces 5346 and/or 5348 (as shown in fig. 2G) of first conduit 1022a and/or second conduit 1022b are engaged to adjust the relative positioning of conduits 1022a, 1022b in the event that the pre-weld profile data determines that adjustment is needed. In one embodiment, one or more processors 5140 operate (or are otherwise controlled) the supports 5330 (shown in fig. 10A and 10B) and 6010A and 6010B (shown in fig. 73) to engage the outer surfaces 5346 and/or 5348 (shown in fig. 2G) of the first conduit 1022a and/or the second conduit 1022B to adjust the relative positioning of the conduits 1022a, 1022B in the event that the pre-weld profile data determines that adjustment is needed.
In one embodiment, the first clamp 5142 and/or the second clamp 5144 is released in the event that the pre-weld profile data determines that an adjustment is required in order to enable adjustment of the relative positioning of the conduits 1022a, 1022 b. In one embodiment, the first and second clamps are internally positioned clamps and released in the event that the pre-weld profile data determines that adjustment is required, so that the relative positioning of the conduits 1022a, 1022b can be adjusted. In one embodiment, the first and second clamps are externally positioned clamps and released in the event that the pre-weld profile data determines that adjustment is required, so that the relative positioning of the conduits 1022a, 1022b can be adjusted. In one embodiment, the first and second clamps comprise both internally positioned clamps and externally positioned clamps. In one embodiment, both the internally positioned clamps and the externally positioned clamps are released in the event that the pre-weld profile data determines that adjustment is required, so that the relative positioning of the conduits 1022a, 1022b can be adjusted.
In one embodiment, adjustment of the relative positioning of the conduits 1022a, 1022B (based on pre-weld profile data) can be performed automatically by the processor 5140 controlling the externally positioned rollers 5332 (as shown in fig. 10A and 10B) or by an operator using a crane and (internal/external) clamps. In one embodiment, adjustment of the relative positioning of the conduits 1022a, 1022b (based on pre-weld profile data) may also be referred to as realignment of the conduits 1022a, 1022 b.
In one embodiment, the adjustment of the relative positioning of the conduits 1022a, 1022b (based on the pre-weld profile data) may include an adjustment along a longitudinal axis of the conduits 1022a, 1022b and/or an adjustment along a radial axis of the conduits 1022a, 1022 b. In one embodiment, the adjustment of the relative positioning of the conduits 1022a, 1022b (based on the pre-weld profile data) may include a position adjustment and an orientation adjustment of the conduits 1022a, 1022 b. In one embodiment, adjustment of the relative positioning of the conduits 1022a, 1022b (based on the pre-weld profile data) may include upward and downward movement and longitudinal movement (along the longitudinal axis of the conduits 1022a, 1022 b).
In one embodiment, the inner and/or outer clamps are released (holding the pipes 1022a, 1022b in place during the pre-weld process), and a crane, electronically controlled externally positioned rollers 5332, or other such devices may be used to manipulate the pipes based on the pre-weld profile data. In one embodiment, the inner and/or outer clamps are released prior to the realignment process (holding the conduits 1022a, 1022b in place during the pre-weld process). In one embodiment, after the conduits 1022a, 1022b are realigned, the conduits 1022a, 1022b are again clamped using external and/or internal clamps.
In one embodiment, the new pipe to be welded 1022a can be rotated about its longitudinal axis relative to the existing pipe already welded 1022b based on pre-weld profile data obtained from the inspection detector (e.g., inspection laser) 5056. In particular, the pre-weld profile data may be used to determine that in some cases, the relative rotational position of the conduits 1022a and 1022b may be changed to achieve a better weld match. For example, if each of the conduits 1022a, 1022b has a slight ovality thereto, matching the conduits such that the major axis of each of the two conduits is substantially aligned and the minor axis of each of the two conduits is substantially aligned may have an overall beneficial effect. Thus, in one embodiment, the verification detector 5056 may generate signals that are processed by the one or more processors 5140 to determine a more beneficial rotational position for the incoming conduit 1022a to be welded. This rotation can be achieved by one or more processors 5140 activating the pre-rotation motor 5030 to rotate the conduit 1022a prior to the welding operation. Specifically, to rotate the lead-in conduit 1022a, the central frame 5068 remains rotationally fixed relative to the previously welded conduits. This rotationally fixed relationship between the central frame 5068 and the pipeline 1022b is achieved by the one or more processors 5140 actuating the rear clamp 5144 into fixed engagement with the interior surface of the pipeline 1022b so as to prevent relative rotation therebetween. With the exception that the rear clamp 5144 and the center frame 5068 are rotationally fixed relative to the pipe, the rear rotation motor 5074 is not activated by the processor 5140 and its motor shaft is locked from rotation. Since the rear rotating motor shaft is prevented from rotating, the entire rotatable hub 5078 remains rotationally fixed relative to the central frame 5068 and the conduit 1022 b. The front spin motor 5030 is then activated. Its shaft rotates to drive a gear train as shown in fig. 19 and described above, such that the gear train 23 rotatably engages the gear teeth 5023 of the ring gear 5021. Because the wire feed module 5020 (which is fixed to the rotatable hub 5078) and the rotatable hub 5078 are fixed against rotation, the front rotary motor 5030 and the gear 5023 operatively connected thereto are driven circumferentially along the ring gear 5021. This rotational driving force formed on the front rotation motor 5030 causes the entire foremost end portion frame 5026 to which the motor 5030 is connected to rotatably move. The rotation of the foremost end portion frame 5026 in turn rotatably drives the front clamp 5142. The clamp 5142 rotates about the rotatable hub 5078 on bearings 5108, 5098 between the clamp 5142 and the rotatable hub 5078. As the clamp 5142 extends and tightens to the interior surface of the conduit 1022a, the conduit 1022a is thus rotated to a position determined by one or more processors 5140 based on the pre-weld scan information received from the inspection detector 5056. During rotation of the pipeline 1022a, if the outer support (5330, 6010A, 6010B) engages the outer surface of the pipeline, the one or more processors 5140 instruct the rollers 5332 on the outer support (5330, 6010A, 6010B) to optionally be in a free-running state (where the rollers 5332 are passive), or optionally the one or more processors 5140 instruct one or more motors operatively connected with the rollers 5332 to drive the rollers 5332 at a rotational speed comparable to (similar to or the same as) the speed at which the front rotary motor 5030 is driven to rotate from inside the pipeline 1022 a. This latter approach provides rotational force to the conduit from both the inside and outside of conduit 1022a, although in some embodiments, only the driving force may be sufficient.
In the embodiment just described, the clamps 5142 and 5144 engage the associated conduits 1022a and 1022b to prevent relative rotation between the frame 5026 and the conduits 1022a, and to prevent rotation between the central frame 5068 and the conduits 1022 b. However, in one or more embodiments, clamps 5142 and 5144 need not be responsible for this function. Rather, the wheels operatively associated with the two frames may be configured to engage the associated pipe with sufficient friction and/or outward force to prevent relative rotation between the pipe and the frames. In one embodiment, wheels that effect or allow motion between the frame and the pipe allow for substantially longitudinal movement only between the frame and the pipe and prevent relative rotational movement therebetween. This may be true for the wheels on one or more of the frames. The wheel engagement option may be used on only one of the frames, on two of the frames, and may optionally be used in combination with a clamping method for one or both of the frames.
The pipe rotation techniques described herein may also be used to return the frame to a desired "starting" or "original" rotational position after the welding operation is complete and a new pipe enters for the next pre-weld scan.
In one embodiment, the one or more processors 5140 are configured to send the pre-weld profile data to a remote processor for further processing.
In one embodiment, the one or more processors 5140 are configured to interact with the verification detector 5056 to scan the joint region 5136 between the conduits 1022a, 1022b to determine a profile of the joint region and generate dynamic profile data at a region of the joint 5136 between the conduits 1022a, 1022b prior to deposition of welding material thereon during a welding operation.
The dynamic scanning/inspection procedure is the same for the joint internal welding system 3001 and the purge and inspection system 7001, and therefore will not be described again with respect to the joint internal welding system 3001 and the purge and inspection system 7001.
In various embodiments, dynamic profile data refers to data obtained from inspection detectors during a welding operation. For example, the dynamic profile data is obtained from a location immediately before (forward of) the area being welded (e.g., 1-6 inches forward of the area being welded). In particular, the inspection detector scans the joint area in the area to be welded in order to provide data on the profile of the joint area where the welding material is to be deposited. It will be appreciated that the profile of the joint region between the pipes may change slightly as more and more joint regions are welded. In other words, the sequential welding itself may slightly alter the alignment/positioning of the pipe at the joint region at the unwelded portion of the joint region. Immediately prior to depositing welding material of the welding torch on the non-welding area of the joint area, an inspection detector measures a profile of the joint area, and one or more processors receive and use signals from the inspection detector to output signals/instructions to the welding torch and/or its motor in order to control various welding torch parameters to adapt the weld to the pipe as the pipe is welded. The welding torch parameters may include one or more of the following: wire feed speed, wire consumption, swing width, swing waveform, swing amplitude, welding time, gas flow rate, power level of the welding arc, welding current, welding voltage, welding impedance, welding torch travel speed, position of the welding tip of the welding torch along the pipe axis, angular position of the welding tip of the welding torch relative to its rotational plane, and/or distance of the welding tip of the welding torch to the inner surface of the pipe to be welded.
In one embodiment, the dynamic weld profile data may include high and low (stagger) data. In one embodiment, elevation (stagger) may generally refer to the difference in height between the beveled edges of a pipe after it is aligned. In one embodiment, the elevation (stagger) data may include a comparison between each of the location and magnitude of the minimum elevation difference and the location and magnitude of the maximum elevation difference and its respective predetermined value. In one embodiment, the high-low (stagger) data may include a comparison between the average height difference and its corresponding predetermined value. In one embodiment, the elevation (stagger) data may include elevation difference deviations of the pipe at all locations on the circumference of the pipe based on the comparison.
In one embodiment, the dynamic weld profile data may include weld seam characteristics.
In one embodiment, the dynamic weld profile data may include a width of the weld joint and a root gap of the weld joint.
In one embodiment, the one or more processors 5140 are configured to generate a welding signal to control the welding torch 5502 based on the dynamic profile data. In one embodiment, the one or more processors 5140 are configured to control the position and speed of the welding torch 5502 during a welding operation based on dynamic profile data. In one embodiment, the torch motor 5588 is operatively connected to the one or more processors 5140 to control the angle of the welding torch 5502 during a welding operation.
In one embodiment, the one or more processors 5140 are configured to instruct the one or more torch motors 5512 to move the welding tip 5503 further away from the joint region 5136 after each weld pass to accommodate the accumulation of weld material. In one embodiment, the one or more processors 5140 are configured to control the axial welding torch motor 5550 to control the axial movement of the welding torch 5502 (i.e., move the welding tip 5503 further away from the joint region 5136).
In one embodiment, the one or more processors 5140 are configured to generate an initially planned weld profile based on the pre-weld profile data and modify/adapt the initially planned weld profile based on the dynamic profile data.
In one embodiment, the wire feed speed, the swing width, the power level of the welding arc, and/or the distance of the welding tip 5503 of the welding torch 5502 from the surface of the pipe to be welded may be controlled based on dynamic profile data.
In one embodiment, the one or more processors 5140 are configured to interact with the verification detector 5056 to scan the joint region 5136 between the conduits 1022a, 1022b to determine the profile of the joint region 5136 between the conduits 1022a, 1022b after a welding operation and generate post-weld profile data based thereon. In one embodiment, post-weld profile data is obtained with the verification detector 5056 positioned within the first conduit 1022a and/or the second conduit 1022b without disengaging the first conduit engagement structure 5052 or the second conduit engagement structure 5054 from the inner face 5130 of the first conduit 1022a or the inner face 5132 of the second conduit 1022b, respectively.
The post-weld scanning/verification procedure is the same for the joint internal welding system 3001 and the purge and verification system 7001, and therefore will not be described again with reference to the joint internal welding system 3001 and the purge and verification system 7001.
Additionally or alternatively, the one or more processors 5140 are configured to interact with the inspection camera 5112, an x-ray radiographic inspection device, a gamma ray inspection device, an ultrasonic inspection device, a magnetic particle inspection device, an eddy current inspection device, or other inspection device to scan the joint region 5136 between the pipes 1022a, 1022b to determine the profile of the joint region 5136 after the welding operation.
In one embodiment, the post-weld profile data may include a profile of the formed weld bead. In one embodiment, the post-weld profile data may include a profile of the formed root channel weld layer. In one embodiment, the post-weld profile data may include weld shape characteristics such as mismatch, bead concavity, and re-entrant angle.
In one embodiment, the one or more processors 5140 are configured to cause another welding operation to be performed on the joint region 5136 between the conduits 1022a, 1022b based on the post-weld profile data.
Certain weld variables/parameters have well known relationships. That is, a change in one weld variable/parameter has a corresponding change in another weld variable/parameter. Welding variables/parameters such as welding current, welding voltage, welding torch travel speed, and heat input are all linked. For example, if the welding current increases and all other welding variables/parameters remain constant, the voltage should decrease. Additionally, if the welding torch travel speed is increased and all other welding variables/parameters are held constant, the heat input should be decreased. In one embodiment, the one or more processors 5140 are configured to analyze the collected data (e.g., before, after, or during the welding operation) to verify issues and make process/parameter changes. In one embodiment, based on the analysis and detection, the one or more processors 5140 are configured to take the internal welding system 5004 offline for maintenance as needed to prevent the problem from recurring.
In one embodiment, each data point collected/received by the one or more processors 5140 before, after, or during the welding operation is compared to its corresponding (golden-home) ideal weld value. These differences may be noted if any process variable changes exceed set/predetermined limits. If the difference persists longer than the maximum allowable defect size, the welding process may be stopped so that the weld may be repaired. The ideal weld values and allowable limits may improve over time as more weld data is collected.
In one embodiment, the one or more processors may be configured to observe what happens just before the deviation occurs and determine if there is a shortcoming in the control loop programming that allows the deviation to occur. If so, the one or more processors can send an updated control loop program to internal welding system 5004 and observe whether the change improves the performance of internal welding system 5004.
In one embodiment, the one or more processors may also be configured to monitor commands given to the internal welding system 5004 locally by an operator. If it is determined that these commands result in a weld defect, the one or more processors are configured to send a message to the operator to stop providing commands to internal welding system 5004. If it is determined that these commands prevent the weld defect, the one or more processors are configured to send a message to all operators instructing them to begin using the commands.
In one embodiment, the one or more processors are configured to collect and analyze non-invasive (NDT) data. In one embodiment, the location at which the weld defect is detected may again be compared to the weld parameters recorded at the same location, even if the defect is small enough not to require repair. In one embodiment, the one or more processors are capable of knowing weld defects that are not included in traditional inspection reports. This gives the one or more processors a very good statistical sample for each welding parameter and the quality of the resulting weld. This statistical model can be used to determine the best settings for each welding parameter and the allowable deviation from the settings. As each new NDT scan improves the statistical model, these new parameters may be communicated directly to the internal welding system 5004.
In one embodiment, computer system 5138 (including one or more processors 5140) may be a computer system local to field system 5000 as described herein. In another embodiment, computer system 5138 may be a computer system located remotely from field system 5000 (e.g., remote computer system 13704 or other remote computer system) and communicatively coupled to field system 5000 or its local computer system, as described herein.
In one embodiment, the one or more processors 5140 may receive (via a receiver) from the field system 5000 inspection data (e.g., raw data from an inspection device, 2D or 3D imaging data, or other data from an inspection) associated with inspection of the joint region 5136 between the conduits 1022a, 1022 b. The one or more inspection devices used for inspection may include one or any combination of inspection lasers, inspection cameras, radiographic inspection devices, gamma ray inspection devices, ultrasonic inspection devices, magnetic particle inspection devices, eddy current inspection devices, temperature monitors, or other inspection devices. The inspection data may accordingly include one or any combination of laser inspection data, camera inspection data, x-ray inspection data, gamma ray inspection data, ultrasonic inspection data, magnetic particle inspection data, eddy current inspection data, temperature inspection data, or other inspection data.
In one embodiment, the one or more processors 5140 may automatically generate a response including profile data (e.g., pre-weld profile data, dynamic profile data, post-weld profile data, or other data) for the joint region 5136 based on the received inspection data and transmit (via a transmitter) the profile data to the field system 5000. In one embodiment, for example, where the received inspection data is based on a scan of the joint region prior to the welding operation, the one or more processors 5140 may use the received inspection data to generate a response including the pre-weld profile data of the joint region 5136 and transmit (via a transmitter) the pre-weld profile data to the field system 5000. In one embodiment, where the received inspection data is based on a scan of the joint region during the welding operation, the one or more processors 5140 may use the received inspection data to generate a response including dynamic profile data for the joint region 5136 and transmit (via a transmitter) the dynamic profile data to the field system 5000. In one embodiment, where the received inspection data is based on a scan of the joint region after the welding operation, the one or more processors 5140 may use the received inspection data to generate a response including the post-weld profile data of the joint region 5136 and transmit (via a transmitter) the post-weld profile data to the field system 5000.
In one embodiment, the one or more processors 5140 may generate a response including 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 operating data to the field system 5000. For example, after receiving the operating protocol, the field system 5000 may perform one or more operations based on the received operating protocol. In another embodiment, the one or more processors 5140 can generate profile data based on the received inspection data to obtain profile data (e.g., pre-weld profile data, dynamic profile data, post-weld profile data, or other profile data) for the joint region 5136. In another embodiment, one or more processors 5140 may use the profile data to obtain a welding protocol or other operating protocol and transmit (via a transmitter) the operating protocol to the field system 5000.
In one embodiment, the one or more processors 5140 may generate a welding protocol or other operating protocol based on inspection data associated with one or more other pipes (in addition to the pipes 1022a, 1022 b), data related to input parameters (e.g., welding or other parameters) for performing one or more operations (e.g., welding or other operations) on the other pipes, data related to observations of the operations, or other data. For example, the one or more processors 5140 may obtain inspection data from one or more field systems and analyze the inspection data to determine whether and which of the pipes have defects. The processor may then compare one or more sets of observations of the operation performed on the one or more objects determined to have a defect (after the operation is performed) with one or more other sets of observations of the same operation performed on one or more other objects that are not defective to determine a condition that may lead to a defect (as described in further detail elsewhere herein). Based on the comparison, the one or more processors 5140 may generate a welding protocol or other operating protocol such that when the operating protocol is used for one or more subsequent operations (e.g., subsequent operations that are the same as or similar to the operations performed and observed), the operating protocol avoids or otherwise addresses the situation (which may have resulted in a flaw).
In one embodiment, the one or more processors 5140 can obtain pre-weld profile data for the joint region 5136 (between the conduits 1022a, 1022 b), wherein the pre-weld profile data is based on a scan of the joint region 5136 at the field system 5000 prior to the welding operation. For example, the one or more processors may receive pre-weld profile data from the field system 5000. As another example, the one or more processors 5140 may generate pre-weld profile data based on inspection data received from the field system 5000. After acquisition, the one or more processors 5136 can analyze the pre-weld profile data to generate a response to the field system 5000. In one embodiment, the one or more processors 5140 can compare one or more characteristics of the pre-weld profile data (e.g., pipe ovality/roundness characteristics, pipe bevel profile characteristics, weld joint fit-up and alignment characteristics, or other characteristics) to one or more characteristics of an acceptable predefined pre-weld profile. Based on the comparison, the processor 5140 may transmit (via the transmitter) a response to the field system 5000 as control operation data to the field system 5000 indicating whether the field system 5000 is to begin a welding operation.
For example, the response may specify that the joint region 5136 is within specifications of the welding operation, thereby instructing the field system 5000 to begin the welding operation. The response may additionally or alternatively include one or more welding protocols for the welding operation. As another example, the response may specify that the joint region 5136 is not within specification, indicating that the field system 5000 should not perform a welding operation on the joint region 5136 in its current state. In one use case, the response may indicate a need to modify the joint region 5136 (e.g., a need to realign or otherwise modify the conduits 1022a, 1022 b) prior to the welding operation. Thus, the response may cause the field system 5000 to operate the pipe joint structure of the field system 5000 to alter the joint region 5136 prior to the welding operation such that the joint region 5136 is within specifications of the welding operation.
In one embodiment, the one or more processors 5140 may compare one or more characteristics of the profile data (obtained based on a scan of the joint region 5136 at the field system 5000) to one or more predetermined profile characteristics to determine one or more matching characteristics. For example, based on the matching characteristics, the one or more processors 5140 may automatically determine one or more welding protocols for the joint region 5136 between the weld conduits 1022a, 1022b and transmit (via a transmitter) the one or more welding protocols to the field system 5000 to cause the field system 5000 to perform a welding operation on the joint region 5136 based on the one or more welding protocols. For example, the welding protocol may include one or more input parameters, such as wire feed speed, wire consumption, swing width, swing waveform, swing amplitude, weld time, gas flow rate, power level of the welding arc, welding current, welding voltage, welding impedance, welding torch travel speed, position of the welding tip of the welding torch along the pipe axis, angular positioning of the welding tip of the welding torch relative to its plane of rotation, distance of the welding tip of the welding torch from the inner surface of the pipe to be welded, or other parameters.
In one embodiment, the one or more processors 5140 can obtain dynamic profile data for the joint region 5136 (between the conduits 1022a, 1022 b), wherein the dynamic profile data is based on a scan of the joint region 5136 at the field system 5000 during a welding operation. For example, the one or more processors 5140 may receive (via a receiver) dynamic profile data from the field system 5000. As another example, one or more processors 5140 may generate dynamic profile data based on inspection data received from field system 5000. After acquisition, the one or more processors 5140 may analyze the dynamic profile data to generate a response to the field system 5000. In one embodiment, the one or more processors 5140 may compare one or more characteristics of the dynamic profile data (e.g., pipe ovality/roundness characteristics, pipe bevel profile characteristics, weld joint fit-up and alignment characteristics, weld shape characteristics, or other characteristics) to one or more characteristics of an acceptable predefined profile (e.g., a predefined pre-weld profile, a predefined post-weld profile, or other profile). Based on the comparison, the processor 5140 may transmit a response to the field system 5000 that includes a dynamic update to one or more weld characteristics for the welding operation. For example, the response may cause the field system 5000 to control the welding torch based on dynamic updates to the welding characteristics during the welding operation.
In one embodiment, the one or more processors 5140 may obtain post-weld profile data for the joint region 5136 (between the conduits 1022a, 1022 b), wherein the post-weld profile data is based on a scan of the joint region 5136 at the field system 5000 after the welding operation. For example, the one or more processors 5140 may receive (via a receiver) post-weld profile data from the field system 5000. As another example, the one or more processors may generate post-weld profile data based on inspection data received from the field system 5000. After acquisition, the one or more processors 5140 may analyze the dynamic profile to generate a response to the field system 5000. In one embodiment, the one or more processors 5140 may compare one or more characteristics of the post-weld profile data (e.g., weld shape characteristics or other characteristics) to one or more characteristics of an acceptable predefined post-weld profile. Based on the comparison, the processor 5140 may transmit (via the transmitter) a response to the field system 5000 indicating whether the results of the welding operation are acceptable. Additionally or alternatively, the one or more processors 5140 may automatically determine one or more welding protocols for subsequent operations (e.g., operations to repair or compensate for defects generated by the welding operation, operations that typically follow the welding operation if no significant defects are detected, etc.) and include the one or more welding protocols in the transmitted responses.
For example, if the welding operation is for a root pass, the response may specify that the layer of the root pass resulting from the welding operation is within specification, and the response may specify that preparation for a subsequent welding operation for a hot pass is to begin. Thus, the response may cause the field system 5000 to initiate performance of the hot aisle operation on the joint region 5136. As another example, the response may specify that the resulting root channel layer is not within specification. For example, in one use case, the response may specify that the field system 5000 should not continue hot aisle operation until further notice. In another use case, the response may specify that the field system 5000 continue with a different welding protocol (other than that otherwise pre-planned for hot aisle operation), where the different welding protocol repairs or compensates for the resulting root aisle layer that is not within specification.
In one embodiment, where one or more processors 5140 are local to the field system 5000 (e.g., are part of a computer system local to the field system 5000), one or more processors 5140 may transmit inspection data associated with the inspection of the area between the conduits 1022a, 1022b (e.g., the joint area 5136 or other area) to a remote computer system. The transmitted verification data may, for example, comprise one or any combination of the types of verification data described herein. In one embodiment, one or more processors 5140 can receive (via a receiver) a response (e.g., a response including pre-weld profile data, dynamic profile data, post-weld profile data, confirmation of transmitted profile data, a weld or other operating protocol, an alert indicating a defect, or other data) from a remote computer system in response to transmitting the inspection data to the remote computer system. In one embodiment, the response may be derived from the transmitted verification data and additional data received by the remote computer system. For example, the additional data may be related to observations of one or more operations performed on other pipes, checks of other pipes, one or more input parameters for performing the observed operations, or other data (as described herein). Thus, for example, one or more operations in a field system (e.g., field system 5000 or other field systems) may be managed based on having a large pool of data from the same field system and/or other field systems that was not previously available. For example, a data pool (including observations regarding operations on other pipes, inspections of other pipes, data of input parameters for performing the observed operations, or other data from the same or other field systems) may be used to generate and select one or more welds or other operating protocols for subsequent operations (as described herein) to prevent or reduce weld defects or produce better welds for current and future customers. As another example, a large pool of data from different field systems may be used to improve their inspection and analysis (as described herein) in order to provide better products to current and future customers (e.g., by reducing weld defects, detecting defects earlier in the process, etc.).
In one embodiment, where the one or more processors 5140 are local to the field system 5000 (e.g., are part of a computer system local to the field system 5000), the one or more processors 5140 may transmit a profile of the joint region 5136 between the conduits 1022a, 1022b (e.g., a profile based on a scan of the joint region 5136) to a remote computer system. In response, the one or more processors 5140 can receive (via a receiver) a confirmation of the profile of the joint region or a modified version of the profile of the joint region 5136 from a remote computer system. In one embodiment, the one or more processors can cause the welding torch of the welding system 5004 to generate a weld at the joint region 5136 based on the confirmed or modified version of the profile of the joint region 3136.
For example, the one or more processors 5140 of the field system 5000 may cause one or more inspection devices to inspect the joint region 5136 between the conduits 1022a, 1022b to obtain inspection data (e.g., raw data from the inspection devices, 2D or 3D imaging data, or other data from the inspection). The test device used for testing may comprise one or any combination of the types of test devices described herein. The obtained verification data may accordingly comprise one or any combination of the types of verification data described herein. As another example, the one or more processors 5140 may determine the profile of the joint region 5136 based on the obtained inspection data, but may also transmit the inspection data to a remote computer system to evaluate the inspection data. The one or more processors 5140 may transmit the profile of the joint region 5136 it determines to a remote computer system for accuracy checking. Based on its own evaluation of the inspection data, the remote computer system can respond to the one or more processors 5140 with a confirmation of the profile of the joint region 5136, an indication that the provided profile is inaccurate, or other response. Additionally or alternatively, if the provided profile is inaccurate, the remote computer system can respond from its own modified version of the profile of the joint region 5316 that the remote computer system evaluates to the inspection data. For example, in response to receiving the confirmation, the one or more processors 5140 can cause the welding torch of the welding system 5004 to begin or continue a welding operation based on the profile of the joint region 5136 that it determined to produce a weld at the joint region 5316. However, if a modified version of the profile is received, the one or more processors 5140 can cause the welding torch of the welding system 5004 to begin or continue a welding operation based on the modified version of the profile to produce a weld at the joint region 5316.
In one embodiment, where the one or more processors 5140 are local to the field system 5000 (e.g., are part of a computer system local to the field system 5000), the one or more processors 5140 may interact with the inspection laser of the welding system 5004 to scan the joint region 5136 between the conduits 1022a, 1022b to determine the profile of the joint region 5136 prior to the welding operation and to generate pre-weld profile data based on the scan. In another embodiment, the one or more processors 5140 can transmit the pre-weld profile data to a remote computer system. In response, the one or more processors 5140 can receive (via a receiver) a confirmation of the pre-weld profile data or a modified version of the pre-weld profile data from a remote computer system. In one embodiment, the one or more processors may operate the tube-joining structure 5052 and/or the tube-joining structure 5054 based on the confirmed or modified version of the pre-weld profile data to modify the joint region 5136 between the tubes prior to the welding operation.
For example, the one or more processors 5140 of the field system 5000 may cause one or more inspection devices to inspect the joint region 5136 between the conduits 1022a, 1022b to obtain inspection data prior to a welding operation on the joint region 5136. The test device used for testing may comprise one or any combination of the types of test devices described herein. The obtained verification data may accordingly comprise one or any combination of the types of verification data described herein. The one or more processors 5140 may generate pre-weld profile data based on the obtained inspection data, but may also transmit the inspection data to a remote computer system to evaluate the inspection data. The one or more processors 5140 may transmit the pre-weld profile data it generates to a remote computer system for accuracy checking. Based on its own evaluation of the inspection data, the remote computer system may respond to the one or more processors 5140 with a confirmation of the pre-weld profile data, an indication that the provided pre-weld profile data is inaccurate, or other response. Additionally or alternatively, if the provided pre-weld profile data is inaccurate, the remote computer system may respond from its own modified version of the pre-weld profile data resulting from the evaluation of the inspection data by the remote computer system. As another example, if the pre-weld profile data indicates that the conduits 1022a, 1022b are not aligned, and confirmation of the pre-weld profile data is received, the one or more processors 5140 may cause the conduit engagement structures 5052, 5054 to realign the conduits 1022a, 1022b prior to the welding operation that produces the weld at the joint region 5136. However, if a modified version of the pre-weld profile data is received, the one or more processors 5140 may instead utilize the modified version to perform subsequent operations, such as using the modified version to determine whether and how to perform realignment is needed, selecting a welding protocol for producing a weld at the joint region 5136, and so forth.
In one embodiment, where one or more processors 5140 are local to the field system 5000 (e.g., are part of a computer system local to the field system 5000), the one or more processors may develop a welding protocol based on a validated or modified version of the pre-weld profile data (received from a remote computer system). For example, if confirmation of the pre-weld profile data is received, the one or more processors 5140 may use the pre-weld profile data it generates to develop a welding protocol for performing a welding operation on the joint region 5136. For example, if a modified version of the pre-weld profile data is received, the one or more processors 5140 may use the modified version to develop a welding protocol for performing a welding operation on the joint region 5136.
In one embodiment, where the one or more processors 5140 are local to the field system 5000 (e.g., are part of a computer system local to the field system 5000), the one or more processors 5140 may interact with the inspection laser of the welding system 5004 to scan the joint region 5136 between the conduits 1022a, 1022b to determine the profile of the joint region 5136 during the welding operation and to generate dynamic profile data based on the scan. In another embodiment, the one or more processors 5140 can transmit (via a transmitter) the dynamic profile data to a remote computer system. In response, the one or more processors 5140 can receive (via the receiver) a confirmation of the dynamic profile data or a modified version of the dynamic profile data from the remote computer system. In one embodiment, the one or more processors 5140 can control the welding torch of the welding system 5004 during a welding operation based on the validated or modified version of the dynamic profile data.
For example, the one or more processors 5140 of the field system 5000 may cause one or more inspection devices to inspect the joint region 5136 between the conduits 1022a, 1022b to obtain inspection data during a welding operation on the joint region 5136. The test device used for testing may comprise one or any combination of the types of test devices described herein. The obtained verification data may accordingly comprise one or any combination of the types of verification data described herein. The one or more processors 5140 may generate dynamic profile data based on the inspection data obtained, but may also transmit the inspection data to a remote computer system to evaluate the inspection data. One or more processors 5140 may transmit the dynamic profile data it generates to a remote computer system for accuracy checking. Based on its own evaluation of the inspection data, the remote computer system can respond to the one or more processors 5140 with a confirmation of the dynamic profile data, an indication that the provided dynamic profile data is inaccurate, or other response. Additionally or alternatively, if the provided post-weld profile data is inaccurate, the remote computer system may respond from its own modified version of the dynamic profile data resulting from the evaluation of the inspection data by the remote computer system.
As another example, if an acknowledgement of the dynamic profile data is received, the one or more processors 5140 can use the dynamic profile data it generates to update a welding parameter protocol for controlling a welding torch of the welding system 5004 when performing a welding operation (to perform the welding operation on the joint region 5136). As another example, if a modified version of the dynamic profile data is received, the one or more processors 5140 can use the modified version to update a welding parameter protocol used to control a welding torch of the welding system 5004 when performing a welding operation (to perform the welding operation on the joint area 5136).
In one embodiment, where the one or more processors 5140 are local to the field system 5000 (e.g., are part of a computer system local to the field system 5000), the one or more processors 5140 may interact with the inspection laser of the welding system 5004 to scan the joint region 5136 between the conduits 1022a, 1022b to determine the profile of the joint region 5136 after the welding operation and generate post-weld profile data based on the scan. In another embodiment, the one or more processors 5140 can transmit the post-weld profile data to a remote computer system. In response, the one or more processors 5140 can receive (via a receiver) a confirmation of the post-weld profile data or a modified version of the post-weld profile data from a remote computer system.
For example, the one or more processors 5140 of the field system 5000 may cause one or more inspection devices to inspect the joint region 5136 between the conduits 1022a, 1022b to obtain inspection data after a welding operation on the joint region 5136. The test device used for testing may comprise one or any combination of the types of test devices described herein. The obtained verification data may accordingly comprise one or any combination of the types of verification data described herein. The one or more processors 5140 may generate post-weld profile data based on the obtained inspection data, but may also transmit the inspection data to a remote computer system to evaluate the inspection data. The one or more processors 5140 may transmit the post-weld profile data it generates to a remote computer system for accuracy checking. Based on its own evaluation of the inspection data, the remote computer system may respond to the one or more processors 5140 with a confirmation of the post-weld profile data, an indication that the provided post-weld profile data is inaccurate, or other response. Additionally or alternatively, if the provided post-weld profile data is inaccurate, the remote computer system may respond from its own modified version of the post-weld profile data resulting from the evaluation of the inspection data by the remote computer system.
In an embodiment where the one or more processors 5140 are local to the field system 5000 (e.g., are part of a computer system local to the field system 5000), the one or more processors 5140 may cause another welding operation to be performed on the joint region 5136 between the pipes based on a confirmed or modified version of the post-weld profile data (received from a remote computer system). For example, if confirmation of the post-weld profile data is received, the one or more processors 5140 may use the post-weld profile data it generates to determine whether the results of the welding operation have one or more defects, whether the joint region 5136 is ready for the next operational stage, or other determination. For example, in one use case, after the root pass operation is completed in the joint region 5316, the post-weld profile data of the root pass layer in the joint region 5316 may indicate that the root pass layer thickness is insufficient. In response, the post-weld profile data may be utilized to determine welding parameters for a welding operation that repairs the thickness deficiency or a thermal channeling operation that produces a thermal channel layer (on the root channel layer) that compensates for the thickness deficiency. As another example, if a modified version of the pre-weld profile data is received, the one or more processors 5140 may perform the foregoing operations using the modified version in place of the post-weld profile data it generates.
In one embodiment, the welding parameters that affect the quality of the weld may include voltage, current, welding torch travel speed, wire feed speed, gas flow, and the like. In one embodiment, other welding parameters that affect the quality of the weld may include impedance, temperature, and the like.
In one embodiment, the voltage used during the welding process may affect the bead width and bead shape. In one embodiment, the voltage is measured in volts. In one embodiment, a welding system may include a voltage sensor configured to measure a voltage of a power source used to generate a welding arc.
In one embodiment, the current used during the welding process may affect the penetration of the weld bead. In one embodiment, the current is measured in amperes. In one embodiment, a welding system may include a current sensor configured to measure a current of a power source used to generate a welding arc.
In one embodiment, the welding feed speed is the rate of travel of the welding electrode along the weld joint during the welding process. In one embodiment, the welding electrode is fed from a welding torch. In one embodiment, the welding speed may be controlled by controlling a welding torch that feeds a welding electrode. In one embodiment, the welding speed during the welding process may affect the size of the weld bead and/or the penetration of the weld bead. In one embodiment, the welding speed is measured in millimeters per second or inches per second.
In one embodiment, the wire feed speed/wire use is the rate at which the welding electrode material/filler material is consumed (or fed into the weld) during the welding process. In one embodiment, the linear feed speed is measured in millimeters per second or inches per second. In one embodiment, the welding system may include a wire feed speed sensor configured to sense the flow of welding electrode material.
In one embodiment, the rate of change of the weight of the wire spool allows the welding system to measure the rate at which wire bond 5007 is fed into the weld. In one embodiment, the feed motor is running at a set/predetermined rate, but the wheels of the pusher wire 5007 may slip due to minor changes in the wire 5007 or due to wear of the feed wheel itself. These slips can be temporary in nature, and their presence can be recorded and used in a quality control feedback loop. If the slip is persistent, the one or more processors 5140 may be configured to increase the speed of the feed motor to compensate. The speed overdrive ratio may need to increase over time. Eventually, compensation will not be possible and the welding system 5004 will be taken out of service for maintenance. In one embodiment, tracking the rate of overdrive ratio increase throughout the welding system allows the one or more processors to determine an optimum limit for the maximum allowable overdrive ratio. This setting may then be transmitted to all components of the welding system that are in service. In one embodiment, one or more processors 5140 may be configured to update values at any time as data becomes available in order to minimize the frequency of process interruptions and minimize the frequency of machine downtime for maintenance.
In one embodiment, a welding system may include a gas flow sensor configured to sense/detect a flow rate of a shielding gas used in a welding process. In one embodiment, the shielding gas may be an active gas configured to shield the molten weld pool. In one embodiment, the gas flow sensor is configured to provide a signal proportional to the gas flow rate in the shielding gas line. In one embodiment, the one or more processors 5140 of the field system 5000 is configured to stop welding if the gas flow rate of the shielding gas is not within a predetermined gas flow rate range.
In one embodiment, the tube is preheated prior to the welding process. In one embodiment, the temperature of the pipe may be monitored by one or more temperature sensors of the welding system. In one embodiment, the one or more temperature sensors are configured to measure the temperature of the pipe at each point along the weld. In one embodiment, the one or more processors 5140 of the field system 5000 is configured to stop the welding process if the temperature of the pipe is not within a predetermined temperature range.
In one embodiment, a welding system may include an impedance sensor configured to sense/detect an input electrical impedance of the welding system.
In one embodiment, the correct wire/welding electrode/filler material is used for each welding pass. For example, the only difference between the two reel spools is a 0.1 millimeter difference in wire diameter. If the manufacturer of the spool of wire is marked as contaminated or obscured, the wrong spool may be loaded into the welding system. The RFID tag on the spool has a spool identifier. In one embodiment, the RFID tag on the spool may be read by a sensor on the welding system. If the RFID tag has the wrong spool identifier, the welding system is configured to not feed wire material and alert the user to change to the correct wire.
In one embodiment, the weight of the spool may be monitored by one or more processors 5140 of the on-site system 5000. If the wire runs out during the welding process, the voltage signal used by the processor to manage the distance between the welding tip and the workpiece becomes zero. In response, the processor moves the tip closer to the workpiece, which causes the tip to contact the molten weld metal and result in defects containing copper. Thus, knowing the exact weight of the wire remaining on the wire spool helps the welding system prevent welding lanes that initially require more wire than is available. Additionally, if the spool weight stops changing, this may indicate that the spool is empty or that the wire feed mechanism is malfunctioning. In either case, the one or more processors 5140 of the field system 5000 is configured to stop the welding process.
In one embodiment, one or more processors 5140 of field system 5000 is configured to track the weight of each spool in real time. Each weld pass in the weld joint requires a different amount of wire due to the variation in diameter and the variation in width of the filled weld groove.
If one or more processors 5140 of field system 5000 determines that the spool will end with too little wire to complete the next weld pass, but it will have enough wire to complete a different weld pass, one or more processors 5140 of field system 5000 may be configured to notify the operator to remove the spool and hand it to a different operator. For example, the spool starts with 10 pounds of wire and the weld pass performed through the welding system requires 1.3 pounds of wire. The welding system was able to complete its weld pass over 7 weld joints before the spool had too little wire.
When the spool was removed after the 7 th weld pass, 0.9 pounds of wire on the spool was wasted. If there is another weld lane requiring, for example, 1.1 pounds of wire, the one or more processors 5140 of the field system 5000 are configured to alert the operator to remove the wire spool after only 6 weld lanes. In this case, the spool would have 2.2 pounds of wire remaining. This spool can then be used for a weld pass that only requires 1.1 pound of wire to complete 2 such weld passes (and no wire is wasted).
In one embodiment, wire 5507 passes through welding tip 5503. Tip welding tip 5503 also carries a high welding current. Both of these factors cause wear of the bore of welding tip 5503. When this occurs, the contact point on the inside shifts, which inherently affects the arc characteristics and thus the weld quality. In one embodiment, welding parameters like voltage, current, wire feed, power, and impedance are monitored in real time. This data is sent by the one or more processors to the tablet computer for analysis against a profile comparison of the variables described above due to the computationally intensive nature of the analysis. When the analysis detects an impending problem, the internal welding system 5004 and operator are sent a message to change the welding tip 5503 before the next weld. Additionally, this data may be used in a quality control feedback loop. In one embodiment, the results from the quality control feedback loop may be used to dynamically update the weld tip loss profile.
In one embodiment, exemplary welding parameters for both the uphill and downhill welding procedures are shown in fig. 72D. For example, in one embodiment, at least one of the plurality of welding torches 5502 welds in an upward rotational direction (i.e., uphill) while at least another of the plurality of welding torches 5502 welds in a downward rotational direction (i.e., downhill). In one embodiment, the welding parameters shown herein are exemplary and are by no means optimized or include everything that may need to be changed during these welding procedures. In one embodiment, the travel speed for the downhill welding process is 13.5 inches/minute and for the uphill process is 10.0 inches/minute. In one embodiment, the amplitude of the oscillation across the groove is 0.09 inches for a downhill welding procedure and 0.15 inches for an uphill welding procedure. In one embodiment, the swing speed is 160 times/minute for a downhill welding procedure and 130 times/minute for an uphill welding procedure. In one embodiment, wave control 1 (i.e., related to line feed speed) is 400 for a downhill welding process to 370 for an uphill welding process. In one embodiment, the welding channel welds at a power supply control voltage of 16.5V.
The operation of the internal welding system 5004 will now be described. In one embodiment, the internal welding system 5004 is configured to operate through repeated cycles of operation.
After determining that welding is complete in the current weld joint, the one or more processors 5140 are configured to send a communication signal to the wire feed electronics module 5046 to control (via a control signal) the welding torch motors 5512, 5550, 5588 to retract the welding torch 5502 to its initial retracted position. The one or more processors 5140 are also configured to send communication signals to the front-most portion electronics module 5014 to control/close (via control signals) the front clamp control valve 5018 to retract the first engagement structure 5052 to its original retracted position, and to send communication signals to the central portion electronics module 5064 to control/close (via control signals) the rear clamp control valve 5062 to retract the second engagement structure 5054 to its original retracted position. Internal welding system 5004 (including welding torch 5502 and clamps 5144, 5142) must be moved to the next weld joint.
In one embodiment, the one or more processors 5140 are configured to generate communication signals to the drive section electronics module 5118 to control (via control signals) the drive motor 5124 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 internal welding system 5004 accelerates may be 6 feet/second.
When the second coupling structure 5054 is positioned at the next weld joint, the drive section electronics module 5118 sends a communication signal to the wire feed electronics module 5046 to check alignment with the pipe end. In one embodiment, the line feed electronics module 5046 is configured to operate (open) one or more verification detectors 5056 to measure the position of the second engagement structure 5054 relative to the end of the tubing. In one embodiment, the rotatable hub 5072 may not operate when the one or more verification detectors 5056 measure the position of the second engagement structure 5054 relative to the end of the pipe.
In one embodiment, the wire feed electronics module 5046 is configured to send the measured distance data to the drive portion electronics module 5118. In one embodiment, the drive section electronics module 5118 is configured to control (via control signals) the drive motor 5124 to move the first engagement structure 5052 and the second engagement structure 5054 by the measured distance data.
In one embodiment, when the second coupling structure 5054 is properly aligned and positioned relative to the pipe end, the drive portion electronics module 5118 is configured to send a communication signal to the center portion electronics module 5064 that the internal welding system 5004 is positioned at the next weld joint. In one embodiment, the mid-section electronics module 5064 controls (via a control signal to open) the rear clamp control valve 5062 to raise the second engagement structure 5054 and clamp the old/existing tubing.
The next/new pipe segment 1002a is then introduced by the personnel and slid into place on the forwardmost portion 5006 of the internal welding system 5004. At this point, the one or more processors 5140 are configured to send communication signals to the line feed electronics module 5046 to operate the one or more check detectors 5056 to check the alignment of the pipes. In one embodiment, the one or more processors 5140 may rotate the rotatable hub 5078 to take measurements at multiple locations.
If the pipe alignment data is within the predetermined tolerance, the wire feed electronics module 5046 sends a communication signal to the front most electronics module 5014 to actuate the front clamp 5142. In one embodiment, the front-most electronic module 5014 controls/opens (via a control signal) the front clamp control valve 5018 to raise the first engagement structure 5052 and clamp the new tube segment 1002 a.
If the conduit alignment data is not within the predetermined tolerance, the line feed electronics module 5046 sends a communication signal (message) to the one or more processors 5140 identifying the misalignment between the conduits 1022a, 1022 b. In one embodiment, this information may be relayed to the crane operator via conventional crane operator gesture signals or to a computer display terminal in the crane cab via electronic signals.
After clamping the pipe, the one or more processors 5140 are configured to send communication signals to the wire feed electronics module 5046 to operate the one or more verification detectors 5056 to measure gaps and radial runout (stagger) at multiple points along the circumference of the weld joint. In one embodiment, this data is transmitted out to the one or more processors 5140 and compared to allowable tolerances.
If the joint fit-up (i.e., gap and radial offset (mismatch)) is within a predetermined tolerance, one or more of the processors 5140 or the wire feed electronics module 5046 sends a communication signal to the operator indicating that welding may begin, or sends a communication signal to the wire feed electronics module 5046 to automatically begin the welding process.
If the joint fit-up (i.e., gap and radial offset (mismatch)) is not within a predetermined tolerance, a warning is sent to the operator, who may restart the clamping sequence or ignore the warning. In one embodiment, internal welding system 5004 is configured to weld up to 4 millimeters of clearance and radial offset (stagger).
In one embodiment, the wire feed electronics module 5046 is configured to automatically begin a welding process. In one embodiment, the one or more processors 5140 are configured to send a communication signal to the welding power supply via the umbilical 5034 to turn the welding power supply on to the welding torch 5502. In one embodiment, wire feed electronics module 5046 is configured to control/move one or more welding torches 5502 radially, axially, and/or angularly to the proper welding position. In one embodiment, the wire feed electronics module 5046 moves the one or more welding torches 5502 radially, axially, and/or angularly to the correct working distance from the pipe and to the center of the weld joint as measured by the one or more verification detectors 5056.
In one embodiment, wire feed electronics module 5046 is further configured to operate (open) shielding gas valve 5042 to supply shielding gas to welding torch 5502 and to operate a motor of welding feed system 5044 to begin feeding wire or electrode to welding torch 5502.
In one embodiment, the wire feed electronic module 5046 sends a communication signal to both the front most electronic module 5014 and the center portion electronic module 5064 to begin rotation of the rotatable hub 5078. In one embodiment, the wire feed electronics module 5046 sends communication signals to both the front most electronics module 5014 and the central electronics module 5064 to synchronize the front rotating motor 5030 and the rear rotating motor 5074. In one embodiment, the wire feed electronics module 5014 sends control signals to operate the front rotation motor 5030 and the central portion electronics module 5064 sends control signals to operate the rear rotation motor 5074. The front rotation motor 5030 and the rear rotation motor 5074 are configured to rotate the rotatable hub 5078 while keeping the front clamp 5142 and the rear clamp 5144 stationary. In one embodiment, the rotatable hub 5078 rotates continuously the full length of the weld.
In one embodiment, the wire feed electronics module 5046 is configured to operate one or more verification detectors 5056 to locate the center of the weld joint and move the weld torch 5502 axially to follow the weld joint.
In one embodiment, the line feed electronics module 5046 is configured to measure a voltage of the welding power. The measured voltage data may be used by the wire feed electronics module 5046 to determine the distance of the welding torch 5502 from the pipe. In one embodiment, wire feed electronics module 5046 is configured to radially adjust welding torch 5502 to maintain a constant distance of welding torch 5502 from the conduit. In one embodiment, the wire feed electronics module 5046 may oscillate the welding torch 5502 axially to improve the quality of the weld.
In one embodiment, wire feed electronics module 5046 is configured to change the tilt angle of weld torch 5502 based on which portions of the weld joint are welded. For example, the tilt angle of welding torch 5502 in the travel plane is adjusted to compensate for gravity.
In one embodiment, the wire feed electronics module 5046 may be configured to change the wire feed speed or send a communication signal to the welding power supply (via the umbilical 5034) to change the welding current based on measurement data from the one or more verification detectors 5056.
In one embodiment, the welding process may be performed by rotating a welding torch 360 ° in a welding channel. In one embodiment, the start and stop positions of the weld may be any position along the weld joint.
In one embodiment, the welding process may be performed using N equally spaced welding torches 5502, wherein the rotatable hub 5078 is rotated through (360/N) degrees to deposit a weld pass. In one embodiment, the welding procedure may be performed using N equally spaced welding torches 5502, wherein the rotatable hub 5078 is rotated through (2 times 360/N) degrees to deposit two weld passes. For example, in an embodiment where internal welding system 5004 has three equally spaced welding torches 5502, rotatable hub 5078 rotates through 120 ° to deposit one weld pass and rotates through 240 ° to deposit two weld passes.
When welding torch 5502 reaches the point at which the previous welding torch 5502 started its weld path, one or more verification detectors 5056 detect the existing weld bead, and wire feed electronics 5046 are configured to move welding torch 5502 radially to compensate.
In one embodiment, two weld passes may be deposited as above with breaks between the weld passes to allow for full laser and visual post weld inspection. In one embodiment, welding may be performed 360 ° using N unequally spaced welding torches 5502, where each welding torch 5502 deposits a continuous weld pass for a total of N360 ° weld passes plus the distance from the first torch to the nth torch.
After determining that the weld is complete, the one or more processors 5140 are configured to send communication signals to the wire feed electronics module 5046 to control (via control signals) the weld torch motors 5512, 5550, 5588 to retract the weld torch 5502 to its initial retracted position. For example, welding torch 5502 may be retracted to its original home position for each axis (radial, axial, tilted).
In one embodiment, the rotatable hub 5078 continues to rotate while the wire feed electronics module 5046 operates one or more inspection detectors 5056 and a 2D camera 5112 to inspect the quality of the weld. In one embodiment, if certain types of weld defects are found (e.g., underfill, lack of reinforcement), the one or more processors 5140 are configured to send a communication signal to the wire feed electronics module 5046 to move the welding torch 5502 to this location and apply additional weld material to repair the defect.
Once the verification and any repairs are completed and confirmed by the operator, the operator may send a communication signal to the front most electronic module 5014 to control/close (via a control signal) the front clamp control valve 5018 to retract the first engagement structure 5052 to its original retracted position, and a communication signal to the central portion electronic module 5064 to control/close (via a control signal) the rear clamp control valve 5062 to retract the second engagement structure 5054 to its original retracted position.
In an onshore pipeline application, both angular and positional pipe alignment errors can be corrected by sending control signals (to control the associated rollers 5332) from one or more processors 5140 to the support 5330 or supports 6010A and 6010B.
In one embodiment, the purge and verification system 7001 or the internal welding system 5004 may include a clamp constructed and arranged to clamp the inner surface of the first conduit 1022 b. In one embodiment, rack 5330 or racks 6010A and 6010B are configured to move second/introduction conduit 1022a into position. In one embodiment, the one or more processors 7062 or 5140 are configured to interact with the test detectors 5056 or 7042 to check alignment between the conduits and send control signals to the support 5330 or supports 6010A and 6010B to correct any conduit 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 pipes (to correct their alignment errors). In one embodiment, this procedure can be used on small or thick-walled pipes with very low (< 20) diameter-to-wall ratio, since any amount of clamping force cannot significantly change the shape of the low D/t pipe.
In one embodiment, the purge and verification system 7001 or the internal welding system 5004 may include two clamps. For example, one clamp is constructed and arranged to clamp the inner surface of the first conduit 1022 b. In one embodiment, rack 5330 or racks 6010A and 6010B are configured to move second/introduction conduit 1022a into position. In one embodiment, the second clamp is constructed and arranged to clamp the inner surface of the second/introduction conduit 1022 a. In one embodiment, the one or more processors 7062 or 5140 are configured to interact with the verification detectors 5056 or 7042 to check alignment between the pipes. For example, if the alignment is not good, the second clamp releases the second conduit 1022 a. The one or more processors 7062 or 5140 are configured to send control signals to the support 5330 or the supports 6010A and 6010B to correct for any pipe 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 conduits (to correct alignment errors thereof), for example, by altering the positioning of the conduits 1022 a. The process may continue until acceptable conduit alignment is achieved by checking the detector or a predetermined number of attempts (e.g., 10) in which the second conduit 1022a is rejected and a new second conduit is moved into position.
In one embodiment, crane and clamp alignment is used in an onshore pipeline alignment and welding process. In an onshore pipeline application, angular pipe alignment errors may be corrected by providing instructions to the crane operator, and positional alignment errors may be corrected by providing instructions to the worker to place shims between the clamps and the pipe.
In one embodiment, the purge and verification system 7001 or the internal welding system 5004 may include a clamp constructed and arranged to clamp the inner surface of the first conduit 1022 b. In one embodiment, the crane operator moves the second/lead-in conduit 1022a into position and the worker places an external clamp around the seam. In one embodiment, the one or more processors 7062 or 5140 are configured to interact with the verification detectors 5056 or 7042 to check alignment between the pipes. If the verification detector 5056 or 7042 detects an angular misalignment/pipe alignment error, instructions are sent to the crane operator to correct the angular misalignment/pipe alignment error and the worker releases the clamp as the pipe moves. If the verification detector 5056 or 7042 detects a misalignment/pipe alignment error, instructions are sent to the worker regarding the placement and thickness of the shims needed to correct the misalignment/pipe alignment error. The worker removes the fixture, places the shim, and replaces the fixture. The process is repeated until the alignment of the pipe is accepted by the inspection detector.
In one embodiment, the purge and verification system 7001 or the internal welding system 5004 may include two clamps. For example, one clamp is constructed and arranged to clamp the inner surface of the first conduit 1022 b. In one embodiment, a crane operator moves the second/introduction conduit 1022a into position. In one embodiment, the second clamp is constructed and arranged to clamp the inner surface of the second/introduction conduit 1022 a. In one embodiment, the one or more processors 7062 or 5140 are configured to interact with the verification detectors 5056 or 7042 to check alignment between the pipes. If the verification detector 5056 or 7042 detects an angular misalignment/pipe alignment error, the second clamp releases the second pipe and sends instructions to the crane operator to correct the misalignment. If the verification detector 5056 or 7042 detects a misalignment/pipe alignment error, the second clamp releases the second pipe and sends instructions to the worker regarding the placement and thickness of the shims needed to correct the misalignment/pipe alignment error. The crane operator moves the second pipe away from the first pipe and the worker places the gasket. The crane operator moves the second pipe back into position. The second clamp clamps the second pipe. The process is repeated until the alignment of the pipe is accepted by the inspection detector.
Fig. 103B illustrates the pipe alignment, welding, and inspection process of internal welding system 5004.
In one embodiment, the verification detector 5056 scans the joint region 5136 between the conduits 1022a, 1022b 360 ° before any welding occurs. In one embodiment, the verification detector 5056 is positioned between clamps and/or seals of the internal welding system 5004 and is opened during the process of generating pre-weld profile data. In one embodiment, welding torch 5502 is turned off during the process of generating the pre-weld profile data. In one embodiment, the one or more processors 5140 are configured to interact with the verification detector 5056 to scan the joint region 5136 to obtain pre-weld profile data after the first clamp 5142 and the second clamp 5144 are engaged with the first conduit 1022a and the second conduit 1022b, respectively.
In one embodiment, one or more processors 5140 operate (or are otherwise controlled) the supports 5330 (shown in fig. 10A and 10B) and 6010A and 6010B (shown in fig. 73) to engage the outer surfaces 5346 and/or 5348 (shown in fig. 2G) of the first conduit 1022a and/or the second conduit 1022B to adjust the relative positioning of the conduits 1022a, 1022B in the event that the pre-weld profile data determines that adjustment is needed. In one embodiment, the inner surfaces 5130, 5132 of the first and/or second conduits 1022a, 1022b are engaged and manipulated by the first and second clamps 5142, 5144, respectively, to adjust the relative positioning of the conduits 1022a, 1022b in the event that the pre-weld profile data determines that adjustment is needed.
In one embodiment, during the process of generating dynamic weld profile data, the inspection detector 5056 is positioned between clamps and/or seals of the internal welding system 5004 and opened. In one embodiment, the one or more processors 5140 are configured to control the position and speed of the welding torch 5502 (or 7502) based on the dynamic weld profile data. In one embodiment, the dynamic scanning/inspection process is performed during a root pass welding process, a hot pass welding process, a fill pass welding process, and a facing pass welding process. In one embodiment, an optional photogrammetric inspection process (e.g., 1044 as shown in fig. 1B and described with reference to fig. 1B) may be performed between the dynamic scan/inspection and hot aisle welding process and the dynamic scan/inspection and fill and cap aisle welding process.
In one embodiment, the verification detector 5056 scans the joint region 5136 between the conduits 1022a, 1022b 360 ° after the welding operation. In one embodiment, during the process of generating post-weld profile data, the verification detector 5056 is positioned between a clamp and/or seal of the internal welding system 5004 and is opened. In one embodiment, the welding torch 5502 is turned off during the process of generating post-weld profile data.
In one embodiment, the weld inspection process (e.g., 1008 as shown in fig. 1B and described with reference to fig. 1B) is performed after the post-weld scanning/inspection process.
The process of fig. 103B is described with reference to the internal welding system 5004. However, as shown in fig. 103B, it is contemplated that the same procedure is applicable to the joint internal welding system 3001 and the purge and verification system 7001, and thus will not be described again with reference to the joint internal welding system 3001 and the purge and verification system 7001.
In one or more embodiments, because the pipe is welded from the inside (i.e., the root weld pass is applied from inside the pipe), the resulting root weld may be superior because it better accounts for any misalignment and/or high and low areas within the pipe. Furthermore, if a hot weld channel (the second weld layer on top of the root channel layer) is also applied internally, the pipe may also be provided with positive root reinforcement on top of the root weld channel. A heat welded channel and even another welded channel applied internally may provide a slightly inwardly extending small curved protrusion in the pipe to further strengthen the pipe. For example, the inner diameter of the pipe may be configured to be slightly smaller at the area of the weld than at the area of the weld pipe containing only pipe material without the weld. In one aspect of the present application, at least a portion of the hot channel weld layer of weld material is disposed closer to the longitudinal axis than the interior surface of the welded pipe, the at least a portion being in a region of the welded pipe immediately adjacent to the weld material on an opposite side of the weld material.
In some embodiments, the internal welding system 5004 disclosed herein is configured to weld pipes that are at least 30' long. In other embodiments, the internal welding systems 5004, 3001 disclosed herein are configured to weld pipes having a diameter of 26 "or less. In yet other embodiments, the internal welding system 5004 can weld pipes having a diameter less than 24 ". In yet other embodiments, the internal welding system 5004 disclosed herein is configured to weld pipes that are at least 30' long and less than 24 "in diameter.
Fig. 73-85 illustrate and disclose another embodiment of an internal welding system according to another embodiment of the present patent application.
The present application provides a system for aligning and welding together the faces of two pipe sections. The system includes an external alignment mechanism and a welding mechanism. The external alignment mechanism may be as complex as the alignment module shown in the drawings or as simple as the tipton clamp shown in U.S. patent No. 1,693,064. The mechanism used may also be adapted to onshore or offshore pipeline construction. U.S. patent No. 1,693,064 is incorporated by reference herein in its entirety. Regardless of the mechanism employed, an external alignment mechanism supports each segment and adjustably positions each segment such that the segments are substantially collinear or axially aligned along their longitudinal axes.
The external alignment mechanism may support the pipe segment and may include a powered feature that allows the position and orientation of the pipe to be adjusted. In particular, the external alignment mechanism may include rollers that allow the pipe to move longitudinally. The pipe may also be supported by rollers that allow the pipe to roll about the longitudinal axis and move up and down. The position and orientation adjustments may be automated by motor power or hydraulics that are controlled at the operator station or fed into a central controller that automatically controls the alignment of the segments based on predetermined alignment parameters or feedback from an internal laser that reads the joint or seam profile.
The welding mechanism is an internal welding machine that applies a weld (e.g., gas metal arc welding "GMAW") from a face or edge seam of a lateral section within a pipe segment and creates a V-shaped opening (other cross-sectional shapes than V may also be used) formed by the beveled edges of two pipe segments. The welding mechanism includes: a bracket capable of engaging an inner wall of the pipe to secure or lock the welding mechanism itself in a fixed position within the pipe; and a welding part rotatably supported by the bracket within the pipe. Specifically, the internal welder is positioned within the alignment pipe and then positioned longitudinally such that the welding head or torch is longitudinally adjacent the edge seam. The welding mechanism further includes a rotation mechanism for rotating the welding portion relative to the carriage. The welding head or torch is rotatably supported on the welded portion about the longitudinal axis of the pipe such that the torch closely follows the entire internal joint during orbital rotation. Specifically, during welding, the torch of the articulating head follows the edge joint around the entire inner circumference of the pipe, thereby applying the welding material. In addition to rotating relative to the circumference of the carriage, various control elements may move the welding head relative to the carriage axially along the pipe, radially toward and away from the joint, and pivotally about a point or axis (e.g., an axis parallel or perpendicular to the pipe longitudinal axis a-a). The controller may direct the torch to pivot. These degrees of freedom of articulation allow the horn to be very effective and efficient in filling the joint profile optimally and where needed.
The welding mechanism also includes a laser tracking mechanism that works in conjunction with a welding torch of the welding portion to sense the joint seam profile and/or the welding material profile in order to apply the welding material to the edge seam in the proper location and amount. The laser mechanism surveys the weld and sends a signal to the controller of the articulating weld head to control the movement of the head around the entire edge joint. Specifically, the torch follows the laser as the weld head control system continuously receives weld profile information from the edge joint. This information is then used to continuously adjust the torch to achieve the desired weld configuration.
In addition to the laser tracking mechanism, the system may include a 2D camera for visually inspecting the weld. The 2D camera is mounted on the weld portion and follows the welding torch so that once the weld is produced by the welding torch, an operator can inspect the weld. The visual signal is delivered to an external operator display. For example, the 2D camera may be a color camera, and the color change may indicate the weld defect to the operator. The perceived change in profile may also indicate a defect.
Referring to fig. 73-75, a system for welding pipeline sections together is described below. Fig. 73 illustrates external alignment mechanisms 6010A and 6010B capable of supporting, positioning, and repositioning lengths of pipeline. Each mechanism 6010A and 6010B may include a support (e.g., a roller) on which a length of pipeline may be supported. Longitudinal rollers 6012 movably support the pipeline section 6105 such that the section 6105 is repositionable along its longitudinal direction defined by arrow a. In addition, rotating rollers 6014 may rotate on either side of section 6105 about an axis parallel to axis a-a of support section 6105, thereby enabling the section 6105 to rotate or adjust the angular orientation of section 6105 about axis a-a. The external alignment mechanism 6010 is capable of automatically adjusting the multiple segments into various positions and orientations by motors, hydraulics, etc. For example, the segments may be raised, lowered, rotated, tilted, pivoted, etc.
As shown in fig. 73, the external alignment mechanisms 6010A and 6010B support multiple sections 6105, 6110 and adjust their position and orientation until the sections 6105, 6110 are both aligned such that their longitudinal axes a-a are collinear and one end of each of the sections 6105, 6110 abut at a joint edge. In particular, fig. 74 shows an enlarged detailed view 6100 of fig. 73 with the edge forming a tube joint 6120 (also referred to as an "assembly" seam).
The line alignment and welding system of the present patent application applies a weld from inside the fitting sections 6105, 6110 to the interior of the joint 6120. To apply a weld to the interior of the seam 6120, the internal welding mechanism 6300 is rolled into the end of one of the segments 6105, as shown in fig. 75. The second section 6110 is then placed on the external alignment mechanism 6010B and maneuvered until both sections 6105, 6110 are satisfactorily aligned. An external force may be applied to the tie bar 6345 of the internal welding mechanism 6300, or the mechanism may include automated self-propelled means for adjusting its axial position within the alignment sections 6105, 6110.
As shown in fig. 76-79, the welding mechanism 6300 includes a bracket 6301 and a welding portion 6302. The bracket 6301 includes at least one alignment mechanism 6340A, 6340B that is radially expandable to engage the inner surface of the segment 6105 or 6110. Both of this expansion and engagement fix the axial/longitudinal position of the welding mechanism 6300 relative to the segments 6105, 6110, and align or radially center the welding mechanism 6300 within the segments 6105, 6110. The bracket 6301 also includes a main body 6311, and the rotation mechanism 6335 is supported on the main body 6311. The body 6311 includes a plurality of elongate structural support members extending between the alignment mechanisms 6340A and 6340B. As discussed below, the welded portion 6302 includes a similar corresponding structure 6313.
The welding portion 6302 is rotatably connected to the bracket 6301 and extends from an end of the bracket 6301. Relative rotation between the bracket 6301 and the welding portion 6302 is facilitated by the rotation mechanism 6335. A rotation mechanism 6335 is fixed to the bracket 6301 and automatically (by a motor and gears) rotates the welding portion 6302 relative to the bracket 6301 about the longitudinal axis a-a. The welding portion 6302 may be suspended from a bracket 6301, or may be supported by an additional alignment mechanism 6340C positioned such that welding torch 6305 is positioned between alignment mechanisms 6340B and 6340C. When the alignment mechanism 6340C is provided, the welded portion 6302 may be rotated relative to the alignment mechanisms 6340B and 6340C and between the alignment mechanisms 6340B and 6340C as the alignment mechanisms 6340B and 6340C expand to secure themselves to the interior of the segment. Further, the bracket 6301 may include a pull rod 6345, which pull rod 6345 may be configured as an extension that is elongated from the bracket 6301 that an operator may grasp to insert/push or retract/pull the welding mechanism 6300 in order to axially position it within the segments 6105, 6110.
Fig. 76 shows an enlarged view of the portion 6200 of fig. 75, where only the section 6105 is present and the section 6110 is not present. As shown in fig. 76, the welding portion 6302 includes a weld group 6303, which weld group 6303 includes a welding torch 6305, a laser sensor 6310, and a color camera 6320. The welding portion 6302 also has a main body 6313, and the welding torch 6305, the laser sensor 6310, and the color camera 6320 are supported on the main body 6313. Laser 6310 tracks the internal seam of sections 6105, 6110 and detects the joint profile for positioning torch 6305 when applying a weld to the seam joint. The body 6313 extends between the alignment mechanisms 6340B and 6340C. Portion 6200 shows welding mechanism 6300 located inside section 6105, where welding torch 6305 is directed generally in a radially outward direction and positioned to apply a weld to face seam 6120. Fig. 77 illustrates an embodiment of a generally schematic cross-sectional view of welding mechanism 6300 through portion B-B, which shows weld group 6303 as viewed in the insertion direction of welding mechanism 6300. Fig. 77 also shows the direction of rotation D of the welding set 6303 when rotated by the rotation mechanism 6335. Thus, the welding action at a particular point along weld joint 6120 is effected first by laser sensor 6310, then by welding torch 6305 and finally by 2D inspection camera 6320.
Fig. 82-84 illustrate various perspective views of the weld portion 6302. Fig. 82 illustrates a wire delivery system 6322. The wire delivery system 6322 includes a wire spool storage device 6323, an optional wire straightener 6325, and a wire feed mechanism 6330, which wire feed mechanism 6330 is automatically controlled to deliver the appropriate amount of wire to a welding torch 6305. As rotation mechanism 6335 rotates welding portion 6302, wire is fed to welding torch 6305 through wire delivery mechanism 322.
As mentioned above, the welding torch 6305 may be positioned and oriented in a variety of ways by a variety of mechanisms. The welding torch 6305 is supported on the manipulator. The manipulator includes a radial positioner, an axial positioner, and a pivot rotator. In particular, a radial positioner 6307 (e.g., a rack and pinion) on which the welding torch 6305 is supported can move the welding torch radially toward and away from the interior surface of the segments 6105, 6110. In other words towards and away from the joint of the sections 6105, 6110 to be welded. Further, an axial positioner 6309 (e.g., a rack and pinion) may move torch 6305 axially within sections 6105, 6110. The manipulator also includes a pivot rotator 6308 that allows the welding torch to pivot (e.g., about an axis parallel to the segment longitudinal axis a-a). The pivoting movement through the pivot rotator 6308 may be powered by a motor and gear 6306. For example, the motor may be a stepper motor.
The torch manipulator may synthesize the manipulative movement of the above-mentioned elements by correlatively supporting the elements. For example, the body 6313 may support an axial positioner, which in turn supports a radial positioner, which in turn supports a pivot rotator, which in turn supports a welding torch. Similarly, the axial positioner may be supported by the radial positioner. Further, any support sequence may be employed.
The elements of the manipulator are controlled by a controller that receives as input a series of signals including the signal from the laser 6310 and then processes the information before transmitting the signals to at least the radial positioner 6307, the axial positioner 6309, the pivot rotator 6308, and the wire delivery system 6322. Torch 6305 is then continuously repositioned and reoriented based on the signals from profile-reading laser 6310 according to predetermined parameters of the controller.
The operation of the current internal welding system will now be described. Fig. 73, 80, and 81 illustrate the process of positioning and welding the sections 6105 and 6110 together. In operation, one or more of the following alphabetical steps may be performed such that: a) placing the pipe segment 6105 on the alignment apparatus/pipe rack 6010A; b) the internal welding machine 6300 is then inserted into the pipe segment 6105; c) the second pipe segment 6110 is then aligned with the pipe segment 6105 and the welding mechanism 6300 is pulled forward by the pull rod 6345 or automatically driven so that the welding torch 6305 is substantially aligned with the face seam 6120 of the pipe segments 6105, 6110; d) the alignment mechanisms 6340A, 6340B (and 6340C, if desired) are then engaged to secure the welding mechanism 6300 within the pipe segments 6105, 6110; e) in one embodiment (optional), a rotation mechanism 6335 rotates the weld head 6305 to perform an initial scan of the joint seam 6120 of the tube segments 6105, 6110 by the laser sensor device 6310 to ensure optimal fit; f) if desired, steps (c), (d), and (e) may be repeated, i.e., realigning/rotating the tube segments 6105, 6110 and rescanning by laser 6310 to improve "set-up"; g) optionally, an internal alignment mechanism 6340C engaged on the rear of the welding mechanism 6300 to maintain the axial position of the welding mechanism 3600 relative to the conduit portions 6105, 6110; h) with the welding mechanism 6300 stationary in the pipe segments 6105 and 6110, a root weld (first weld) cycle begins such that laser 6310 scans the pipe joint 6120, torch 6305 follows laser 6310, and the output from laser 6310 is used to control the position of articulating torch 6305, where the position and orientation of torch 6305 relative to joint 6120 is controlled to produce the best weld quality; i) in addition to the signal from laser 6310, arc current monitoring may also be used in pilot torch position; j) after completing the 360 ° weld, the weld head 6305 rotates back to the initial position; k) performing the contouring (using laser 6310) and visual inspection (using 2D color camera 6320) in a previous step (j) or on a separate inspection run; l) after inspection, release the alignment mechanisms 6340A-C and pull or drive the welding mechanism 6300 forward toward the open ends of the welded conduits 6105, 6110, and with the front end of the welding mechanism 6300 exposed, place the pipe segment 6110 on the outer alignment mechanism 6010B and advance to the next joint as in (B); m) then repeating steps (c) to (1) for the entire production run.
In one embodiment, a signal from the laser sensor 6310 is sent to the electronic controller of the internal alignment mechanism 6010 to automatically reposition one or both of the sections 6105, 6110 for a more desirable facing seam 6120 arrangement. Further, the foregoing steps may be performed in the order recited. However, variations in the order are also contemplated.
In another embodiment, rather than stopping after the first 360 ° weld, rotation continues to lay down another weld path, after the second weld, laser 6310 may be used to perform inspection and tracking simultaneously while the following 2D color camera continues to perform inspection.
In yet another embodiment, instead of welding a full 360 ° weld, the weld is performed in half of two 180 ° with the same starting position. This implementation requires multiple laser sensors for tracking or a mechanism to physically oscillate the laser and/or the torch in order to maintain the leading position of the tracking sensors in both rotational directions (i.e., rotate the torch and laser so that they switch positions).
In one embodiment, the present application discloses a joint internal welding system 3001. In one embodiment, joint internal welding system 3001 incorporates all features of internal welding system 5004. In one embodiment, additional features of the joint internal welding system 3001 include a large capacity battery, such that the joint internal welding system 3001 can travel long distances and have onboard welding power. In one embodiment, the joint internal welding system 3001 is configured to operate autonomously such that there is no external cabling to the joint internal welding system 3001.
Since the welding power, motive power, and other required power are carried on-board (a full battery system carried by the frame), the joint internal welder system 3001 can be used to traverse very long pipe spans and perform welding operations at these locations. This is achievable because the system does not need to be tethered for power from an external power source.
In one embodiment, the joint internal welding system 3001 may also include a means for pulling the pipes together to close any gaps. In one embodiment, the device used to draw the pipes together to close any gaps may be referred to as an gapless device (gapping device). In one embodiment, the slackless arrangement is constructed and arranged such that one of the clamps is configured to be movable relative to the other clamp. In one embodiment, the gapless device is constructed and arranged to be external to the main weld portion. In one embodiment, the slackless arrangement is constructed and arranged within a pipe.
In one embodiment, joint internal welding system 3001 includes a forwardmost portion 3002, a central portion 3004, and a drive portion 3006 similar to those in internal welding system 5004. In one embodiment, the structure, configuration, components, and operation of the forward-most portion 3002, the central portion 3004, and the drive portion 3006 of the joint internal welding system 3001 are similar to the forward-most portion, the central portion, and the drive portion of the internal welding system 5004 described in detail above, and thus the structure, configuration, components, and operation of the forward-most portion 3002, the central portion 3004, and the drive portion 3006 of the joint internal welding system 3001 will not be described in detail herein. In one embodiment, the electronic module of the frontmost portion 3002, the electronic module of the central portion 3004, and the electronic module of the driving portion 3006 each include one or more processors.
For example, the joint internal welding system 3001 includes: a frame configured to be placed within conduits 1022a, 1022 b; a plurality of rollers 3125 configured to rotatably support a frame of the joint internal welding system 3001; a drive motor 3124 that drives the roller 3125 to move the frame of the joint internal welding system 3001 within the conduits 1022a, 1022 b; a braking system that secures the frame of the joint internal welding system 3001 at a desired location within the conduits 1022a, 1022b without movement; a verification detector carried by the frame of the joint internal welding system 3001 and configured to detect characteristics of the joint region between the conduits 1022a, 1022 b; and a welding torch carried by the frame of the joint internal welding system 3001. In one embodiment, as with the internal welding system 5004, the braking system of the joint internal welding system 3001 may include clamps of the joint internal welding system 3001 configured to clamp to the conduits 1022a, 1022b, respectively. In one embodiment, as with the internal welding system 5004, the brake system of the joint internal welding system 3001 may include a brake cylinder and brake valve of the joint internal welding system 3001. In one embodiment, the structure, configuration, and/or operation of the rollers 3125, drive motor 3124, inspection detector, and welding torch of the joint internal welding system 3001 are similar to that of the internal welding system 5004, and therefore will not be described in detail herein.
In one embodiment, joint internal welding system 3001 further comprises one or more processors operatively connected to drive motor 3124, the inspection detector, and the welding torch. The configuration and operation of the one or more processors of the joint internal welding system 3001 is similar to that of the internal welding system 3004, and therefore will not be described in detail herein.
In one embodiment, the joint internal welding system 3001 is completely untethered. In particular, the joint internal welding system 3001 need not include a pull rod or umbilical, and all communications to and from the joint internal welding system 3001 are completely wireless. In one embodiment, the joint internal welding system 3001 may comprise: a transmitter configured to transmit all communication signals from the joint internal welding system 3001 completely wirelessly to a remote uLog processing system; and a receiver configured to receive all communication signals completely wirelessly from a remote uLog processing system. In one embodiment, one or more processors and/or all electronic modules of the joint internal welding system 3001 are configured to communicate entirely wirelessly with a remote uLog processing system. In one embodiment, the inspection detectors, inspection cameras, all sensors, all motors, all valves, and/or other components/elements of the joint internal welding system 3001 are configured to communicate entirely wirelessly with the remote uLog processing system.
In one embodiment, any information from the welding system inside the joint may be wirelessly communicated with the system outside the pipe via WiFi, bluetooth, NFC, via radio frequency, or via cellular tower transmission (for example only). In some embodiments, information is transmitted using repeaters or extenders where appropriate, with the transmission signal traveling long distances or traveling through curved areas.
In one embodiment, the one or more processors and one or more sensors of the joint internal welding system 3001 are configured to monitor the charge levels of the onboard welding power supply, the onboard kinematic power supply, and other onboard power supplies. For example, the voltage output by these power supplies may be monitored (continuously or at regular intervals). In one embodiment, the transmitter of the joint internal welding system 3001 transmits the monitored battery life/charge level information completely wirelessly to a remote uLog processing system for further processing. For example, the monitored charge level information of the on-board power supply may be used to determine an estimated remaining operating time of the joint internal welding system 3001. In one embodiment, the one or more processors of the joint internal welding system 3001 may be configured to determine the estimated remaining operating time of the joint internal welding system 3001 locally on the joint internal welding system 3001. In one embodiment, the remote uLog processing system may be configured to determine an estimated remaining operating time of the joint internal welding system 3001 based on wirelessly transmitted battery life/charge level information. In one embodiment, the remote uLog processing system may be configured to transmit the estimated remaining operating time of the joint internal welding system 3001 to one or more processors of the joint internal welding system 3001. In one embodiment, the remote uLog processing system may also be configured to transmit (transmit completely wirelessly to the joint internal welding system 3001) additional instructions regarding the operation of the joint internal welding system 3001 based on the estimated remaining operating time of the joint internal welding system 3001.
In one embodiment, the one or more processors and one or more sensors of the intra-joint welding system 3001 are configured to monitor the gas levels of the on-board inert (shielding/purging) gas supply, the on-board air supply, and other on-board gas supplies (e.g., the volume or pressure of compressed air in the on-board compressed air tank, the volume or pressure of shielding or purging gas in the on-board shielding/purging gas tank, etc.). For example, the gas consumption of these gas supplies may be monitored (continuously or at regular intervals). In one embodiment, the transmitter of the joint internal welding system 3001 transmits the monitored gas level information completely wirelessly to a remote uLog processing system for further processing. For example, the monitored gas level information of the on-board gas supply may be used to determine an estimated remaining operating time of the internal joint welding system 3001. In one embodiment, the one or more processors of the joint internal welding system 3001 may be configured to determine the estimated remaining operating time of the joint internal welding system 3001 locally on the joint internal welding system 3001. In one embodiment, the remote uLog processing system may be configured to determine an estimated remaining operating time of the joint internal welding system 3001 based on wirelessly transmitted gas level information. In one embodiment, the remote uLog processing system may be configured to transmit the estimated remaining operating time of the joint internal welding system 3001 to one or more processors of the joint internal welding system 3001. In one embodiment, the remote uLog processing system may also be configured to transmit (transmit completely wirelessly to the joint internal welding system 3001) additional instructions regarding the operation of the joint internal welding system 3001 based on the estimated remaining operating time of the joint internal welding system 3001.
In one embodiment, the one or more processors and one or more sensors of the intra-joint welding system 3001 are configured to monitor the wire material level of the intra-joint welding system 3001. For example, the rotation of a wire feed motor (dispensing wire) in the intra-joint welding system 3001 and the weight of the remaining wire material may be monitored (either continuously or at regular intervals) to determine the wire material level of the intra-joint welding system 3001. In one embodiment, the transmitter of joint internal welding system 3001 transmits the monitored wire bond material level information completely wirelessly to a remote uLog processing system for further processing. For example, the monitored wire material level may be used to determine an estimated remaining operating time of the intra-joint welding system 3001 (e.g., before the wire material runs out or falls below a minimum threshold level for operating the intra-joint welding system 3001). In one embodiment, the one or more processors of the joint internal welding system 3001 may be configured to determine the estimated remaining operating time of the joint internal welding system 3001 locally on the joint internal welding system 3001. In one embodiment, the remote uLog processing system may be configured to determine an estimated remaining operating time of the welding system within the joint based on the wirelessly transmitted wire bond material level information. In one embodiment, the remote uLog processing system may be configured to transmit the estimated remaining operating time of the joint internal welding system 3001 to one or more processors of the joint internal welding system 3001. In one embodiment, the remote uLog processing system may also be configured to transmit (transmit completely wirelessly to the joint internal welding system 3001) additional instructions regarding the operation of the joint internal welding system 3001 based on the estimated remaining operating time of the joint internal welding system 3001.
In one embodiment, a remote uLog processing system receives battery charging data from a plurality of joint internal welding systems at different locations (e.g., different locations across a country or across the earth) and builds a database thereon. This database is used by the uLog processing system to determine expected battery life times based on different operating parameters of the internal welding system based on a large data set. This can be used by the uLog processing system and/or by one or more processors of the joint internal welding system 3001 to predict battery life times of various components based on their current operating states. This information may be used by the one or more processors to reduce or adjust power consumption of the one or more components by modifying one or more operating parameters. For example, if one or more processors determine that such operating states can be modified without adversely affecting the associated operations being performed, then the overall welding speed, wire bonding speed, voltage, and current may be adjusted (e.g., reduced) to conserve battery life.
In one embodiment, any of battery life, voltage output, and operating parameters are wirelessly transmitted to a user interface (such as a computer monitor with a computer display) so that they may be monitored by a user.
In one embodiment, the joint internal welding system 3001 further includes a power portion 3008 positioned adjacent to the drive portion 3006 (i.e., at a rear portion of the joint internal welding system 3001).
In one embodiment, referring to fig. 101, the frontmost portion 3002 comprises a frontmost portion frame 3522, the central portion 3004 comprises a central portion frame 3524, the drive portion 3006 comprises a drive portion frame 3526, and the power portion 3008 comprises a power portion frame 3528. In one embodiment, the frame or frame assembly of joint internal welding system 3001 includes a front-most portion frame 3522, a center portion frame 3524, a drive portion frame 3526, and a power portion frame 3528. In one embodiment, the frame or frame assembly of the joint internal welding system 3001 is configured to be placed within the conduits 1022a, 1022 b.
In one embodiment, power section 3008 includes a universal joint 3010, a motor power supply 3012, a welding torch power supply 3014, a welding power supply 3016, and adjustable wheels 3018.
In one embodiment, the drive portion 3006 may be connected to the power portion 3008 by a universal joint 3010. In one embodiment, the universal joint 3010 is constructed and arranged to allow the joint internal welding system 3001 to articulate about bends in a pipeline.
In one embodiment, the welding torch power supply 3014 may include a plurality of welding torch power batteries 3014a-3014 e. In one embodiment, welding torch power supply 3014 is configured to power welding torch 3502. In one embodiment, the welding torch power supply 3014 is carried by a frame assembly of the joint internal welding system 3001. In one embodiment, the number of welding torch power batteries may vary. In one embodiment, the welding torch power supply 3014 is configured to supply power to the welding torch power supply 3016 for generating a welding arc. In one embodiment, the welding torch power supply 3014 is separate from the other electrical systems such that if the welding torch power is exhausted, the remainder of the joint internal welding system 3001 remains operable.
In one embodiment, the motor power supply 3012 is configured to power an electric drive motor 3124 in the drive portion 3006. In one embodiment, the motor power supply 3012 may include a plurality of motor power batteries 3012a-3012 e. In one embodiment, the motor power supply 3012 may also be referred to as a drive power supply. In one embodiment, the motor power source 3012 is carried by the frame assembly of the joint internal welding system 3001. In one embodiment, the number of motor power cells may vary. In one embodiment, the motor power source 3012 is used only for driving (i.e., supplying power to the electric drive motor 3124 in the drive section 3006), such that the intra-joint welding system 3001 is not trapped in the pipeline in the event that the other battery packs 3014a-3014e are depleted.
In one embodiment, the motor power supply 3012 (including batteries 3012a-3012e) and the welding torch power supply 3014 (including batteries 3014a-3014e) are carried by a frame of the internal joint welding system 3001. In one embodiment, one or more battery cells (e.g., motor power supply 3012, welding torch power supply 3014, battery 3514, etc.) of the joint internal welding system 3001 are configured to power the drive motor 3124, the inspection detector, and the welding torch. In one embodiment, the one or more battery cells 3514, 3012, or 3014 of the joint internal welding system 3001 can comprise a plurality of individual battery cells. In one embodiment, the battery cells 3014, 3014a-3014e for the welding torch are independent of the battery cells 3012, 3012a-3012e, 3514 for the drive motor and the inspection detector. In one embodiment, the battery cells 3012, 3012a-3012e for driving the motor 3124 are independent of the battery cell 3514 for the inspection detector. That is, in one embodiment, the battery cells 3012, 3012a-3012e are configured to power the drive motor 3124, the battery cell 3514 is configured to power the inspection detector, and the battery cells 3014, 3014a-3014e are configured to power the welding torch of the internal-joint welding system 3001.
In one embodiment, referring to fig. 101, drive motor 3124 is configured to drive roller 3125 so as to move the frame or frame assembly of joint internal welding system 3001, the first pipe engaging structure 3127, the second pipe engaging structure 3129, and the test detector 3130 of joint internal welding system 3001 along at least one of the pipes 1022a, 1022b within an interior thereof. In one embodiment, the drive roller 3125 is configured to engage the inner surfaces 5130, 5132 of one or more of the conduits 1022a, 1022 b. In one embodiment, the joint internal welding system 3001 comprises a plurality of drive rollers 3125, the drive rollers 3125 configured to rotatably support a frame or frame assembly of the joint welding system 3001.
In one embodiment, welding power supply 3016 is configured to draw DC power from welding torch power supply 3014 and convert the DC power to the correct current and voltage waveforms for the welding procedure performed by welding torch 3502.
In one embodiment, the adjustable wheels 3018 are constructed and arranged to be adjusted such that the power portion 3008 of the joint internal welding system 3001 runs linearly and horizontally in the pipeline.
Fig. 103 illustrates a schematic diagram showing the flow of power (including welding power), communication data, and control data through the joint internal welding system 3001, wherein some components of the joint internal welding system 3001 are not shown for the sake of clarity and to better illustrate other components and/or features of the joint internal welding system 3001.
The flow of communication data and control data through the joint internal welding system 3001 in fig. 103 is similar to the flow of communication data and control data through the internal welding system 5004 in fig. 71, except for the differences noted below.
In one embodiment, the drive portion electronics module 3126 is configured to operatively connect to the drive battery 3012 located in the power portion 3008 of the joint internal welding system 3001.
In one embodiment, the battery 3012 of the power section 3008 is connected to the drive motor 3124 of the joint internal welding system 3001 through a drive section electronics module 3126.
The flow of welding power through joint internal welding system 3001 in fig. 103 and 103A is different than the flow of welding power through internal welding system 5004 in fig. 71.
For example, in internal welding system 5004 and joint internal welding system 3001, the welding power comes from different directions. That is, unlike the internal welding system 5004 where welding power comes from the front of the system through its umbilical 5034, for the joint internal welding system 3001, welding power comes from the back. This configuration, where the welding power comes from the rear of the welding system 3001 inside the joint, may be achieved by adding a second slip ring or by turning the welding portion and pushing it back through the tubing (which may make it difficult to access the wire spool for maintenance).
In one embodiment, welding power is received from on-board welding torch power supply 3014 by welding torch 3502 of joint internal welding system 3001. In one embodiment, welding power from the on-board welding torch power supply 3014 is supplied to the welding power supply 3016. In one embodiment, the welding power supply 3016 is configured to generate a welding arc. That is, welding power supply 3016 is configured to draw DC power from welding torch power supply 3014 and convert the DC power to the correct current and voltage waveforms for the welding procedure performed by welding torch 3502. In one embodiment, the correct current and voltage waveforms from the welding power supply 3016 are supplied to the welding torch 5502 through the backward slip ring 3512.
As with the internal welding system 5004, in one embodiment, the battery 3514 of the drive portion 3006 is configured to supply power to all of the electronic modules in the joint internal welding system 3001 (including the front-most electronic module, the wire feed electronic module, the central portion electronic module, and the drive portion electronic module 3126), and is also configured to supply power to all of the electric drive motors in the joint internal welding system 3001, including the front rotary motor, the wire feed system motor, the rear rotary motor, the drive motor, the axial welding torch motor, the radial welding torch motor, and the tilt welding torch motor. In one embodiment, battery 3514 is configured to power the inspection camera and/or inspection detector of the joint internal welding system 3001. However, the battery 3514 of the driving portion 3006 is configured not to supply power to the drive motor 3124 of the joint internal welding system 3001. In one embodiment, the battery 3012 of the power section 3008 is configured to supply power to the drive motor 3124 of the joint internal welding system 3001. In one embodiment, the battery 3012 of the power section 3008 is connected to the drive motor 3124 of the joint internal welding system 3001 through a drive section electronics module 3126.
In one embodiment, the batteries used in the joint internal welding system 3001 may be electrically connected in series to achieve higher current and higher energy content. For example, two 12 volt batteries are connected in series to obtain 24 volts. In one embodiment, two batteries are mounted to the same frame and wired together in series. In one embodiment, the batteries may also be connected to each other (e.g., via a universal joint or otherwise) such that the batteries may articulate relative to each other to manipulate the conduit.
In one embodiment, the joint internal welding system 3001 can include four batteries, wherein one battery can be used to drive the joint internal welding system 3001 and the other three batteries can be connected in parallel and can be used for the welding process of the joint internal welding system 3001.
In one embodiment, the joint internal welding system 3001 may use an internally positioned clamp (positioned inside the pipe) or an externally positioned clamp (positioned outside the pipe). For example, in one embodiment, the joint internal welding system 3001 may use internally positioned (positioned inside the pipe) clamps during its welding process. In one embodiment, the joint internal welding system 3001 may use an externally positioned (positioned outside of the pipe) clamp during the internal scanning procedure (where an internally positioned laser/detector and/or other device is configured to scan the weld joint from inside the pipe).
Joint welding is performed to weld the elongated pipe to another elongated pipe. Generally, the new pipe to be welded is at least 120 feet long and can be more than two miles long. The joint internal welding machine disclosed herein has on-board battery power and may be used to perform the joint root weld path and optional thermal weld path from inside the pipe.
In one embodiment, the conduits are externally aligned. As with the internal welding machines disclosed herein, a joint welder may be provided with only a single welding head (with a single welding torch) or multiple welding heads (e.g., any of 2 through 8, for example only).
As shown in fig. 103C and 103D, and as understood from the previous discussion herein, the joint welding machine 9000 has a nose cone portion 9002 for electronics, support wheels 9004, an on-board welding power supply 9006, and a pair of clamps 9008 to ensure that the joint internal welder is concentric with the pipe. As described in more detail later, the joint welder includes clockwise and counterclockwise horn "pods" 9010 with individual lasers and 2D color cameras. In fig. 103C and 103D, the joint welder machine is shown positioned within a slightly curved (e.g., 30D curved) conduit 9012 having a 38 inch inner diameter. As also shown in fig. 103C and 103D, the splice welder has a drive system and brake 9014 that is offset by 90 degrees to reduce length and an on-board power source (i.e., battery pack) 9020 for driving the motor and brake.
As will be understood from fig. 103E-J and the following description, the mold shown has four welding heads, two rotating clockwise (welding heads 9022 and 9024) during the welding operation and two rotating counterclockwise (welding heads 9032 and 9034) during the welding operation. In an alternative embodiment, all 4 horns shown rotate in a single direction of rotation, as described elsewhere in this application. Further, in the embodiment shown in fig. 103E-J, four on-board welding power sources/supplies (e.g., batteries) are provided, labeled 9042, 9044, 9046, 9048. The more welding heads/torches provided, the shorter the welding cycle time may be. This is true whether the welding is performed in a single rotational direction or in both clockwise and counterclockwise directions. However, it should be understood that rotation in a single rotational direction may be faster than both clockwise and counterclockwise rotation, where the latter may employ reversal of the motor direction.
Each horn 9022, 9024, 9032 and 9034 has the following equipment: a welding torch, at least one torch motor of the type previously described herein that allows angular, axial, and side-to-side movement of each torch, a wire feeder, a wire straightener, and a wire spool that feeds wire material to the welding torch. A laser inspection/detector device of the type previously described is also provided to guide the welding torch and inspect the weld. In addition, a color CCD/CMOS camera is used to inspect the bond in the manner previously described.
Each welding head is associated with and connected to one of four power supplies 9042, 9044, 9046 and 9048. Four welding heads and four power supplies are all mounted on the rotary assembly 9050. The rotational assembly performs the same function as the rotatable hub 5078 previously described. The rotating assembly may be driven by one or more orientation motors, as previously described.
To effect the welding operation, a joint welding machine is fed into one open end of one of the pipes (e.g., the shorter pipe or the one with less obstruction to drive out). The face of the second conduit matches and aligns (externally) with the face of the first conduit. The joint welding machine is driven to where the welding head is just at the pipe joint area. The laser detector provides feedback and at least one welding torch motor aligns the welding torch tip at the proper position at the joint. The clamps 9008 are actuated and expanded (they act as expanders) to make the joint welder machine concentric with the pipe, and the clamps are engaged to maintain a position on the joint welder machine. When the joint welder machine is secured by the clamp, the axis of rotation of the rotatable mechanism 9050 is coaxial with the longitudinal axis of the conduit 9012.
In one embodiment, welding is accomplished by first operating the welding heads 9032 and 9034 in a counterclockwise direction. As shown in fig. 103H, the four welding heads are rotated 90 degrees apart. As they weld, the weld head 9032 begins at 12 o 'clock and the weld head 9034 begins at 9 o' clock, as shown in fig. 103H. The rotary assembly 9050 is rotated 90 degrees until the welding head 9032 stops at 9 o 'clock and the welding head 9034 stops at 6 o' clock (see progress through fig. 103H and 103I). At this point, the welding heads 9032 and 9034 discontinue welding (at fig. 103I), and the welding heads 9022 and 9024 weld (at fig. 103I). The one or more orientation motors then rotate the rotatable assembly 9050 in a clockwise direction as shown in fig. 103J until the welding head 9022 stops at 3 o 'clock and the welding head 9024 stops at 6 o' clock. In this way a full root weld pass is accomplished.
After the root weld is laid, the rest of the weld can be done from the outside using an automatic welding machine or manually. The expander or clamp is then disengaged and the joint welder is driven to the open end of the pipe.
In one embodiment, each of the power supplies 9042, 9044, 9046 and 9048 includes a rechargeable battery compartment that is insertable in the associated opening 9062, 9064, 9066 and 9068. After insertion into the opening, the battery case is electrically connected to its associated soldering tip. Each battery compartment can be easily removed for recharging and then replaced.
As shown, the splice welder has a self-powered drive and brake mechanism 9014 that is powered by an onboard welding power supply 9020. In various previous embodiments described herein, this splice welder may utilize all attributes of an internal welding machine without on-board power capability.
In this joint welder embodiment as described, it can be appreciated that a plurality (e.g., two) of the welding torches are dedicated to clockwise welding while another plurality (e.g., two) are dedicated to counterclockwise welding. Further, as described, all welding torches perform welding in a downward direction. Thus, the welding torch may optionally be fixed at a predetermined welding angle (which is true for any of the internal welding machines disclosed herein, whether of the joint unbolted or tethered type) such that the torch tip points in a forward welding direction ("pushing" the weld pool). Alternatively, as discussed above with reference to fig. 56A, the welding torch may be mounted for pivotal movement about point P such that welding torch axis a may be positioned on either side of radial line R. This alternative enables the same torch to be used for both clockwise and counterclockwise welding by pivoting the welding torch such that the welding torch can pivot in the forward welding direction whether the welding is performed in a clockwise or counterclockwise direction.
In one embodiment, the welding torch is configured to be positioned outside of first conduit 1022a and/or second conduit 1022b to provide an external welding operation. In one embodiment, an externally positioned welding torch is mounted to the outer surface of the conduits 1022a, 1022 b.
In one embodiment, referring to fig. 86, the present patent application provides a purge and check system 7001. For example, in one embodiment, first tube segment 1022a and second tube segment 1022b may each be made, in whole or in part, of some corrosion-resistant alloy (CRA) material that may require shielding gas on both sides of the weld. In one embodiment, the purge and verification system 7001 may be positioned internally within the conduits 1022a, 1022b to provide a purge gas chamber 7054 (shown in fig. 89) inside the conduits 1022a, 1022b and around the joint region 5136 (shown in fig. 97) while an external welding system 7500 (shown in fig. 97) performs welding processes (including a root pass welding process 1002, a hot pass welding process 1004, and a fill and cap pass welding process 1006) from outside the conduits 1022a, 1022b at the joint region 5136.
In one embodiment, the purge and verification system 7001 also provides an internal clamp positioned internally within the conduits 1022a, 1022b to be welded. That is, in one embodiment, the clamps 7050 and 7052 of the purge and verification system 7001 are configured to clamp the inner surfaces 5130, 5132 of the conduits to be welded 1022a, 1022b (as shown in fig. 33).
In one embodiment, the purge and verification system 7001 also provides a verification detector 7042 and/or a verification camera 7044 positioned internally within the conduits 1022a, 1022 b. In one embodiment, the verification detector 7042 and/or the verification camera 7044 of the purge and verification system 7001 are positioned in the purge gas chamber 7054 of the purge and verification system 7001. In one embodiment, one or more processors 7062 (shown in fig. 90) of the purging and inspection system 7001 are configured to interact with the inspection detector 7042 and/or the inspection camera 7044 to scan the joint region 5136 between the conduits 1022a, 1022b to determine a profile of the joint region 5136 between the conduits 1022a, 1022b before, during, and after the welding procedure, to generate pre-weld profile data, dynamic weld profile data, and post-weld profile data based on the scan data, and to control the external welding system 7500 or operation thereof based on the generated pre-weld profile data, dynamic weld profile data, or post-weld profile data.
In one embodiment, the purge and check system 7001 may be used with the first and second pipe segments 1022a, 1022b having an outer diameter of 26 to 28 inches. In one embodiment, the purge and check system 7001 may be used with the first and second pipe segments 1022a, 1022b having an outer diameter less than 24 inches.
In one embodiment, the purge and check system 7001 includes a forwardmost portion 7002, a central portion 7004, and an actuation portion 7006. In one embodiment, the structure, configuration, assembly, and operation of the forwardmost portion, central portion, and actuation portion of the purge and inspection system 7001 are similar to the forwardmost portion, central portion, and actuation portion of the internal welding system 5004 described in detail above, and thus the structure, configuration, assembly, and operation of the forwardmost portion, central portion, and actuation portion of the purge and inspection system 7001 will not be described in detail herein, except for the differences noted below.
Unlike the central portion of internal welding system 5004, central portion 7004 does not include a welding torch assembly mounted on a rotatable hub thereof. In one embodiment, the central portion 7004 of the purge and check system 7001 includes a check detector 7042 mounted on a rotatable hub 7012 thereof. In one embodiment, the central portion 7004 of the purge and check system 7001 includes a check detector 7042 and a check camera 7044 mounted on a rotatable hub 7012 thereof. In one embodiment, the central portion 7004 of the purge and check system 7001 includes a check camera 7044 mounted on a rotatable hub 7012 thereof.
In one embodiment, the forwardmost portion 7002 houses all of the purge support assemblies. In one embodiment, the central portion 7004 is the portion of the purge and inspection system 7001 that aligns the conduits, seals the purge area, and inspects the welds. In one embodiment, the actuation portion 7006 contains the batteries, compressed air, and purge gas needed to purge and verify the remainder of the 7001 for operation.
Figure 87 shows a detailed view of the forwardmost portion 7002 of the purge and verification system 7001, and figure 88 shows a detailed view of the purge assembly of the forwardmost portion 7002. In one embodiment, the forward-most portion 7002 of the purge and verification system 7001 includes a hitch, a forward-most electronics module, a forward slip ring, a forward clamp control valve, a forward position sensor, an adjustable swash plate, a forward-most portion frame, a guide wheel, a forward rotary motor, and a forward rotary union 7104, and the structure and operation of each of these components are similar to those in the forward-most portion of the internal welding system 5004.
In one embodiment, the forwardmost portion 7002 of the purge and check system 7001 does not include a wire feed assembly. In contrast, the forwardmost portion 7002 of the purge and verification system 7001 includes a purge assembly 7014.
In one embodiment, the purge assembly 7014 is rotatably connected to the rotatable hub 7012 of the central portion 7004 such that when the rotatable hub 7012 is rotated by the first and second rotary motors, the purge assembly connected to the rotatable hub 7012 also rotates with the rotatable hub 7012.
In one embodiment, the purge assembly 7014 is configured to house valves, sensors, and regulators to control the flow of purge gas into the purge gas chamber 7054. In one embodiment, the purge assembly 7014 is also configured to house the electronics for operating all of the components in the purge assembly and the rotatable hub 7012.
In one embodiment, referring to fig. 88, the purge assembly 7014 comprises a low purge valve 7016, a primary low purge regulator 7018, a secondary low purge regulator 7020, a high purge valve 7022, a high purge regulator 7024, an oxygen sensor 7026, a pump 7028, a purge assembly frame 7030, and a purge electronics module 7032.
In one embodiment, the low purge valve 7016 is configured to control the flow of purge gas into the purge gas chamber 7054. In one embodiment, a low purge is generally referred to as a purge while the purge and verification system 7001 maintains an inert atmosphere within the purge gas chamber 7054. In one embodiment, the output from the low purge valve 7016 goes to the primary low purge regulator 7018. In one embodiment, the low purge valve 7016 is always open (or on), except when the seals 7046 and 7048 (as shown in fig. 89) are not charged and no purge is performed in the purge and check system 7001.
In one embodiment, the primary low purge regulator 7018 is configured to reduce the pressure of the purge gas from 5 pounds of pressure to 0.5 pounds of pressure. In one embodiment, the output from the primary low purge regulator 7018 goes to the secondary low purge regulator 7020. In one embodiment, the primary low purge regulator 7018 is configured to be set manually.
In one embodiment, the secondary low purge regulator 7020 is an electronic device configured to feedback control the pressure (between 0.1 and 0.5 pounds) flowing into the purge gas chamber 7054 through a closed loop. In one embodiment, the output from the secondary low purge regulator 7020 goes to the purge gas chamber 7054.
In one embodiment, the high purge valve 7022 is configured to control the flow of purge gas into the purge gas chamber 7054. In one embodiment, a high purge is generally referred to as a purge when the purge and verification system 7001 establishes an inert atmosphere within the purge gas chamber 7054. In one embodiment, the output from the high purge valve 7022 goes to the high purge regulator 7024. In one embodiment, the high purge valve 7022 is configured to close when oxygen in the purge gas chamber 7054 (as measured by the oxygen sensor 7026) is below a predetermined oxygen content value.
In one embodiment, the high purge regulator 7024 is configured to reduce the pressure of the purge gas from the supply pressure (up to 75 pounds) to a maximum desired low purge pressure (typically 5-20 pounds). In one embodiment, the output from the high purge regulator 7024 goes to the purge gas chamber 7054. In one embodiment, the high purge regulator 7024 is configured to be set manually. In one embodiment, the high purge regulator 7024 is configured to be open or operable until oxygen in the purge gas chamber 7054 (as measured by the oxygen sensor 7026) is below a predetermined oxygen content value.
In one embodiment, the input of the oxygen sensor 7026 is connected to the outlet port of the purge gas chamber 7054. In one embodiment, the oxygen sensor 7026 is operatively connected to one or more processors 7062. In one embodiment, the oxygen sensor is configured to detect the amount of oxygen between the first seal 7046 and the second seal 7048. In one embodiment, the oxygen sensor 7026 is configured to measure the oxygen content of the gas in the purge chamber 7054 and send oxygen content data to the one or more processors 7062, the oxygen content data being indicative of the oxygen content of the gas in the purge chamber 7054. In one embodiment, the oxygen sensor 7026 is configured to measure the level of oxygen present in the gas exiting the purge gas chamber 7054 and send oxygen content data to the purge electronics module 7032.
In one embodiment, the one or more processors 7062 are configured to enable a welding operation after an amount of oxygen between the first seal 7046 and the second seal 7048 is below a threshold level or a predetermined oxygen content value. In one embodiment, the one or more processors 7062 are configured to receive oxygen content data, compare the received oxygen content data to its predetermined oxygen content value, and generate an oxygen excess signal if the oxygen content data is greater than the predetermined oxygen content value. In one embodiment, based on the oxygen excess signal, the purge and clamp system 7100 may be configured to open the high purge regulator 7024 to allow the purge gas (from the purge gas source/canister 7070) to flow into the purge chamber 7054 until the measured oxygen content falls below a predetermined oxygen content value. In one embodiment, based on the oxygen excess signal, the one or more processors 7062 of the purge and clamp system 7100 may send a communication signal to the external welding system 7500 to stop the welding process.
In one embodiment, the predetermined oxygen content value is 500 parts per million (ppm). In one embodiment, the oxygen content value may be in a predetermined range of 50 to 100 ppm.
In one embodiment, during a low purge, the low pressure in the purge gas chamber 7054 does not generate sufficient flow through the oxygen sensor 7026. In one embodiment, a pump 7028 is used to draw gas from the purge gas chamber 7054, through the oxygen sensor 7026. In one embodiment, the pump 7028 can be used continuously or intermittently. In one embodiment, the pump 7028 is used for low purge operations.
In one embodiment, the purge electronics module 7032 is configured to transmit communications upstream through the front slip ring 7034 to the front-most portion electronics module 7036. In one embodiment, the purge electronics module 7032 is configured to communicate downstream through the rear slip ring 7038 to the central portion electronics module 7040.
In one embodiment, the purge electronics module 7032 is configured to control all of the sensors and valves of the rotatable hub 7012 attached to the central portion 7004. For example, in one embodiment, the purge electronics module 7032 is configured to control the oxygen sensor 7026, the pump 7028, the low purge valve 7016, the high purge valve 7022, and the secondary low purge register 7020. In one embodiment, the purge electronics module 7032 is configured to communicate with and control one or more inspection detectors 7042 and a camera 7044.
Fig. 89 and 90 show front and cross-sectional views of the central portion 7004 of the purge and check system 7001, and the structure and operation of each of these components are similar to those in the central portion of the internal welding system 5004. Fig. 91 illustrates a detailed view of the purge seal 7046 or 7048, and fig. 92 illustrates a detailed view of the rotatable hub 7012.
In one embodiment, as discussed above, the frame of the forward-most portion 7002 is connected to the front clamp 7050 of the central portion 7004 (as shown in fig. 95), and the purge assembly 7014 is rotatably connected to the rotatable hub 7012.
In one embodiment, the central portion 7004 of the purge and check system 7001 includes a front clamp 7050, first and second conduit engagement structures 7050, 7052, a check detector 7042, a check camera 7044 (as shown in fig. 92), a rear clamp 7052, a rear clamp control valve 7058, a central portion electronics module 7040, a front cluster wheel, a central portion frame, an adjustable ramp, a rear rotary union 7072, a rear rotary motor, a rear position sensor, a rotary module 7012, purge seals 7046 and 7048, and a rear slip ring 7038.
In one embodiment, the purge seals 7046 and 7048 are configured to inflate at the same time as the clamps 7050 and 7052 are actuated. After both of the purge seals 7046 and 7048 are inflated, they are constructed and arranged to engage the inner surfaces 5130, 5132 of the conduits 1022a, 1022b, respectively, to form the chamber 7054 therebetween. In one embodiment, the purge seals 7046 and 7048 are joined on opposite sides of the joint region 5136 after inflation. In one embodiment, the chamber 7054 is a closed volume that may be referred to as a purge gas chamber 7054. In one embodiment, the chamber 7054 is constructed and arranged to receive a purge gas (or inert gas) therein.
In one embodiment, the front clamp control valve 7056 and the rear clamp control valve 7058 are sequential 4-way directional valves (e.g., having four hydraulic connections corresponding to the inlet port (P), the actuator ports (a and B), and the return port (T), and one physical signal port connection (S)). For example, in one embodiment, one of the actuator ports a or B is used to extend its corresponding clamp 7050 or 7052 and inflate its corresponding seal 7046 or 7048, and the other of the actuator ports a or B is used to retract its corresponding clamp 7050 or 7052 and deflate its corresponding seal 7046 or 7048.
Figure 93 illustrates a detailed side view of the actuation portion 7006 of the purge and check system 7001. In one embodiment, the drive portion 7006 of the purge and verification system 7001 includes a shielding gas tank 7070, a battery, a drive portion electronics module 7064, pneumatic valves, drive wheels, a drive motor 7068, brakes, and a compressed air tank, and the structure and operation of each of these components are similar to those in the drive portion of the internal welding system 5004.
Figure 94 shows a schematic diagram showing the flow of purge gas through the purge and verification system 7001, with some components of the purge and verification system 7001 not shown for the sake of clarity and to better illustrate other components and/or features of the purge and verification system 7001.
In one embodiment, the inert/purge gas supply line is configured to deliver a purge/inert gas source 7070 to the region 7054 between the first seal 7046 and the second seal 7048. In one embodiment, gas from the inert/purge gas source 7070 is directed into the region 7054 between the first seal 7046 and the second seal 7048 to reduce oxidation during the welding operation.
Referring to fig. 94, a purge gas tank 7070 is shown in the drive portion 7006 of the purge and verification system 7001. In one embodiment, the high pressure regulator 7074 may be located in the actuation portion 7006 of the purge and check system 7001. In one embodiment, the high pressure regulator 7074 may be positioned in the central portion 7004 of the purge and check system 7001. In one embodiment, the rear rotary union 707, the rotatable hub 7012, the purge gas chamber 7054, the front and rear clamps 7050, 7052, and the front and rear seals 7046, 7048 are shown in the central portion 7004 of the purge and check system 7001. A low purge valve 7016, a primary low purge regulator 7018, a secondary low purge regulator 7020, a high purge valve 7022, a high purge regulator 7024, an oxygen sensor 7026, and a pump 7028 are shown in the forward-most portion 7002 of the purge and check system 7001.
In one embodiment, the purge gas tank 7070 is configured to be maintained at a pressure of 500-. The purge gas tank 7070 is in fluid communication with a rear rotary union 7072 via a fluid communication line. In one embodiment, the purge gas tank 7070 is in fluid communication with a rear rotary union 7072 through a valve 7071 and a high pressure regulator 7074. In one embodiment, the high pressure regulator 7074 is configured to automatically shut off the flow of purge gas at a pressure of 75 pounds. That is, the high pressure regulator 7074 is typically provided to reduce the pressure in the purge gas tank 7070 to about 75 pounds of the fluid communication line downstream of the high pressure regulator 7074 and from the rear rotary union 7072 to the low purge valve 7016 and the high purge valve 7022.
In one embodiment, rear rotary union 7072 is in fluid communication with low purge valve 7016 and high purge valve 7022 via a fluid communication line. In one embodiment, the purge gas stored in the purge gas tank 7070 is sent to the rear rotary union 7072 through a fluid communication line, and then from the rear rotary union 7072 to the low purge valve 7016 and the high purge valve 7022 through a fluid communication line.
In one embodiment, the high purge regulator 7024 is connected to the outlet of the high purge valve 7022. That is, the high purge regulator 7024 is positioned downstream of the high purge valve 7022. In one embodiment, the high purge regulator 7024 is configured to reduce the pressure output by the high purge valve 7022 to between typically 30 and 5 pounds in the fluid communication line downstream of the high purge regulator 7024 and between the high purge regulator 7024 and the purge gas chamber 7054.
In one embodiment, a fluid communication line extends from the low purge valve 7016 to the primary low purge regulator 7018. In one embodiment, the primary low purge regulator 7018 is connected to the outlet of the low purge valve 7016. That is, the primary low purge regulator 7018 is positioned downstream of the low purge valve 7016.
In one embodiment, the primary low purge regulator 7018 is generally configured to reduce the pressure output through the low purge valve 7016 to between about 0.5 and 5 pounds in the fluid communication line downstream of the primary low purge regulator 7018 and between the primary low purge regulator 7018 and the secondary low purge regulator 7020.
In one embodiment, a fluid communication line extends from the primary low purge regulator 7018 to the secondary low purge regulator 7020. In one embodiment, the secondary low purge regulator 7020 is positioned downstream of the primary low purge regulator 7018.
In one embodiment, the secondary low purge regulator 7020 is configured to reduce the pressure output by the primary low purge regulator 7018 to typically between 0.1 and 0.5 pounds in the fluid communication line downstream of the secondary low purge regulator 7020 and between the secondary low purge regulator 7020 and the purge gas chamber 7054.
In one embodiment, the welding process begins at a pressure of about 0.5 pounds, and the secondary low purge regulator 7020 may then be turned back to 0.1 pounds during the welding process when leakage of purge gas through the weld joint is slowed by the weld (e.g., based on how much of the gap between the tubes is welded).
In one embodiment, the pump 7028 is in fluid communication (via a fluid communication line) with the output/outlet port of the purge gas chamber 7054 on one side and the oxygen sensor 7026 on the other side. In one embodiment, the pump 7028 is in fluid communication with an output of the purge gas chamber 7054 such that the pump 7028 is configured to operate (continuously or intermittently) to draw a gas sample from the purge gas chamber 7054.
In one embodiment, the purge gas from the purge gas tank 7070 is used only to fill and maintain the purge gas in the purge gas chamber 7054. In one embodiment, compressed air is used to inflate the seals 7046 and 7048 and expand the clamps 7050 and 7052. In one embodiment, the actuation portion 7006 of the purge and verification system 7001 may include both a purge gas tank 7070 as well as a compressed air gas tank.
Figure 95 illustrates a schematic diagram showing the flow of compressed air through the purge and check system 7001, where some components of the purge and check system 7001 are not shown for the sake of clarity and to better illustrate other components and/or features of the purge and check system 7001.
The flow of compressed air through the purge and verification system 7001 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.
In one embodiment, the valve 7076 is positioned on the fluid communication line 7078. In one embodiment, the fluid communication line 7078 is between the rear clamp control valve 7058, the rear clamp 7052, and the rear seal 7046, and is configured to supply compressed air to expand the rear seal 7046 of the rear clamp 7052. In one embodiment, one output of the valve 7076 is configured to supply compressed air to expand the rear clamp 7052 and another output of the valve 7076 is configured to supply compressed air to inflate the rear seal 7046.
In one embodiment, the valve 7082 is positioned on the fluid communication line 7084. In one embodiment, a fluid communication line 7084 is between the front clamp control valve 7056 and the front clamp 7050 and the front seal 7046 and is configured to supply compressed air to expand the front clamp 7050 and the rear seal 7046. In one embodiment, one output of the valve 7082 is configured to supply compressed air to expand the front clamp 7050 and another output of the valve 7082 is configured to supply compressed air to inflate the front seal 7046.
Figure 96 illustrates a schematic diagram showing the flow of purge gas through the purge and verification system 7001, with some components of the purge and verification system 7001 not shown for the sake of clarity and to better illustrate other components and/or features of the purge and verification system 7001. For example, in one embodiment, in the smaller purge and verification system 7001, the purge gas not only serves to fill and maintain the purge gas in the purge gas chamber 7054, but also inflates the seals 7046 and 7048 and expands the clamps 7050 and 7052.
The flow of purge gas through the purge and verification system 7001 in figure 96 is similar to the flow of purge gas through the purge and verification system 7001 in figure 94, except for the differences noted below.
In one embodiment, rear rotary union 7072 is in fluid communication with low purge valve 7016, high purge valve 7022, and front rotary union 7104 via a fluid communication line. In one embodiment, the purge gas stored in the purge gas tank 7070 is sent to the rear rotary union 7072 through a fluid communication line, and then from the rear rotary union 7072 to the low purge valve 7016 and the high purge valve 7022 through a fluid communication line. In one embodiment, purge gas is also sent from rear rotary union 7072 to front rotary union 7104 through a fluid communication line. The front rotary union has substantially the same components and operates in substantially the same manner as front rotary union 5032 shown in fig. 25, and therefore is not shown in the same detail as front rotary union 5032.
In one embodiment, purge gas is sent from rear rotary union 7072 to rear clamp control valve 7058 via a fluid communication line. In one embodiment, purge gas from the rear clamp control valve 7058 is supplied through the fluid communication line 7088 to expand the rear clamp 7052 and through the fluid communication line 7090 to inflate the rear seal 7048. In one embodiment, the pressure regulator 7092 is positioned on the fluid communication line 7090 and is configured to automatically shut off the flow of purge gas to the seal 7048 at a predetermined pressure in one embodiment, purge gas from the rear clamp 7052 is received by the rear clamp control valve 7058 via the fluid communication line 7094 to retract the rear clamp 7052.
In one embodiment, purge gas is sent from front rotary union 7104 to front clamp control valve 7056 through a fluid communication line. In one embodiment, purge gas from the front clamp control valve 7056 is supplied through the fluid communication line 7098 to expand the front clamp 7050 and through the fluid communication line 7100 to inflate the front seal 7046. In one embodiment, the pressure regulator 7102 is positioned on the fluid communication line 7100 and is configured to automatically shut off the flow of purge gas to the seal 7046 at a predetermined pressure in one embodiment, purge gas from the front clamp 7050 is received by the front clamp control valve 7056 via the fluid communication line 7096 to retract the front clamp 7050.
Fig. 97 shows a partial view of a purging and inspection system 7001 in which an inspection detector 7042 and a camera 7044 are configured to perform inspection from inside the pipe while an external weld torch 7502 of an external welding system 7500 is configured to perform welding outside of the pipes 1022a, 1022 b. In one embodiment, an externally positioned welding torch 7052 may be mounted to an outer surface of one of the first conduit 1022a and the second conduit 1022 b.
For example, in fig. 97, the weld torch 7502 is shown in ideal alignment with the chamfer 7106 (along the longitudinal axis a-a of the conduits 1022a, 1022 b). Fig. 98 shows a close-up view of welding torch 7502 perfectly aligned with bevel 7106. The conduits 1022a, 1022b shown in fig. 97 and 98 are perfectly aligned and do not have any staggers.
Fig. 99 and 100 show close-up views of the external welding torch of the external welding system used in the prior art system and the purge and verification system 7001, respectively, with the conduits having a gap and a radially offset (staggered) alignment. For example, as shown in fig. 99 and 100, conduits 1022a, 1022b have a 1 mm gap and radial offset (stagger).
As shown in fig. 99, in prior art systems, the raised edge of the pipe protects the right side of the weld groove, resulting in a reduction in weld penetration. As shown in figure 100, an external welding system 7500 for use with the purge and inspection system 7001 is configured to receive weld profile data from the purge and inspection system 7001 (e.g., before, during, and after a welding procedure) and to offset and/or tilt its external welding torch 7502 based on the received weld profile data to achieve full weld penetration. Thus, the weld profile data from the purge and inspection system 7001 may be used by the external welding system 7500 to make a better weld.
The operation of the purge and verification system 7001 will now be described. In one embodiment, the purge and verification system 7001 is configured to operate through repeated cycles of operation.
After determining that welding is complete in the current weld joint, the one or more processors 7062 (of the computer system 7060) are configured to send communication signals to the purge electronics module 7032 to control (via control signals) the low purge valve 7016, the high purge valve 7022, and the secondary low purge regulator 7020 to deflate the purge seals 7046 and 7048. The one or more processors 7062 are also configured to send communication signals to the front-most electronics module 7036 to control/close (via control signals) the front clamp control valve 7056 to retract the first engagement structure 7050 to its initial retracted position and/or to deflate the purge seal 7046. The one or more processors 7062 are also configured to send communication signals to the central portion electronics module 7040 to control/close (via control signals) the rear clamp control valve 7058 to retract the second engagement structure 7052 to its initial retracted position and/or to deflate the purge seal 7048. The purge and verification system 7001 (including the purge seals 7046 and 7048 and the clamps 7050 and 7052) must be moved to the next weld joint.
In one embodiment, the one or more processors 7062 are configured to generate communication signals to drive portion electronics module 7064 to control (via control signals) drive motor 7068 to accelerate purge and inspection system 7001 for a predetermined speed travel and then decelerate and stop at the next weld joint. In one embodiment, the predetermined rate of acceleration of the purge and verification system 7001 may be 6 feet/second.
When the second joining structure 7052 is positioned at the next weld joint, the drive portion electronics module 7064 sends a communication signal to the purge electronics module 7032 to check for alignment with the ends of the conduits. In one embodiment, the purge electronics module 7032 is configured to operate (turn on) one or more check detectors 7042 to measure the position of the second engagement structure 7052 relative to the end of the tube. In one embodiment, the rotatable hub 7012 may not be operated when the one or more inspection detectors 7042 measure the position of the second engagement structure 7052 relative to the end of the pipe.
In one embodiment, the purge electronics module 7032 is configured to send the measured distance data to the drive portion electronics module 7064. In one embodiment, the drive portion electronics module 7064 is configured to control (via a control signal) the drive motor 7068 to move the second engagement structure 7052 the measured distance data.
In one embodiment, when the second joining structure 7052 is properly aligned and positioned relative to the pipe ends, the drive portion electronics module 7064 is configured to send a communication signal to the central portion electronics module 7040 that the purge and verification system 7001 is positioned at the next weld joint. In one embodiment, the central portion electronics module 7040 controls (via a control signal to open) the rear clamp control valve 7058 to raise the second engagement structure 7052 and clamp the old/existing tubular. In one embodiment, the central portion electronics module 7040 controls (via a control signal to open) the rear clamp control valve 7058 to inflate the rear seal 7048 at the same time.
The next/new pipe segment 1002a is then introduced by the staff member and slid into place on the forwardmost portion 7002 of the purge and inspection system 7001. At this point, the one or more processors 7062 are configured to send communication signals to the purge electronics module 7032 to operate the one or more verification detectors 7042 to check the alignment of the conduits. In one embodiment, the one or more processors 7062 may rotate the rotatable hub 7012 to make measurements at multiple locations.
If the tube alignment data is within the predetermined tolerance, the purge electronics module 7032 sends a communication signal to the front-most electronics module 7036 to actuate and operate the front clamp 7050. In one embodiment, the front-most electronics module 7036 controls/opens (via a control signal) the front clamp control valve 7056 to raise the first engagement structure 7052 and clamp the new pipe segment 1002 a. In one embodiment, the front-most electronics module 7036 controls/opens (via a control signal) the front clamp control valve 7056 to inflate the front seal 7046 at the same time.
If the conduit alignment data is not within the predetermined tolerance, the purge electronics module 7032 sends a communication signal (message) to the one or more processors 7062 identifying the misalignment between the conduits 1022a, 1022 b. In one embodiment, this information may be relayed to the crane operator via conventional crane operator gesture signals or to a computer display terminal in the crane cab via electronic signals.
After clamping the pipe, the one or more processors 7062 are configured to send communication signals to the purge electronics module 7032 to operate the one or more inspection detectors 7042 to measure the gap and radial offset (stagger) at multiple points along the circumference of the weld joint. In one embodiment, this data is communicated out to the one or more processors 7062 and compared to allowable tolerances.
If the joint fit-up (i.e., gap and radial offset (mismatch)) is within a predetermined tolerance, the one or more processors 7062 or the purge electronics module 7032 send a communication signal to the operator indicating that welding may begin.
If the joint fit-up (i.e., gap and radial offset (mismatch)) is not within a predetermined tolerance, a warning is sent to the operator, who may restart the clamping sequence or ignore the warning.
In one embodiment, the purge electronics module 7032 is configured to send a control signal to the high purge valve 7022 to open and a control signal to the high purge regulator 7024 to operate. In one embodiment, the purge electronics module 7032 is configured to continuously monitor readings of oxygen content levels in the purge gas chamber 7054 from the oxygen sensor 7026. When the measurement data of the oxygen sensor 7026 is below a predetermined oxygen content value (e.g., 500 parts per million (ppm)), the purge electronics module 7032 is configured to send a closed control signal to the high purge valve 7022 and an open control signal to the low purge valve 7016. In one embodiment, the measurement data of the oxygen sensor 7026 is within a predetermined range (e.g., 50 to 100 ppm).
In one embodiment, when the high purge valve 7022 is open, the purge electronics module 7032, together with the front-most electronics module 7036 and the center portion electronics module 7040, are configured to measure the gap and stagger of the weld joint at multiple points along the circumference of the weld joint using one or more check detectors 7042. The results of the scan are transmitted to one or more processors 7062 to pre-program external welding system 7500.
In one embodiment, the secondary low purge regulator 7020 is configured to maintain a constant set pressure in the purge gas chamber 7054 after the low purge valve 7016 is closed. In one embodiment, the secondary low purge regulator 7020 is configured to maintain a pressure between 0.1 and 0.5 pounds and is configured to stop its operation when the pressure is above 0.5 pounds.
In one embodiment, the pressure is initially at a relatively high value (e.g., 5 pounds) and progressively changes to a lower value as the weld progresses. In one embodiment, the secondary low purge regulator 7020 may include a pressure sensor 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 purge chamber 7054 and send pressure data to the one or more processors 7062, the pressure data indicative of the pressure of the purge gas in the purge chamber 7054. In one embodiment, the one or more processors 7062 are configured to receive the pressure data, compare the received pressure data to its predetermined pressure value, and generate an overpressure signal if the pressure data is greater than the predetermined pressure value of 0.5 pounds. In one embodiment, based on the over-pressure signal, the purge and verification system 7100 may be configured to open the vent valve structure to release the pressure in the purge chamber 7054 until the measured pressure falls below a predetermined pressure value. In one embodiment, based on the overpressure signal, the purge and verification system 7100 may be configured to send a communication signal to the external welding system to stop the welding process.
In one embodiment, a communication signal is sent from the umbilical that the correct purge gas level has been reached and the welding process can begin. In one embodiment, an operator issues a command to external welding system 7500 to begin a welding process. In one embodiment, a command is automatically sent from the one or more processors 7062 to the external welding system 7500 to begin the welding process.
In one embodiment, the purge electronics module 7032, together with the front-most electronics module 7036 and the center portion electronics module 7040, are configured to measure the gap and stagger of the weld joint at a short distance before where the external welding system 7500 is currently welding using one or more inspection detectors 7042. In one embodiment, the inspection data from the inspection detector 7042 may be communicated in real time to the one or more processors 7062, which the one or more processors 7062 use to send updated welding parameters to the external welding system 7500.
In one embodiment, the external welding system 7500 is configured to communicate its location to one or more processors 7062, which processor or processors 7062 forward the information to the purge electronics module 7032 so that the purge electronics module 7032 can maintain the proper purge gas chamber pressure and properly control the location of the inspection detector 7042.
In one embodiment, the welding process may be performed in several different ways.
In one embodiment, the welding process may be performed top to bottom on one side of the pipe and then top to bottom on the other side of the pipe. In one embodiment, the second weld begins after the first weld is completed. In this case, the inspection detector 7042 scans in real time prior to welding.
In one embodiment, the welding process may be performed top to bottom on each side of the pipe, with the second weld beginning before the first weld is completed. In one embodiment, the inspection detector 7042 scans a distance before one weld faster than the welder travels, and then quickly changes position to another weld to scan before it. In one embodiment, the inspection detector 7042 may alternate between two weld locations until the first weld is completed.
In one embodiment, the welding process may be performed around the entire pipe in one pass, with the inspection detector 7042 scanning a short distance before the weld.
In one embodiment, after the weld is complete, the rotatable hub 7012 continues to rotate while the purge electronics module 7032 inspects the weld using the inspection detector 7042 and the camera 7044. In one embodiment, the weld inspection data is transmitted to the one or more processors 7062.
In one embodiment, if one or more weld defects are detected in the weld inspection data, the weld defect may be repaired while the clamps 7050 and 7052 remain in place and the purge gas chamber 7054 remains filled with inert gas.
In one embodiment, once the inspection and any repairs are completed and confirmed by the operator, the operator sends commands to the front most portion electronics module 7036 and the central portion electronics module 7040 to close the front and rear clamp control valves 7056 and 7058, lower/retract the clamp brake straps 7050 and 7052, and deflate the seals 7046 and 7048.
In one embodiment, the one or more processors 7062 of the purge and verification system 7100 may be operatively connected to the front-most electronics module of the purge and verification system 7100, the purge electronics module 7032, the central portion electronics module of the purge and verification system 7100, and the drive portion electronics module 7064.
In one embodiment, the field system of the present application may include one or more of a splitter/hub/router configured to transmit data, control signals, and communication signals between one or more processors 5140 or 7062 and one or more electronic modules described herein.
During a pipeline forming process (e.g., for offshore or onshore applications), a section of conduit 1022a or 1022b is joined to another section of conduit 1022b or 1022a at a joint weld (where the two conduit sections are welded together) by aligning the two butt ends of the conduit sections and forming a weld seam 1026. This welded joint 1026 connects the two conduit portions 1022a, 1022b at their butt ends, such that the welded joint 1026 creates a fluid-tight seal and thus a continuous fluid pathway between the two joined conduit portions. Each conduit section 1022a, 1022b can be quite long (e.g., hundreds or thousands of feet or even 1 mile long), making it difficult to provide internal cooling within the conduit sections 1022a, 1022b at or near the joint weld after the weld joint 1026 is formed. In particular, placing a cooling structure internally within the conduit portions 1022a, 1022b and removing such structure for cooling at the weld joint 1026 may be a challenge.
The internal cooling system of the present patent application provides internal cooling within the ducting sections 1022a, 1022b after the ducting sections 1022a, 1022b are secured together by the welded seam 1026. In one embodiment, the internal cooling system may be an internal heat exchanger, which may be referred to as "IHEX". In one embodiment, an internal cooling system comprises: a cooling portion that provides direct cooling to the interior surface portions of conduits 1022a, 1022 b; and a control section or controller configured to control the components of the cooling section and also configured to facilitate mobility of the internal cooling system within the conduit sections 1022a, 1022 b. In one embodiment, the cooling portion utilizes a coolant to provide cooling internally within the conduit portions 1022a, 1022 b. In one embodiment, the internal cooling system may further comprise a coolant supply portion comprising coolant supplied to the cooling portion during operation of the internal cooling system. In one embodiment, the internal cooling system of the present patent application comprises: a mechanism configured to internally cool conduit portions 1022a, 1022b after conduit portions 1022a, 1022b are welded together; and a mechanism for placing the internal cooling system within the conduit portions 1022a, 1022b and retrieving the internal cooling system from the conduit portions 1022a, 1022b during the pipeline formation process, which allows for a reduction in the time required to cool the conduit portions after heating, and also speeds up the progression through the stations required for manufacturing.
Fig. 104 illustrates an exemplary internal cooling system 2010 of the present patent application. In one embodiment, the internal cooling system 2010 includes a suitably rigid frame housing components of the internal cooling system, wherein the frame includes a plurality of longitudinally or lengthwise extending rods 2019, 2021 constructed of one or more suitable materials (e.g., a metal such as steel or other suitably rigid and durable material) and having a suitable configuration to allow the frame to be inserted within the conduit portions to facilitate internal cooling within the conduit portions 1022a, 1022 b.
The first portion 2011 of the frame includes a coolant supply 2012, the coolant supply 2012 including one or more canisters (a single canister is shown in fig. 104) secured within the first portion 2011. The coolant supply tank may include any suitable cooling fluid including, but not limited to, water, a cryogenic fluid such as liquid argon or liquid nitrogen, and the like. A second cooling section 2016 is secured at an intermediate portion of the frame adjacent the first section 2011 and communicates with the coolant supply 2012 through a suitable valve structure 2014 (e.g., shown in fig. 104 as one or more valves, regulators, conduits, etc.) that facilitates the supply of coolant from the coolant supply 2012 to an outlet nozzle 2007 of the cooling section 2016 at one or more suitable pressures and/or flow rates.
The third portion 2018 of the frame is disposed adjacent the cooling portion 2016 and includes a plurality of bars 2021 forming a cage-like housing around the controller 2020. A pneumatic and/or electronic drive system 2022 may also be disposed at least partially within third portion 2018, and may include one or more motor-controlled rollers 2025 and/or any other suitable kinematic structure configured to engage with interior surface portions of the conduit portions when internal cooling system 2010 is disposed within such conduit portions to control movement of internal cooling system 2010 within the conduit portions in forward and reverse directions during the processes described herein. In one embodiment, drive system 2022 may be in communication (e.g., hardwired or wireless communication) with controller 2020 to facilitate controlling forward and reverse movement of interior cooling system 2010 by controller 2020 during a process (e.g., controlling rotation of motor-controlled rollers of drive system 2022 and thus controlling forward or backward movement of interior cooling system 2010 by controller 2020). In one embodiment, drive system 2022 may be substantially included within and/or be a portion of the frame of internal cooling system 2010. In one embodiment, drive system 2022 may include structures that extend beyond the frame. In one embodiment, drive system 2022 may include suitable cable structures extending from internal cooling system 2010 and through one or more conduit portions to open ends of the conduit portions, wherein the cable structures are used to facilitate forward and/or reverse movement of internal cooling system 2010 within the conduit portions (e.g., via winch structures provided within the internal cooling system frame and/or at anchor locations external to the conduit portions and connected with the cable structures). In one embodiment, rollers may also be provided at one end of the internal cooling system 2010 (e.g., roller 2023 provided at the terminal end of the frame first portion 2011 as shown in fig. 104) to enhance mobility of the internal cooling system 2010 within the conduit portions 1022a, 1022 b.
In one embodiment, the controller 2020 may include at least one suitable processor that controls the operation of the interior cooling system 2010 through suitable control process logic instructions stored within the memory of the controller and through electronic signals provided remotely by another user-controlled device disposed at a suitable distance from the interior cooling system. In one embodiment, the controller 2020 may be configured to communicate with a remote control device (e.g., a computer, a manual control device, or any other suitable electronic device) operable by a user via electronic signals, wherein the electronic signals are transmitted via a wireless or hardwired link between the controller 2020 and the remote control device. In one embodiment, the remote control device is illustrated in fig. 104 as a computer 2030 (e.g., a laptop, notepad, personal digital assistant, smartphone, etc.), which computer 2030 communicates with the controller 2020 through a wireless communication link (illustrated in fig. 104 as a dashed line). The electronic signal communications may include two-way communications between the controller 2020 and a remote control device, such that the controller 2020 is configured to provide information, such as measured internal temperature information and/or other types of measured conditions within the pipe section, and received control information to the remote control device to enable remote control operation of the interior cooling system 2010.
In one embodiment, one or more electronic sensors 2017 may be provided at one or more suitable locations within the internal cooling system frame and may be in communication (via a hardwired or wireless communication link) with the controller 2020 to provide information regarding conditions within the pipe section during the process. For example, in one embodiment, the one or more electronic sensors 2017 include one or more temperature sensors (e.g., IR temperature sensors, RTD temperature sensors, thermocouples, etc.) that may be provided at one or more different locations at the first portion 2011, the cooling portion 2016, and/or the third portion 2018 of the internal cooling system 2010, wherein the temperature sensors are configured to measure temperature during a procedure and provide such measured temperature information to the controller 2020. In one embodiment, the one or more electronic sensors 2017 include pressure and/or flow rate sensors that may be provided within the tank 2012 of the coolant source 2012, within the valve structure 2014, and/or at one or more suitable locations adjacent the outlet nozzle 2007 of the cooling section 2016, wherein measured pressure and/or flow rate information is provided from such sensors to the controller 2020 during a process. It should be understood that the sensors 2017 may also include a combination of temperature and pressure sensors. In one embodiment, one or more cameras 2027 controlled by controller 2020 (and remotely controlled by a remote control device) may also be provided at one or more suitable locations to facilitate viewing within the duct sections (e.g., to determine a suitable location for positioning interior cooling system 2010 within duct sections 1022a, 1022b during a process). Exemplary pressure/temperature sensors and/or cameras are shown generally at locations 2017 and 2027 in fig. 104.
In one embodiment, the internal cooling system 2010 may include a suitable power supply to provide power to the controller 2020, the drive system 2022, the electronic sensors, the valve structure 2014 (e.g., to electrically control one or more valves and thus control the flow of coolant from the coolant supply 2012 to the cooling portion 2016). In one embodiment, the power supply may be housed within the internal cooling system frame (e.g., one or more batteries disposed in a battery pack provided within the third portion 2018 or at any other suitable location within the internal cooling system frame). In one embodiment, the power supply may be located outside of the duct section, with cables connecting the power supply with the internal cooling system 2010 to provide power to the various components of the internal cooling system.
In one embodiment, the cooling section 2016 may include any suitable structure that facilitates cooling via heat exchange with the inner weld sections and other inner wall portions of the conduit sections. In one embodiment, coolant from the coolant supply 2012 is provided to the cooling section 2016 through the valve section 2014. In one embodiment, the cooling section 2016 includes a plurality of nozzles 2007, the plurality of nozzles 2007 being disposed around the periphery of the cooling section 2016 to facilitate the flow of coolant from the cooling section 2016 toward the interior surfaces at the weld joint and other interior portions of the two joined conduit sections at a suitable flow rate (as controlled by the nozzle design of the valve section 2014 and the cooling section nozzles 2007).
Operation of the internal cooling system 2010 with respect to the pipeline welding process will now be described with reference to fig. 105-107. In preparation for welding the open end of the first conduit portion 1022a to the contra-open end of the second conduit portion 1022b, the two conduit portions 1022a, 1022b are axially aligned with one another in position. In one embodiment, the two conduit portions 1022a, 1022b can be held in this alignment using a fitting clamp (not shown in fig. 105 and 107). A suitable fitting clamp (e.g., clamp 5302 (positioned outside of the pipe), as disclosed elsewhere in this application) may be secured externally to the butt ends of the pipe sections 1022a, 1022b to hold the sections 1022a, 1022b in place relative to one another during the welding process. In one embodiment, an inner joint clamp (e.g., inner clamps 5142, 5144 (positioned inside the pipe) as disclosed elsewhere in this application) may be used to hold the butt ends in place during the welding process. Two types of joint clamps(external and internal) are known in the art of pipe welding and are therefore not described in further detail herein. After applying the fitting clamps to hold the ends of the conduit portions 1022a, 1022b in place relative to one another, a weld joint 1026 is formed at the fitting weld location (i.e., at the two butt open ends of the first and second conduit portions). The weld joint 1026 is formed in a manner as described in detail above, and may include a root channel weld layer, a hot channel weld layer, a fill channel weld layer, and a cap channel weld layer to ensure that a proper weld joint is formed. In one embodiment, the formation of the weld joint 1026 may involve preheating the butt ends of the first conduit portion 1022a and the second conduit portion 1022b to a minimum temperature of about 150 ℃. The remainder of the soldering process may result in a temperature increase of about 300 c around the soldered joint. After the weld joint 1026 is formed, the weld joint 1026 is typically subjected to AUT (ultrasonic testing) and/or X-ray inspection as disclosed elsewhere in this application to confirm the quality/integrity of the weld joint 1026. In one embodiment, the AUT weld test may not be above about 50 ℃ to about 75 ℃ (T ℃ Maximum of) At a temperature of (a) wherein TMaximum ofIs the highest temperature at which the test can be performed effectively. The AUT weld inspection process of the pipe manufacturing process must be stopped until the pipe temperature near the weld joint 1026 decreases to a temperature around the inspection temperature range. The internal cooling system of the present application is configured to remove heat from the weld area to reduce the temperature of the pipe weld area to at least an acceptable AUT test temperature (T;)Maximum of)。
In one embodiment, after the weld inspection process, a coating (FJC) is also applied to the outer regions of the conduit portions 1022a, 1022b surrounding the weld joint 1026 to provide an insulating barrier to prevent or minimize corrosion at the weld region. This insulation may be generally only above the minimum pipe temperature T at the pipe temperatureMinimum sizeIs effectively applied. Heat is thus added to the welding area until the temperature in the welding area to be insulated rises back to approximately 220 to 240 ℃ (T ℃Minimum size) Wherein T isMinimum sizeIs the lowest temperature at which the insulation can be effectively applied to the insulation area.
After the coating/insulation application process, the pipe may be coiled for field installation. However, at about T Minimum sizeAt temperatures of (a), the winding process may not be effectively accomplished while maintaining weld integrity. Thus, the pipe manufacturing process can be postponed again while the pipe temperature is gradually brought from TMinimum sizeNaturally down to an acceptable winding temperature (T)Maximum of) Wherein T isMaximum ofIs the maximum temperature at which the pipe can be effectively coiled. In one embodiment, the internal cooling system of the present application is configured to remove heat from the welding zone again in order to reduce the temperature to about 50 to about 75 ℃ (T) acceptable for efficient spooling (spooling of the pipe onto a spool)Maximum of) The maximum temperature of (c). Accordingly, the internal cooling system of the present application is configured to reduce the temperature prior to the weld inspection process and/or reduce the temperature prior to the winding process in order to minimize the time it takes to weld, inspect, insulate, and wind a length of pipe.
During the period of operation when the conduit portions 1022a, 1022b are welded together (with subsequent application of the coating/insulation), the internal cooling system 2010 is loaded within the open ends of the conduit portions 1022a, as shown in fig. 105. In one embodiment, one or both conduit portions 1022a, 1022b can comprise a single conduit unit. In another embodiment, one of conduit portions 1022a, 1022b can include multiple conduit units welded together. In one embodiment, when one of the conduit portions 1022a or 1022b includes multiple conduit units that have been welded together, it may be desirable to load the internal cooling system 2010 at the conduit portion 1022a or 1022b (or a conduit portion having a shorter length) that includes a single conduit unit in order to reduce the time required for the internal cooling system 2010 to travel within the conduit portion to reach the joint weld portion. Thus, in one embodiment, ducting section 1022a may comprise a single ducting unit connected to a longer ducting section represented by ducting section 1022b (e.g., two or more ducting units connected by a welded seam).
In one embodiment, the internal cooling system 2010 is loaded into the open end of the conduit portion 1022a (i.e., the end opposite the open end facing the open end of the conduit portion 1022b defining the joint weld location) such that the first portion 2011 of the internal cooling system frame acts as the front end and thus enters first into the conduit portion 1022 a. In one embodiment, internal cooling system 2010 is moved (with first portion 2011 leading) within conduit portion 1022a to a suitable location adjacent to the joint weld location, as shown in fig. 106. In one embodiment, controller 2020 (which may be remotely controlled by a user) is configured to control operation of drive system 2022 (e.g., by controlling one or more motors that move rollers 2025 in contact with an inner wall portion of conduit portion 1022 a) to facilitate advancement of internal cooling system 2010 within conduit portion 1022a and toward the joint welding location. Upon reaching a suitable location adjacent to the joint welding location (e.g., the location of the internal cooling system as shown in fig. 106), controller 2020 may control drive system 2022 to stop further movement of internal cooling system 2010 until such time as the cooling process is initiated. For example, a camera 2027 mounted at a suitable location on first portion 2011 and controlled by controller 2020 may provide video images to a remote control device so that a user can determine how close the internal cooling system is to weld seam 1026. In one embodiment, in combination with the video images provided by the video camera 2027, one or more temperature sensors 2017 suitably located on the frame of the interior cooling system 2010 measure the interior temperature within the conduit portion 1022a and provide such temperature information to the controller 2020. When one or more measured temperatures reach a threshold (e.g., about 100 ℃ or greater), this may provide an indication that the internal cooling system 2010 has reached a location adjacent the weld joint 1026. Any other suitable mechanism may also be utilized to provide a suitable indication of its position within conduit portion 1022a during movement of internal cooling system 2010 toward the joint welding location.
Upon reaching the desired location adjacent or near the joint weld location, the cooling process may be performed after the weld joint 1026 is formed and before the AUT/X-ray inspection occurs (if needed). In one embodiment, the cooling process may be performed after the pipe is reheated and FJC applied (if needed) for application of the outer coating. In one embodiment, when internal cooling system 2010 reaches a suitable position within conduit portion 1022a adjacent to the joint welding location and prior to completion of the welding process, internal cooling system 2010 remains in its position and is ready for cooling once the welding or reheating process is complete. The cooling process is performed by first positioning the cooling section 2016 at a suitable location (e.g., relative to the solder joint 1026, such as shown in fig. 107). This may be accomplished by controller 2020 controlling drive system 2022 (which is user controlled by a remote control device) advancing interior cooling system 2010 from its position in fig. 106 to its position in fig. 107 until interior cooling system 2010 is at a desired position. Movement to this location (e.g., as shown in fig. 107) may be accomplished based on video images provided within the conduit portions 1022a, 1022b of the remote control device, temperature sensor information provided to the remote control device, and/or by any other suitable mechanism.
Upon reaching a desired location within the conduit sections 1022a, 1022b (e.g., where the cooling section 2016 is disposed adjacent the weld joint 1026, as shown in fig. 107), the controller 2020 (which may be user controlled by a remote control device) controls operation of the valve structure 2014 (e.g., by controlling one or more electronic valves) to facilitate flow of coolant at a suitable pressure and/or flow rate from the coolant supply 2012 to the cooling section 2016, wherein the coolant flows from the nozzle 2007 disposed at the cooling section 2016 and appropriately oriented to direct the coolant away from the cooling section 2016 and toward the inner wall surface portions within the conduit sections 1022a, 1022 b. The temperature sensors monitor the internal temperature at the internal cooling system 2010 within the conduit portions 1022a, 1022b and provide measured temperature information to the controller 2020. Sufficient temperature (as measured by a temperature sensor, e.g., T) is reached within conduit portions 1022a, 1022bMaximum ofAt or below DEG CTemperature), the controller 2020 can control the valve arrangement 2014 to stop the flow of coolant to the cooling section 2016.
In one embodiment, internal cooling system 2010 may be moved in a forward or reverse direction by control of drive system 2022 by controller 2020 to provide additional cooling procedures at other locations along the inner wall surface portions of conduit portion 1022a and/or conduit portion 1022b (as needed and based on the measured internal conduit temperature). When it is determined that sufficient cooling is achieved, the internal cooling system 2010 may be removed from the connected conduit portions 1022a, 1022 b. For example, the internal cooling system 2010 may be reversed by controlling the drive system 2022 by the controller 2020 to move toward the free and open end of the conduit portion 1022a such that the third portion 2018 is first exposed from the conduit portion 1022 a. The other ducting section may then be aligned with the free and open end of ducting section 1022a (now connected with ducting section 1022b by weld joint 1026) (the internal cooling system may remain inside section 1022a when the new section is fitted to 1022 a) to form a joint weld location, and the process then repeated with internal cooling system 2010 entering through the free and open end of the other ducting section and advancing towards the joint weld location for performing the cooling process at the weld joint to be formed between the ducting sections.
Although drive system 2022 shown in the embodiment of fig. 104-107 includes rollers 2025 operable by a motor system controlled by controller 2020, drive system 2022 for the interior cooling system may implement any suitable mechanism capable of providing user-controlled movement of the interior cooling system within the duct section. For example, one or more cable/winch systems may be implemented, wherein one or more winches may be provided as part of the internal cooling system and/or at one or more anchoring points external to the pipe portion. A cable extends between each winch and a connection point (at which the internal cooling system or the exterior of the pipe section) to facilitate placement of the internal cooling system within the pipe section and/or removal of the internal cooling system from the pipe section during the process.
It should be noted that the procedures described above with respect to the internal cooling system may be performed for any type of joint welding application between pipeline sections in a pipeline system. For example, internal cooling systems may be used to create pipelines for offshore, subsea applications, and mainline applications. In one embodiment, the internal cooling system 2010 may be used in a spool base joint welding sequence (as shown in FIG. 6 and described with reference to FIG. 6) and a barge welding sequence (as shown in FIG. 7 and described with reference to FIG. 7).
In mainline applications, 40 foot (12 meter) to 80 foot (24 meter) sections of pipe are welded together to form long "joint" sections. In situations where an umbilical cable may be required for controlling movement of the internal cooling system and/or other processes, the length of the umbilical cable may be at least 240 feet (72 meters). The process of loading the internal cooling system within the pipe section and moving the internal cooling system into position for cooling after the welding process (with optional AUT/X-ray weld inspection and coating/insulation/FJC application) occurs similarly to that previously described with respect to fig. 104-107.
Fig. 108 illustrates an internal cooling system 2010-1 according to another embodiment of the present patent application. The internal cooling system 2010-1 is similar to the previously described embodiments, except for the differences noted below. In one embodiment, the interior cooling system 2010-1 is configured to connect with the interior joint clamp 2060 at the end portion 2024 of the third frame portion 2018 of the interior cooling system 2010-1. In one embodiment, the internal fitting clamp 2060 includes a frame 2062 having a suitable configuration that allows the fitting clamp 2060 to be inserted into a conduit portion (e.g., conduit portions 1022a and 1022b), and includes a portion 2064 configured to align and hold the two open and contra-port ends of the conduit portions 1022a, 1022b at the fitting welding location (e.g., by expanding to form a frictional engagement with the inner wall surface portions of the conduit portions at the contra-port ends of the conduit portions when the fitting clamp 2060 is properly positioned within the conduit portions 1022a and 1022 b). In one embodiment, the portion 2064 and the clamp 60 correspond to portions of the internal welding system 5004 having a first tube clamp 5142 and a second tube clamp 5144. In one embodiment, the connection members 2080 (e.g., rod or spring members) are configured to connect the ends 2066 of the joint clamps 2060 with the end portions 2024 of the frame of the internal cooling system 2010-1.
In one embodiment, internal cooling system 2010-1 may be a trailer component for joint clamp 2060. For example, the fitting clamp 2060 to which the internal cooling system 2010-1 is connected (by the connecting member 2080) may be inserted into the pipe section at its end 2065 (i.e., the end of the frame opposite the end of the frame 2066 that is connected to the internal cooling system 2010-1 by the connecting member 2080), wherein movement of the fitting clamp 2060 within the pipe section also results in corresponding movement of the internal cooling system 2010-1 within the pipe section. In one embodiment, the internal cooling system 2010-1 may be inserted into the pipe sections through its first frame portion 2011 and then moved into position to also properly align the joint clamp 2060 with the joint weld location between the two aligned pipe sections. In one embodiment, the drive system 2022 of the internal cooling system 2010-1 may be used to move the joint clamp 2060/internal cooling system 2010-1 combination structure to a suitable location within the pipe portion, or alternatively, this structure may also be moved within the pipe portion using any other suitable drive mechanism (e.g., one or more cable/winch systems).
In one embodiment, the fitting clamp 2060 holds the ends of the conduit portions 1022a, 1022b together until the weld joint 1026 is formed. In one embodiment, the portion 2064 and the clamp 60 correspond to the portion of the internal welding system 5004 having the first tube clamp 5142 and the second tube clamp 5144. After the weld joint 1026 is formed (and the coating formed as desired), the fitting clamp 2060 may be disengaged from the interior wall surface portions of the duct sections to facilitate movement of the internal cooling system 2010-1 to a suitable position (e.g., such that the cooling portion 2016 is aligned with the weld joint) to initiate internal cooling within the duct sections 1022a, 1022 b.
Fig. 109 discloses another embodiment for connecting an internal cooling system to an internal joint clamp, wherein a longer connecting member 2082 (e.g., an elongated rod) is provided to connect the internal cooling system 2010-1 with the joint clamp 2060. In one embodiment, the connecting member 2082 has a longer length dimension than the connecting member 2080 (shown in fig. 108), which minimizes heating of the internal cooling system 2010-1 during the welding process (due to the greater separation distance between the internal cooling system and the joint clamp).
In one embodiment, the process includes loading and aligning the fitting clamp 2060 and the internal cooling system 2010-1 into one of the pipe sections such that the fitting clamp 2060 holds the two butt ends of the pipe sections in place at the fitting weld location. After certain welding procedures (e.g., root pass welding procedures and hot pass welding procedures) are performed, the joint clamp 2060 and the internal cooling system 2010-1 may be moved together and away from the joint welding location to avoid exposure to additional heat from the ongoing welding process required to complete the weld joint. In one embodiment, if the connecting member is of sufficient length (e.g., connecting member 2082 of fig. 109), the joint clamp 2060 and internal cooling system 2010-1 may be moved such that the joint clamp is on one side of the joint weld location while the internal cooling system is on the other side (only connecting member 2082 is disposed directly below or adjacent to the joint weld location). After completion of the welding and AUT/X-ray inspection (if needed), and further after application of any coating/insulation/FJC, the connector clamp 2060 and internal cooling system 2010-1 may be moved into position so that the cooling portion 2016 of the internal cooling system is adjacent the weld joint and a cooling procedure may be performed (e.g., in a similar manner as previously described with respect to the embodiment of fig. 104-107).
In one embodiment, the cooling portion of the internal cooling system may be implemented using any type of cooling structure that rapidly and/or efficiently cools the portion of the conduit at the newly formed weld joint, and is therefore not limited to the exemplary embodiment shown in fig. 104-109. For example, in one embodiment, cooling structures integrated as part of the internal cooling system may include, but are not limited to, cooling fans that push air through the interior surface portions of the conduit portions and/or through heat exchange fins or other cooling elements of the internal cooling system cooling portions (e.g., fan 2122 shown and described below), draining liquid and/or gaseous fluids (e.g., cryogenic fluids, liquids, air) from nozzles 2007 or 2318 of the cooling portions 2016 or 2316 toward the interior surface portions of the conduit portions at suitable pressures and temperatures, utilizing cooling fluids in a closed loop recirculation loop (e.g., pump 2212, manifold 220, and fin member 2218 as shown in fig. 111A and 111 b) and through the heat exchange structures of the cooling portions, utilizing thermoelectric cooling (e.g., through Peltier devices (Peltier devices) in direct contact with the interior wall surface portions of the conduit portions), and the like.
Fig. 110A and 110B illustrate an internal cooling system 2110 according to another embodiment of the present patent application. The internal cooling system 2110 is similar to the previously described embodiments, except for the differences noted below. In one embodiment, the cooling portion 2116 of the internal cooling system 2110 includes a heat sink (including a plurality of fin members 2118 disposed about a periphery of a central support member 2120 of the cooling portion 2116 and extending radially outward from the central support member 2120) and includes a curved outer surface portion corresponding to a curved inner surface portion toward which the fins 2118 of the conduit portion extend. In one embodiment, each fin member 2118 includes a plurality of thin material portions extending radially outward from a central heat sink location of the cooling portion 2116 toward the curved end wall portions of the fin member 2118. In one embodiment, the fin members 2118 are constructed of a material (e.g., copper, aluminum, etc.) having a suitable thermal conductivity to promote a high rate of heat transfer from the inner wall surface portions of the conduit portions 1022a, 1022b to the heat sink of the cooling portion 2116. In one embodiment, the fin member 2118 includes open channels 2120 defined between adjacent thin material portions, wherein the open channels 2120 extend lengthwise through the fin member. In one embodiment, the electric fan 2122 may be mounted to the central support member 2123 and positioned adjacent to an end of the fin member 2118 and in alignment with the fin channel 2120. In one embodiment, the electric fan 2122 provides a flow of air through the fin passages 2120 to cool the fin members 2118, and thus push heat through convective air flow from the heat sink of the cooling portion 2116. In one embodiment, the fan 2122 is in communication with the controller 2020 (e.g., via a hardwired or wireless communication link) to facilitate selective operation of the fan 2122 during a cooling procedure. In one embodiment, each fan 2122 may be implemented at a variable operating speed to selectively control the fan speed and corresponding air flow rate through the fin members 2118 differently and as needed during the cooling process.
The process of the internal cooling system 2110 of fig. 110A and 110B is similar to that previously described for the embodiment of fig. 104-107, with respect to the positioning of the internal cooling system 2110 for cooling after placement during the welding process and completion of the welding process. During cooling, the fan 2122 may be activated to provide a flow of cooling air at one or more desired flow rates through the channels 2120 of the fin members 2118. In one embodiment, the fin members 2118 draw heat from the inner wall surface portions of the conduit portions 1022a, 1022b (including at the weld joint 1026) toward the central support member 2123 of the cooling portion 2116 and push the air flow provided by the fan 2122, removing heat from the fin members 2118, thereby effecting cooling of the conduit portions 1022a, 1022b at the location of the cooling portion 2116. As described in previous embodiments, the temperature sensors of the interior cooling system may provide measured temperature information to the controller 2020, and such measured temperature information may be used to control the operation of the fans 2122 (including changing the fan speed of one or more fans 2122) during the cooling procedure. When the desired temperature is reached within the conduit portions 1022a, 1022b, the fan 2122 may be turned off by the controller 2020. In one embodiment, the internal cooling system 2110 can also be moved to different locations within the conduit portions 1022a, 1022b as needed to achieve cooling at the different locations.
Fig. 111A and 111B illustrate an internal cooling system 2210 according to another embodiment of the present patent application. The internal cooling system 2210 is similar to the previously described embodiments, except for the differences noted below. In one embodiment, the internal cooling system 2210 includes a cooling portion 2216, the cooling portion 2216 including a series of fin members 2218 arranged along the circumference of a central support member 2223 of the cooling portion 2216 and extending radially outward from the central support member 2223, wherein the fin members 2218 have an external shape or profile similar to the fin members 2118 of the embodiment of fig. 110A and 110B. In one embodiment, fin member 2218 can also be constructed from a material having a suitable thermal conductivity (e.g., aluminum or copper). However, each fin member 2218 may have a hollow and sealed interior to facilitate the flow of coolant fluid through fin member 2218. In one embodiment, each fin member 2218 includes an inlet on one end and an outlet on the other end, and suitable piping structures are provided to facilitate a recirculating flow loop of coolant from the pump 2212 to the fin members 2218, where the coolant flows through the fin members 2218 and back to the pump 2212. Any suitable type of coolant may be utilized (e.g., water, cryogenic fluids such as liquid nitrogen or liquid argon, etc.).
In one embodiment, the pump 2212 (shown in fig. 111A) may be positioned outside of the conduit portions 1022a, 1022B with the supply and return flow conduits 2214 extending between the pump 2212 and the manifold structure 2220 (shown in fig. 111B). In one embodiment, manifold structure 2220 includes a plurality of tube connections that connect with the inlets and outlets of fin members 2218. Thus, the cooling portion 2216 promotes heat exchange between the circulating flow of the coolant within the fin member 2218 and the inner wall surface portions of the conduit portions 1022a, 1022b (e.g., at or near the weld joint 1026) during the cooling process.
In one embodiment, the pump 2212 may be controlled (via a suitable hardwired or wireless communication link) by a controller of the internal cooling system 2210. Alternatively, the pump 2212 may be externally controlled (as it is readily accessible to the user). Coolant flow through the pump 2212 may be controlled based on measured temperature information provided by one or more temperature sensors at the internal cooling system 2210. Once the desired temperature is achieved within the conduit portions 1022a, 1022b, the pumps may be deactivated or turned off to stop the recirculating flow of coolant and facilitate movement of the internal cooling system 2210 within the conduit portions 1022a, 1022 b.
Fig. 112A and 112B illustrate an internal cooling system 2310 according to another embodiment of the present patent application. The internal cooling system 2310 is similar to the previously described embodiments, except for the differences noted below. In one embodiment, the internal cooling system 2310 includes a cooling section 2316 having a plurality of spray nozzles 2318 positioned about a central support member 2323 of the cooling section 2316. In one embodiment, spray nozzles 2318 are positioned in a substantially linear row extending lengthwise along central support member 2323. Suitable conduit structures are provided at each end of each linear row of spray nozzles 2318, where the conduit structures are connected to the manifold 2320. The manifold 2320 is connected by a fluid conduit 2314 to a coolant pump 2312 provided outside or outboard of the piping sections. In one embodiment, operation of coolant pump 2312 provides a flow of coolant (e.g., water, a cryogenic fluid such as liquid nitrogen or liquid argon, etc.) from a coolant source through manifold 2320 and out spray nozzles 2318 and toward interior surface portions of conduit portions 1022a, 1022b, including at weld joint 1026. While the embodiment of fig. 112A and 112B shows the pump 2312 located outside of the conduit portions 1022A, 1022B, it should be noted that the cooling portion 2316 aligned with the spray nozzles 318 could also be readily implemented for the embodiment of fig. 104 a and 107 (i.e., where the manifold 2320 and spray nozzles 2318 receive coolant from the coolant source 2012). The cooling sequence of the internal cooling system 2310 may be performed in a similar manner as described for the previous embodiments, wherein the pump 2312 may be controlled by a controller of the internal cooling system 2310 and/or externally, and wherein the coolant flow may be achieved based on measured temperature information provided by a temperature sensor disposed on the internal cooling system 2310.
Accordingly, the internal cooling system of the present patent application is configured to provide improvements to the pipeline welding process, including enhancing the cooling of the joined pipe sections after the weld joint is formed and reducing production time (since cooling can occur faster and more efficiently, increasing the number of weld joints between pipe sections that can occur in a given period of time) by providing controlled cooling internally within the pipe sections. In addition, the number of work stations associated with a welding procedure may be reduced, and the number of resources associated with such welding procedures may also be reduced. For example, the workspace required to weld the pipe sections together may be reduced, and this may become particularly beneficial in situations where the workspace is limited (e.g., on a barge or other water craft).
In one embodiment, a method is provided for welding a pair of insulated conduits (e.g., conduits 1022a, 1022b as shown in fig. 113) to one another. As shown in fig. 113, each conduit 1022a, 1022b includes a metal conduit interior 5244 surrounded by an insulator material 5246. In one embodiment, the end portions 5248, 5250 of the conduits 1022a, 1022b to be welded leave the metal conduit interior 5244 exposed.
In one embodiment, referring to fig. 113-134, the method comprises: aligning the exposed metal pipe ends 5248, 5250 to be welded; welding the exposed metal pipe ends 5248, 5250 to each other; heat welding the exposed end portions 5248, 5250 of the conduits 1022a, 1022 b; applying an insulator 5246 to the heated exposed end portions 5248, 5250 of the welded conduits such that the insulator 5246A (as shown in fig. 118) adheres to the exterior surface 5254 of the metal conduit interior 5244, thereby insulating the previously exposed end portions 5248, 5250 of the conduits 1022a, 1022 b; and applying cooling energy from within the conduits 1022a, 1022b to the inner faces 5130a, 5130b of the metal conduits 1022a, 1022 b.
In one embodiment, applying cooling energy to the interior surface of the metal pipe from within the pipe is performed after applying the insulator. In one embodiment, the method further comprises performing a pipeline deployment procedure. In one embodiment, applying cooling energy reduces the latency between applying the insulator and performing the pipeline deployment procedure. In one embodiment, the pipeline deployment process is a spooling process. In one embodiment, the pipeline deployment procedure is an S-lay procedure.
In one embodiment, the pipeline development process is a pipeline lowering process. In one embodiment, the pipeline deployment procedure is described with reference to fig. 1B of the present patent application.
In one embodiment, a support 5330 (as shown in fig. 10A and 10B) or supports 6010A and 6010B (as shown in fig. 73) is used to carry and move conduits 1022a and 1022B, and to provide an exposed metal conduit end 5248 leading into conduit 1022a at an exposed metal conduit end 5250 of conduit 1022B. That is, the bracket 5330 or 6010A/6010B is used to align the exposed metal conduit ends 5248, 5250 to be welded.
In one embodiment, alignment of the exposed metal pipe ends 5248, 5250 to be welded may be performed automatically by one or more processors 5140 controlling the support 5330 (or 6010A or 6010B), may be performed by hydraulically controlling the support 5330 (or 6010A or 6010B), or may be performed by an operator using a crane and clamp (internal or external) arrangement. In one embodiment, after alignment of the conduits 1022a, 1022B, the conduits 1022a, 1022B can be clamped using the outer clamp 5302 (shown in fig. 7A and 7B) and/or the inner clamp 5142 or 5144. In one embodiment, one or more external or internal clamps may be used during alignment of the exposed metal pipe ends 5248, 5250 (to be welded) as described herein. That is, one or more external or internal clamps may be used independently and/or in combination with the stent. In one embodiment, the operation of one or more external or internal clamps and stents may be controlled by one or more processors 5140.
In one embodiment, the one or more processors 5140 are configured to operate the carriages 5330 (or 6010A and 6010B) based on the pre-weld profile data to adjust the relative positioning of the conduits 1022a, 1022B. In one embodiment, the pre-weld profile data may be obtained from one or more inspection detectors operatively connected to the one or more processors 5140. In one embodiment, the adjustment of the relative positioning of the conduits 1022a, 1022b (based on the pre-weld profile data) may include an adjustment along a longitudinal axis of the conduits 1022a, 1022b and/or an adjustment along a radial axis of the conduits 1022a, 1022 b. In one embodiment, after adjusting the conduits 1022a, 1022b, the conduits 1022a, 1022b are again clamped using external and/or internal clamps. Fig. 113 shows the exposed metal conduit ends 5248, 5250 properly aligned and ready for the conduits 1022a, 1022b for the welding process.
Fig. 114 shows the conduits 1022a, 1022b with the weld joints 1026 formed between the exposed metal conduit ends 5248, 5250. In one embodiment, the welding torch 5502 positioned internally (e.g., inside the conduits 1022a, 1022 b) may be configured to weld the exposed metal conduit ends 5248, 5250 to one another. In one embodiment, an externally positioned (e.g., outside/exterior to the conduits 1022a, 1022 b) welding torch 7502 may be configured to weld the exposed metal conduit ends 5248, 5250 to one another. In one embodiment, a combination of an internally positioned welding torch 5502 and an externally positioned welding torch 7502 may be used to weld the exposed metal pipe ends 5248, 5250 to each other. In one embodiment, the externally positioned welding torch 7502 and/or the internally positioned welding torch 5502 are operatively connected to one or more processors 5140.
In one embodiment, referring to fig. 115A and 115B, the heater 5304 can be configured to heat the exposed end portions 5248, 5250 of the welding conduits 1022a, 1022B. In one embodiment, the heater 5304 may be an induction heating system for heating the exposed end portions 5248, 5250 of the welded conduits 1022a, 1022b of the bobbin 1024 in preparation for application of a coating material or an insulator. In one embodiment, the heater 5304 may include Ultra High Frequency (UHF) induction coils configured to rapidly heat the exposed end portions 5248, 5250 of the welded conduits 1022a, 1022b of the pipeline 1024 to a desired coating temperature. In one embodiment, the heater 5304 may use two induction coils. In one embodiment, the heater 5304 can be an electrical heating system. In one embodiment, the heater 5304 can be a radiant heating system. In one embodiment, the induction coil 5307 of the heater 5304 is shown in fig. 115A.
As shown in fig. 115A and 115B, the heater 5304 is configured to circumferentially surround the exposed end portions 5248, 5250 of the welded conduits 1022a, 1022B of the pipeline 1024. In one embodiment, the heater 5304 can include two half circular, ring-shaped heater members 5304a and 5304 b. In one embodiment, the two half circular, ring-shaped heater members 5304a and 5304b are pivotally connected to each other by a joint 5305 at the top and releasably connected to each other by one or more connector members (not shown) at the bottom.
In one embodiment, the heater 5304 is further configured to adjust the temperature of the exposed end portions 5248, 5250 of the welded conduits 1022a, 1022b of the tubing 1024 to maintain a suitable coating application temperature. In one embodiment, the heater 5304 may further include: a heater feedback system configured to enable the heater 5304 to achieve and maintain a desired coating temperature; and a temperature sensor operatively coupled to the heater feedback system. In one embodiment, the temperature sensor may be a contact or non-contact temperature sensor. In one embodiment, the heater feedback system may include other sensors configured to sense other parameters of the heating process, such as heating time, etc. In one embodiment, the heater feedback system is configured to adjust the current in the inductor coil to achieve a desired coating temperature via a feedback signal from one or more sensors. In one embodiment, heater 5304 and its feedback system are operatively connected to one or more processors 5140. In one embodiment, one or more processors 5140 can be configured to control the operation of heater 5304 and its feedback system.
In one embodiment, referring to fig. 116A, 116B, 117A, and 117B, the insulator supply 5306 is configured to apply an insulator material 5312 to the heated exposed end portions 5248, 5250 of the weld conduits 1022a, 1022B such that the insulator 5246A (as shown in fig. 118) adheres to the exterior surface 5254 of the metal conduit interior 5244, thereby insulating the previously exposed end portions 5248, 5250 of the weld conduits 1022a, 1022B. In one embodiment, the insulator supply 5306 includes: a container 5310 configured to contain an insulator material 5312; and an output nozzle 5308 configured to spray insulator material 5312 onto the exposed end portions 5248, 5250 of the solder conduits 1022a, 1022 b. In one embodiment, a vessel 5310 configured to contain insulator material 5312 may be pressurized.
In one embodiment, the insulator supply 5306 can include: a feedback system configured to enable the insulator supply 5306 to achieve a desired coating on the tube 1024; and one or more sensors operatively connected to the feedback system. In one embodiment, the one or more sensors may be configured to sense the following parameters of the insulator application process — insulator material temperature, insulator material volume, and the like.
In one embodiment, referring to fig. 116A and 116B, the insulator supply 5306 is an automated system and includes a coating frame 5393, the coating frame 5393 configured to be positioned over the weld joint 1026 area. In one embodiment, the coating frame 5393 of the insulator supply 5306 is configured to be preprogrammed to rotate about the solder joint 1026 region in order to achieve a desired dry film thickness of the insulator material. That is, the coating frame 5393 is constructed and arranged to move uniformly around the region of the weld joint 1026. In one embodiment, the spray head (including the receptacle 5310 and the output nozzle 5308) is mounted in a particular position on the coating frame 5393 (e.g., perpendicular to the heated exposed end portions 5248, 5250 of the weld conduits 1022a, 1022 b).
In one embodiment, the insulator supply 5306 shown in fig. 116A and 116B is configured to apply a frit epoxy insulator material to the heated exposed end portions 5248, 5250 of the solder conduits 1022a, 1022B such that the frit epoxy insulator 5246A (shown in fig. 118) adheres to the exterior surface 5254 of the metal conduit interior 5244, thereby insulating the previously exposed end portions 5248, 5250 of the solder conduits 1022a, 1022B.
In one embodiment, the insulator supply 5306 shown in fig. 117A and 117B is configured to apply an injection molded polypropylene insulator material to the heated exposed end portions 5248, 5250 of the welded conduits 1022a, 1022B such that the injection molded polypropylene insulator 5246 is bonded to the exterior surface 5254 of the metal conduit interior 5244. In one embodiment, the insulator supply 5306 of fig. 117A and 117B can be used to apply an injection molded polyurethane insulator material to the heated exposed end portions 5248, 5250 of the welded conduits 1022a, 1022B such that the injection molded polyurethane insulator 5246 is bonded to the exterior surface 5254 of the metal conduit interior 5244.
Referring to fig. 117A and 117B, in one embodiment, the insulator supply 5306 is an automated system and includes a mold 5381 configured to circumferentially surround the weld joint 1026 region and create an annular gap 5383 filled with injection molded insulator material 5246. In one embodiment, a hydraulically operated valve (not shown) is configured to supply/inject molten insulator material 5385 into annular gap 5383. The supplied/injected molten insulator material 5385 enters the mold 5381 (and annular gap 5383), thereby encasing the weld joint 1026 region and forming the inner/inside profile of the mold 5381. In one embodiment, cold water can be supplied to the mold to cool the outer profile of the insulator material such that the injection molded polyurethane insulator 5246 adheres to the outer surface 5254 of the metal conduit interior 5244, thereby insulating the previously exposed end portions 5248, 5250 of the weld conduits 1022a, 1022 b.
In one embodiment, the insulator supply 5306 shown and described above with reference to fig. 116A and 116B can be used for an onshore pipeline application. In one embodiment, the insulator supply 5306 shown and described above with reference to fig. 117A and/or 117B can be used for offshore pipeline applications.
In one embodiment, the insulator supply 5306 described and illustrated above with reference to fig. 116A, 116B, 117A, and/or 117B may also be used to apply other insulator materials described elsewhere in this application and/or other insulating materials as understood by those skilled in the art to the heated exposed end portions 5248, 5250 of the welded conduits 1022a, 1022B.
In one embodiment, the insulator supply 5306 and its corresponding feedback system are operatively connected to the one or more processors 5140. In one embodiment, one or more processors 5140 can be configured to control the operation of insulator supply 5306 and its corresponding feedback system.
In one embodiment, fig. 118 shows a pipeline 1024 in which an insulator material is applied to the heated exposed end portions 5248, 5250 of the welded conduits 1022a, 1022b such that the insulator 5246A bonds to the exterior surface 5254 of the metal conduit interior 5244, thereby insulating the previously exposed end portions of the conduits 1022a, 1022 b.
In one embodiment, referring to fig. 119 and 120, the chiller system 6500 is configured to be positioned within the conduits 1022a, 1022 b. In one embodiment, the chiller system 6500 comprises a frame, a plurality of rollers 6530, a drive motor 6532, and a braking system. In one embodiment, the forwardmost frame 6618, the center frame 6634, and the rear frame 6522 of the cooler system 6500 may be collectively referred to as the frame of the cooler system 6500.
For example, the frame is configured to be placed within the welded conduits 1022a, 1022b, the plurality of rollers 6530 are configured to rotatably support the frame, the drive motor 6532 drives the rollers 6530 to move the frame within the conduits 1022a, 1022b, and the braking system fixes the frame at a desired position within the conduits 1022a, 1022b without movement. The structure, configuration, and operation of the plurality of rollers, drive motors, and brake systems of cooler system 6500 are similar to the plurality of rollers, drive motors, and brake systems of the internal welding system described in this application, and therefore they will not be described in detail herein. For example, in one embodiment, the braking system of cooler system 6500 can include one or more clamps that clamp circumferentially spaced locations on the inner faces 5130, 5132 of welded conduits 1022a, 1022 b. In another embodiment, the braking system of the chiller system 6500 may include a wheel lock that prevents rotation of the roller 6530.
In one embodiment, the cooler system 6500 includes a cooler carried by the frame and applying cooling energy to the interior faces 5130a, 5132a of the metal conduits 1022a, 1022b to facilitate cooling of the weld metal conduits 1022a, 1022 b. In one embodiment, the cooler includes a heat exchanger 6502 carrying a cooling fluid therein and having a conduit contacting surface 6572 that contacts the inner surfaces 5130a, 5132a of the conduits 1022a, 1022b to facilitate cooling of the welded conduits 1022a, 1022 b. In one embodiment, the cooler system 6500 includes a heat exchanger motor 6552 configured to move the heat exchanger 6502 radially outward such that the conduit contact surfaces 6572 may be moved outward to engage the interior surfaces 5130a, 5132a of the welded conduits 1022a, 1022b after the frame is positioned at a desired location within the conduits 1022a, 1022 b.
In one embodiment, the chiller system 6500 includes one or more processors operatively connected with the drive motor 6532, the braking system, and the chiller 6502. In one embodiment, the one or more processors are configured to operate the cooler 6502 to reduce the temperature of the welded conduits 1022a, 1022b to a predetermined level. For example, in one embodiment, the chiller system includes one or more temperature sensors 2017a in operative communication (wired or wirelessly) with one or more processors to determine the temperature of the pipe. In one embodiment, cooling energy may continue until a predetermined threshold temperature is detected.
In one embodiment, the one or more processors are communicatively connected to the brake system, the drive motor 6532, or the cooler 6502 via one or more wired or wireless connections. The wireless connection may include, for example, a Wi-Fi connection, a bluetooth connection, an NFC connection, a cellular connection, or other wireless connection.
In one embodiment, the one or more processors that receive the pipe temperature information from the temperature sensor 2017a are communicatively connected to a remote computer system and configured to transmit pipe cooling data to the remote computer system. In one embodiment, the cooling data transmitted by the one or more processors includes cooling time profile information. In one embodiment, the cooling time profile information includes changes in the temperature of the pipe over time. In one embodiment, the remote computer system contains cooling data from other welding systems and calculates the expected time until the temperature of the welded pipe is below a threshold. In one embodiment, the expected time is sent to one or more processors.
In one embodiment, the chiller system 6500 may comprise a user interface, and wherein the expected time and/or the temperature of the conduit is sent to the user interface by the one or more processors. The user interface may be, for example, a computer with a display.
In one embodiment, the expected time for the pipe (at least a portion of the pipe in question) to cool to a certain threshold temperature is calculated based at least in part on the size (e.g., circumference, thickness, thermal mass, or any combination thereof) of the welded pipe. In another embodiment, the calculation is further based on the cooling energy output of the cooler. For example, this cooling energy output may be based on the volume of water or gas directed at the surface of the pipe, the starting temperature of the pipe or gas, and so forth. As another example, the cooling energy of a closed fluid system heat exchanger may be known in advance, or calculated based on its operating parameters (fluid velocity, fluid temperature, heat transfer efficiency, etc.).
In another embodiment, the cooling energy output and/or the expected cooling time of the cooling system is based on information received from a remote cloud-based computer system containing a large central database of information obtained from several remotely operated chiller systems. In one embodiment, the cooling energy output is predetermined. In one embodiment, the one or more processors are communicatively connected to a remote computer system and configured to transmit coolant consumption data (e.g., the amount of water required to cool a pipe of known size to reach a threshold temperature).
In one embodiment, the chiller system 6500 may be fully untethered. In particular, the cooler system 6500 need not include a tie rod or umbilical, and all communication to and from the cooler system 6500 is completely wireless. In one embodiment, the chiller system 6500 may comprise: a transmitter configured to transmit all communication signals from chiller system 6500 to a remote uLog processing system completely wirelessly; and a receiver configured to receive all communication signals completely wirelessly from a remote uLog processing system. In one embodiment, one or more processors and/or all electronic modules of the chiller system 6500 are configured to communicate entirely wirelessly with a remote uLog processing system. In one embodiment, all sensors, all motors, all valves, and/or other components/elements of the chiller system 6500 are configured to communicate with a remote uLog processing system entirely wirelessly.
In one embodiment, any information from the chiller system 6500 may communicate wirelessly with the system outside the pipe via WiFi, bluetooth, NFC, via radio frequency, or via cellular tower transmission (for example only). In some embodiments, information is transmitted using repeaters or extenders where appropriate, with the transmission signal traveling long distances or traveling through curved areas.
In one embodiment, the one or more processors and one or more sensors of the chiller system 6500 are configured to monitor the charge levels of the on-board cooling power supply, the on-board motive power supply, and the other on-board power supply. For example, the voltage output by these power supplies may be monitored (continuously or at regular intervals). In one implementation, the transmitter of the chiller system 6500 transmits the monitored battery life/charge level information completely wirelessly to a remote uLog processing system for further processing. For example, the monitored charge level information of the on-board power supply may be used to determine an estimated remaining operating time of the chiller system 6500. In one embodiment, the one or more processors of the chiller system 6500 may be configured to determine the estimated remaining operating time of the chiller system 6500 locally on the chiller system 6500. In one embodiment, the remote uLog processing system may be configured to determine an estimated remaining operating time of the chiller system 6500 based on wirelessly transmitted battery life/charge level information. In one embodiment, the remote uLog processing system may be configured to transmit the estimated remaining operating time of the chiller system 6500 to one or more processors of the chiller system 6500. In one embodiment, the remote uLog processing system may also be configured to transmit (transmit completely wirelessly to the chiller system 6500) additional instructions regarding the operation of the chiller system 6500 based on the estimated remaining operating time of the chiller system 6500.
In one embodiment, the one or more processors and one or more sensors of the chiller system 6500 are configured to monitor the level of the on-board coolant supply/tank. For example, the pressure and/or volume of the coolant supply tank may be monitored (continuously or at regular intervals). In one implementation, the transmitter of the chiller system 6500 transmits the monitored coolant consumption data completely wirelessly to a remote uLog processing system for further processing.
For example, the monitored coolant consumption data may be used to determine an estimated remaining operating time of the chiller system 6500 prior to coolant refill/recharging. In one embodiment, the one or more processors of the chiller system 6500 may be configured to determine the estimated remaining operating time of the chiller system 6500 locally on the chiller system 6500 (e.g., prior to a coolant recharge). In one embodiment, the remote uLog processing system may be configured to determine an estimated remaining operating time of the chiller system 6500 (e.g., before the next coolant refill) based on wirelessly transmitted coolant consumption data. In one embodiment, the remote uLog processing system may be configured to transmit the estimated remaining operating time of the chiller system 6500 (e.g., prior to coolant refilling) to one or more processors of the chiller system 6500. In one implementation, the remote uLog processing system may also be configured to transmit (completely wirelessly transmit to the cooler system 6500) additional instructions regarding the operation of the cooler system 6500 based on an estimated operating time of the cooler system 6500 (e.g., prior to coolant refilling).
In one embodiment, a remote uLog processing system receives battery charging data from multiple chiller systems at different locations (e.g., across countries or across the earth) and builds a database thereon. This database is used by the uLog processing system to determine expected battery life times based on different operating parameters of the chiller system based on the large data set. This may be used by the uLog and/or by one or more processors of the chiller system 6500 to predict the battery life time of various components based on their current operating states. This information may be used by the one or more processors to reduce or adjust power consumption of the one or more components by modifying one or more operating parameters. For example, if one or more processors determine that such operating states may be modified without adversely affecting the associated operations being performed, then the overall cooling rate, voltage, and/or current may be adjusted (e.g., reduced) to conserve battery life.
In one embodiment, any of battery life, voltage output, coolant level, and operating parameters are wirelessly transmitted to a user interface (such as a computer monitor with a computer display) so that they may be monitored by a user.
In one embodiment, all other chiller systems described in this application (e.g., 2010, 2110, 2210, 2310) are configured to wirelessly communicate with a remote uLog processing system, as with chiller system 6500.
In one embodiment, referring to fig. 120, the cooler system 6500 is configured to apply cooling energy to the inner surfaces 5130a, 5132a of the metal conduits 1022a, 1022b after application of the insulator material 5312 to facilitate cooling of the metal conduits 1022a, 1022 b. In one embodiment, the chiller system 6500 includes a heat exchanger or chiller 6502 configured to carry a fluid movable therethrough. That is, cooling energy is applied through a movable fluid disposed within the heat exchanger 6502. In one embodiment, the movable fluid may be a gas or a liquid.
For example, in one embodiment, as shown in fig. 119 and 122, the heat exchanger 6502 may have a liquid pathway 6593 therein carrying a liquid movable therethrough, and the cooling energy is applied by the movable liquid disposed within the fluid pathway 6593 of the heat exchanger 6502. In one embodiment, as shown in fig. 124-125, the heat exchanger 6502 may have an air passage 6576 therein carrying air movable therethrough, and cooling energy is applied by movable air disposed within the air passage 6576 of the heat exchanger 6502.
In one embodiment, the contact surface 6572 of the heat exchanger 6502 is configured to be positioned in contact with the inner faces 5130a, 5132a of the welded conduits 1022a, 1022b to remove heat from the welded conduits 1022a, 1022 b.
In one embodiment, the contact surface 6572 of the heat exchanger 6502 may be a conformable, thermally conductive surface. For example, in one embodiment, the contact surface 6572 of the heat exchanger 6502 is configured and shaped to closely conform to the interior surfaces of the welded conduits 1022a, 1022b to remove heat from the welded conduits 1022a, 1022 b. In one embodiment, the contact surface 6572 of the heat exchanger 6502 is constructed and arranged to be thermally conductive.
In one embodiment, the cooling energy is applied by a fluid that is released within the interior of the conduits 1022a, 1022b such that the fluid directly contacts the interior faces 5130a, 5132a of the conduits 1022a, 1022 b. In one embodiment, the fluid comprises a liquid. In one embodiment, the fluid comprises a gas. For example, in one embodiment, the fluid nozzle 6562 (shown in fig. 123) is configured to apply (or spray) a cooling fluid (directly) onto the interior surfaces 5130a, 5132a of the welded conduits 1022a, 1022b to remove heat from the welded conduits 1022a, 1022 b. In one embodiment, a blower 6505 (shown in fig. 133) is configured to apply (or blow) cooling gas (directly) onto the inner faces 5130a, 5132a of the weld conduits 1022a, 1022b to remove heat from the weld conduits 1022a, 1022 b.
In one embodiment, the contact surface 6572 of the heat exchanger 6502 is configured to be positioned in contact with the inner faces 5130a, 5132a of the welded conduits 1022a, 1022b to remove heat from the welded conduits 1022a, 1022 b. For example, as shown in fig. 119, 124, 130, and 132, the contact surface 6572 of each of these different types of heat exchangers 6502 is configured to be positioned in contact with the inner surface 5130a, 5132a of the welded conduits 1022a, 1022b to remove heat from the welded conduits 1022a, 1022 b.
Referring to fig. 119-122, the heat exchanger 6502 of the chiller system 6500 may include a plurality of heat exchanger elements or fins 6580, the plurality of heat exchanger elements or fins 6580 being positioned at circumferentially spaced apart locations on the central frame 6634. In one embodiment, each heat exchanger element 6580 may have one or more coolant lines 6593 passing therethrough. In one embodiment, each heat exchanger element or fin 6580 is supported on a central 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 fig. 120 and 121) and its retracted position (as shown in fig. 122). In one embodiment, as shown in fig. 122, when the heat exchanger element 6580 is in its retracted position, a radial gap G exists between the contact surface 6572 of the heat exchanger element 6580 and the inner surfaces 5130a, 5132a of the conduits 1022a, 1022 b.
In one embodiment, the actuator mechanism 6582 may include a piston 6586, a cylinder 6584, a plurality of first members 6588 and a plurality of second members 6590. In one embodiment, the number of first and second members may depend on the number of heat exchanger elements 6580 being used.
In one embodiment, there may be two actuator mechanisms, one positioned (axially along the conduit axis) on one side of the heat exchanger element 6580 and the other positioned (axially along the conduit axis) on the other side of the heat exchanger element 6580. In one embodiment, both actuator mechanisms may be operated simultaneously to move the heat exchanger element 6580 between its extended and retracted positions. In one embodiment, there may be only one actuator mechanism configured to move each heat exchanger element or fin 6580 between its extended position (as shown in fig. 120 and 121) and its retracted position (as shown in fig. 122).
In one embodiment, each second member 6590 is constructed and arranged to be connected to the heat exchanger element 6580 on one end and to the first member 6588 on the other end. In one embodiment, each first member 6588 is constructed and arranged to be connected to the second member 6590 on one end and to a portion of the piston 6586 (or a member that is movable by the piston 6586) on the other end.
In one embodiment, the second member 6590 is constructed and arranged to be positioned in a radially extending opening 6592 in the (stationary) frame member 6594 such that the radially extending opening 6592 facilitates radial movement (e.g., upward and downward radial movement) of the second member 6590 therein.
In one embodiment, the piston 6586 is configured to be axially movable within the cylinder 6584. In one embodiment, the first member 6588 is moved by an axially reciprocating piston 6586 driven, for example, by fluid (hydraulic or pneumatic) pressure within a cylinder 6584.
By activating the cylinder 6584 such that the piston 6586 moves axially within the cylinder 6584, the heat exchanger element 6580 moves from its retracted position (shown in fig. 122), in which the contact surface 6572 of the heat exchanger element 6580 is not in contact with the inner surfaces 5130a, 5132a of the conduits 1022a, 1022b, to its extended position (shown in fig. 120 and 121), in which the contact surface 6572 of the heat exchanger element 6580 is configured to be in contact with the inner surfaces 5130a, 5132a of the conduits 1022a, 1022 b. Compressed air entering the port 6503 pushes on the piston 6586 to move the heat exchanger element 6580 to its extended position.
In one embodiment, axial movement of the piston 6586 is translated into radial movement of the second member 6590 by the first member 6588. Thus, the radial contact force is generated by the fluid pressure of the compressed air acting on the piston 6586. The piston 6586 drives a first member 6588, which first member 6588 translates axial movement of the piston 6586 into radial movement of the second member 6590. Because each heat exchanger element 6580 is operatively connected to the second member 6590, radial movement of the second member 6590 causes radial movement of the heat exchanger elements 6580 between their extended and retracted positions.
In one embodiment, the size of the air cylinder, the applied fluid pressure, and the size of the various components of the actuator mechanism 6582 may be varied to control the extension and retraction of the heat exchanger element 6580.
In one embodiment, as shown in fig. 123, the cooler system 6500 may include a fluid nozzle 6562 configured to apply a cooling liquid to the interior faces 5130a, 5130b of the welded conduits 1022a, 1022b to remove heat from the welded conduits 1022a, 1022 b. In one embodiment, the fluid nozzles 6562 are water nozzles that blow/spray water onto the inner faces 5130a, 5132a of the conduits 1022a, 1022b to promote cooling of the weld metal conduits 1022a, 1022 b.
In one embodiment, the heat exchanger 6502 may include a plurality of fluid nozzles 6562 positioned at circumferentially and axially (along the conduit axis) spaced locations. In one embodiment, each fluid nozzle 6562 is configured to receive cooling liquid 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 a liquid. In one embodiment, the received coolant is sprayed onto the inner faces 5130a, 5132a of the welded conduits 1022a, 1022b via the fluid nozzles 6562 to remove heat from the welded conduits 1022a, 1022 b.
Fig. 124 and 125 illustrate a heat exchanger element or fin 6574 that is configured to be extendable, for example, using the actuator mechanism 6582 shown and described with reference to fig. 120 and 122. In one embodiment, the contact surfaces 6572 of the heat exchanger elements or fins 6574 are configured to be positioned in contact with the inner surfaces 5130a, 5132a of the welded conduits 1022a, 1022b to remove heat from the welded conduits 1022a, 1022b when the heat exchanger elements or fins 6574 are in the extended position. In one embodiment, the heat exchanger may include a plurality of such heat exchanger elements or fins 6574 positioned at circumferentially spaced locations and extendable and retractable by an actuation mechanism (e.g., pneumatic or otherwise). In one embodiment, the heat exchanger elements or fins 6574 may include a plurality of fluid (air) channels 6576 therein configured to allow fluid to pass therethrough. In one embodiment, the channels 6576 may extend radially and be circumferentially spaced apart.
Referring to fig. 126-128, in one embodiment, the chiller system 6500 may include a drive system 6602. In one embodiment, the drive system 6602 may include a cable structure 6604 that extends from the internal cooler system 6500 and through one or more conduits 1022a, 1022b to an open end 6606 of the conduit 1022 a. In one embodiment, cable structure 6604 is used to facilitate forward movement of intercooler system 6500 within conduits 1022a, 1022 b.
In one embodiment, one or more cable/ winch systems 6608 and 6604 may be implemented, wherein one or more winches 6608 may be provided as part of the internal cooler system 6500 and/or located at one or more anchor points (e.g., 6610) external to the conduits 1022a, 1022 b. In one embodiment, a winch structure may be provided within the internal cooler system 6500 frame.
For example, in one embodiment, a winch structure 6608 is provided at an anchoring location 6610 external to conduits 1022a, 1022b and connected to cable structure 6604. That is, referring to fig. 127 and 128, one end 6612 of the cable structure 6604 is connected to the winch structure 6608, and the other end 6614 of the cable structure 6604 is connected to a member 6616 of the frontmost frame 6618 of the chiller system 6500. This configuration of the cable structure 6604 and the winch structure 6608 facilitates forward movement of the intercooler system 6500 within the conduits 1022a, 1022 b.
In one embodiment, another cable structure may be connected to the member 6620 of the rear frame 6622 (shown in fig. 119) of the chiller system 6500 to facilitate reverse movement of the internal chiller system 6500 within the conduits 1022a, 1022 b. This cable structure may be operated by another winch structure (e.g., provided at an anchoring location behind and outside of the conduits 1022a, 1022 b) to facilitate reverse movement of the intercooler system 6500 within the conduit portions 1022a, 1022 b.
Thus, the cable structure 6604 extends between the winch 6608 and a connection point (at the internal cooler system 6500 or a connection point external to the conduits 1022a, 1022 b) to facilitate placement of the internal cooler system 6500 within the conduits 1022a, 1022b and/or removal of the internal cooler system 6500 from the conduits 1022a, 1022b during the process.
In one embodiment, as shown in fig. 129, the chiller system 6500 may comprise: a plurality of rollers 6530 configured to engage the inner surfaces 5130, 5132 of one or more of the conduits 1022a, 1022 b; and a drive motor 6532 configured to drive the rollers 6530 in order to move the frame assembly 6503 (including the frontmost frame 6618, the center frame 6634, and the drive frame 6622) of the chiller system 6500.
In one embodiment, cooler electronics module 6528 is configured to control operation of drive system 6602 (e.g., by controlling one or more motors 6532 that move rollers 6530 into contact with an inner wall portion of the conduit) to facilitate advancement of internal cooler system 2010 within conduit 1022a and toward the welding location. In one embodiment, the cooler electronics module 6528 of the internal cooler system 6500 is configured to communicate with one or more processors 5140 and one or more other processors or electronics modules as described herein (e.g., operatively connected with a different welding system, operatively connected with a bracket, fixture, or other pipe alignment system, and/or located at a location remote from these systems).
In the illustrated embodiment, each roller 6530 of the cooler system 6500 is operatively connected with its corresponding drive motor 6532. That is, four drive motors 6532 are connected to the 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 that are directly connected to drive motors 6532.
In one embodiment, as shown in fig. 130 and 131, the chiller system 6500 may include a power supply 6526 to provide power to the chiller electronics module 6528, the drive system 6602, the electronic sensors, the valve structures of the chiller system 6500 (e.g., to electrically control one or more valves 6522 and thus control the flow of coolant from the coolant supply 6524 to the heat exchanger 6502). In one embodiment, the power supply 6526 is carried by the frame assembly of the chiller system 6500. In one embodiment, the power supply 6526 includes a plurality of battery cells or battery packs carried by the rear frame 6622 of the cooler system 6500. In one embodiment, seven cells are shown. In one embodiment, the number of batteries may 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 chiller system 6500. In the embodiment shown, the power supply 6526 is shown in a chiller system having a thermoelectric heat exchanger. However, it is contemplated that the power supply 6526 may be used with a chiller system having any type of heat exchanger as described in the present application.
In one embodiment, one or more battery cells carried by the frame of the cooler system 6500 are configured to power the drive motor 6532 and the brake system of the cooler system 6500. In one embodiment, one or more battery cells carried by the frame of the cooler system 6500 are configured to power the cooler 6502 of the cooler system 6500.
In one embodiment, as shown in fig. 130 and 132, the heat exchanger 6502 of the cooler system 6500 may be a thermoelectric heat exchanger 6502. For example, the thermoelectric heat exchanger may be a peltier device.
In one embodiment, the thermoelectric heat exchanger 6502 may have a plurality of frame members 6538, the plurality of frame members 6538 positioned at circumferentially spaced apart locations on the shaft member 6542 of the cooler system 6500. In the embodiment shown, six frame members 6538 are shown. In one embodiment, the number of frame members 6538 may vary. In one embodiment, each frame member 6538 may have a plurality of thermoelectric heat transfer elements 6544 positioned thereon. In the embodiment shown, 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 may vary.
In one embodiment, the frame member 6538 may be supported on the shaft member 6542 of the cooler system 6500 by support members 6540 (e.g., two). In one embodiment, the support member 6540 may be extended and retracted by an actuation mechanism. In one embodiment, the actuation mechanism is configured to extend the support member 6540 such that the frame member 6538 and the thermoelectric element 6544 positioned thereon are positioned in contact with the inner surfaces 5130a, 5132a of the welded conduits to remove heat from the welded conduits 1022a, 1022 b. In one embodiment, the actuation mechanism may be pneumatically controlled, or may be controlled in any other manner as understood by those skilled in the art.
In one embodiment, as shown in fig. 133, the heat exchanger 6502 of the cooler system 6500 may be a blower 6505 configured to blow cooling gas onto the inner faces 5130a, 5132a of the weld conduits 1022a, 1022b to remove heat from the weld conduits 1022a, 1022 b. In one embodiment, the blowers blow air onto the inner faces 5130a, 5132a of the conduits 1022a, 1022b to facilitate cooling of the welded conduits 1022a, 1022 b. In one embodiment, the blower 6505 may include a frame member 6550 having a plurality of apertures 6552 thereon. In one embodiment, the frame member 6550 is constructed and arranged to receive air from an outlet of a compressed air (e.g., high pressure) source 6554. In one embodiment, the frame member 6550 is constructed and arranged to receive air from the outlet of a motor driven fan. In one embodiment, the aperture 6552 formed on the frame member 6550 is configured to act as an outlet for delivering received air to the interior face 5130a, 5132a of the welded conduit to remove heat from the welded conduit 1022a, 1022 b.
In one embodiment, as shown in fig. 134, a camera 6556 mounted at a location CL on the first portion 6558 and controlled by the cooler electronics module 6528 may provide a video image to a remote control device so that a user may determine how close the internal cooler system 6500 is to the weld seam 1026.
In one embodiment, as shown in fig. 135 and 136, cooler system 6500 includes a blower 6650 configured to blow cooling gas onto inner faces 5130a, 5132a of weld conduits 1022a, 1022b to remove heat from weld conduits 1022a, 1022 b. In one embodiment, blower 6505 includes a fan. In one embodiment, the construction, location, and operation of blower 6505 may be similar to fan 2122 described in detail elsewhere in this application.
In one embodiment, referring to fig. 135 and 136, by operating the actuation mechanism 6664, the heat exchanger element 6580 is moved from its retracted position (as shown in fig. 136) in which the contact surface 6572 of the heat exchanger element 6580 is out of contact with the inner surfaces 5130a, 5132a of the conduits 1022a, 1022b, to its extended position in which the contact surface 6572 of the heat exchanger element 6580 is configured to be in contact with the inner surfaces 5130a, 5132a of the conduits 1022a, 1022 b.
In one embodiment, the actuator mechanism 6664 may be a linear actuator. In one embodiment, the actuator mechanism 6664 may include a motor 6652, a lead screw 6654, a lead nut 6656, a plurality of first members 6664, and a plurality of second members 6666. In one embodiment, the number of first and second members may depend on the number of heat exchanger elements 6580 being used. In one embodiment, each second member 6666 is constructed and arranged to be connected to the heat exchanger element 6580 on one end and to the first member 6664 on the other end. In one embodiment, each first member 6664 is constructed and arranged to be connected to a second member 6666 on one end and to a member 6662 movable by a motor 6652 on the other end.
In one embodiment, the motor 6652 is configured (e.g., mechanically coupled) to rotate the lead screw 6654. In one embodiment, motor 6652 is configured to rotate in a clockwise or counterclockwise direction to cause heat transfer element 6580 to raise or lower substantially perpendicular to the conduit axes of conduits 1022a, 1022 b. In one embodiment, the motor 6652 is configured to be directly coupled to rotate the lead screw 6654. In another embodiment, the motor 6652 is configured to be indirectly connected to rotate the lead screw 6654, for example, through a series of gears or a gearbox.
In one embodiment, the lead screw 6654 includes threads machined on its outer surface and extending along its length. In one embodiment, the lead nut 6656 is constructed and arranged to be threaded onto the lead screw 5514 and includes complementary threads machined onto its inner surface.
In one embodiment, the lead nut 6656 is configured to interlock with a portion of the member 6662 such that the lead nut 6656 is prevented from rotating with the lead screw 6654. That is, the lead nut 6656 is constrained to rotate with the lead screw 6654, and thus the lead nut 6656 is configured to travel up and down on the lead screw 6654. In one embodiment, the lead nuts 6656 interlock and are positioned in the openings of the members 6662. In one embodiment, the lead screw 5514 is configured to pass through an opening of the interlock lead nut 5516.
The operation of the actuator mechanism 6664 is discussed in detail below. The lead screw 6656 is driven along the threads as the lead screw 6654 is rotated by the motor 6652. In one embodiment, the direction of movement of the lead screw nut 6656 is dependent on the direction of rotation of the lead screw 6654 caused by the motor 6652. Because the lead nut 6656 interlocks in the opening of the member 6662, the member 6662 is configured to travel with the lead nut 6656 on the lead screw 6654. That is, as the motor 6652 rotates, the member 6662 translates linearly (right to left or left to right). Additionally, because the member 6662 is connected to the first member 6658, movement of the member 6662 causes movement of the first member 6658. Because the second member 6660 is connected to the first member 6658, movement of the first member 6658 causes radial (upward or downward) movement of the second member 6660. That is, linear translation of the member 6662 is translated into radial (up or down) movement of the second member 6660 by the first member 6658.
Because the heat exchanger element 6580 is connected to the second member 6660, radial (up or down) movement of the second member 6660 results in radial (up or down) movement of the heat exchanger element 6580. Thus, the motor 6652 is configured to move the contact surface 6572 of the heat exchanger element 6580 outwardly into engagement with the inner surfaces 5130a, 5132a of the metal conduits 1022a, 1022 b.
In one embodiment, the time taken for the cooler system to cool the tube (e.g., after the coating process and before the winding process) may be in a range between 90 and 150 minutes.
Because the cooler system may be used to apply cooling energy from within the pipe to the interior surface of the metal pipe, the cooling time of the metal pipe may be reduced (e.g., as compared to allowing natural cooling of the metal pipe, or as compared to applying a coolant on top of the insulator material). This may, for example, facilitate cooling of the metal tube after the insulator material is applied to the welded tube, which should be preheated prior to applying the welding material. Thus, the welded pipe may be placed into service or otherwise further processed more quickly. In particular, after the welded pipe is heated to apply the insulator material and the insulator is applied, it should not be subjected to high stresses that may occur during the deployment procedure. For example, in some embodiments, the welded tubing and its insulation (which is applied only after the welded tubing temperature is heated to a temperature of at least 160 ℃) are intended to be wound on a spool in a winding operation. This winding operation is ideally performed only after the welded and insulated metal pipe has cooled below a threshold level (e.g., below 50 ℃). The use of an internal cooler may speed the cooling of the metal pipe below a threshold level. In another application of the internal cooler system, after pipe welding (and before insulator application).
The spooling operation is one of a plurality of deployment procedures that may be desirably performed only after the welded pipe is below a threshold temperature (e.g., by operation of an internal cooler). Other deployment procedures may include an S-lay procedure and/or a J-lay procedure on a pipelaying barge. The welded pipe should be below a threshold temperature before the pipe is submerged in water (e.g., sea or ocean).
Furthermore, in another application, it may be desirable to inspect welds using an ultrasonic detector in an ultrasonic inspection system. The ultrasonic inspection station is configured to operate ideally below a threshold temperature (e.g., below 80 ℃), which can be achieved more quickly (after the pipe has been heated due to the welding operation) by using a chiller system. Thus, in one system, the cooler may be used prior to operation of the ultrasonic inspection system, which is performed after welding and before the pipe is reheated for application of the insulation material.
In one embodiment, referring to fig. 136A, an ultrasonic inspection station 6801 is provided, the ultrasonic inspection station 6801 configured to inspect welds between welded metal conduits 1022a, 1022 b. In one embodiment, the cooler system 6500 is configured to facilitate cooling of the metallic conduits 1022a, 1022b after the conduits 1022a, 1022b are welded and before the welds are inspected by the ultrasonic inspection station 6801.
In one embodiment, a temperature sensor (e.g., 2017a as shown in fig. 104-109) may be used to determine the temperature of the conduits 1022a, 1022b near the weld 1026. For example, referring to fig. 107, the temperature sensor 2017a is configured to be positioned on the internal cooler system and near the weld 1026. In one embodiment, the temperature sensors 2017a may be positioned near heat transfer elements or fins of the internal cooler system to measure the temperature of the (inner diameter) inner surfaces 5130, 5132 of the conduits 1022a, 1022 b. In another embodiment, the temperature sensor may be positioned at the ultrasonic inspection station 6801. In one embodiment, the temperature sensor may be a contact or non-contact temperature sensor.
In one embodiment, temperature sensors 2017a, which sense the temperature of conduits 1022a, 1022b, may be in operative communication with one or more processors. In one embodiment, the one or more processors send operating instructions to the cooler 6502 based on signals received from the temperature sensor 2017 a. In one embodiment, the one or more processors operate the chiller until the sensor 2017a and the processor determine that the temperature of the conduits 1022a, 1022b is below a threshold temperature.
In one embodiment, the one or more processors may be configured to determine that the temperature of the conduits 1022a, 1022b near the weld 1026 is below a predetermined temperature threshold. In one embodiment, the temperature sensor may be configured to detect that the temperature of the conduits 1022a, 1022b near the weld 1026 is below a predetermined temperature threshold.
In one embodiment, the inspection by the ultrasonic inspection station 6801 is performed after the temperature sensor 2017a detects that the temperature of the conduits 1022a, 1022b near the weld 1026 is below a predetermined temperature threshold.
FIG. 136B illustrates a method for pipeline deployment. Fig. 136C and 136D show schematic views of an S-lay pipeline deployment system and a J-lay pipeline deployment system. Fig. 136E shows an S-lay and J-lay unwind barge.
In one embodiment, conduits 1022a, 1022b (e.g., about 40 feet or 80 feet long) are manufactured during the conduit manufacturing process 6902. In one embodiment, the produced pipeline is stored at pipeline storage 6904 before the pipeline for further processing is sent to, for example, an S-lay barge 6942 (as shown in fig. 136C), a reel base, or a J-lay barge 6944 (as shown in fig. 136D). In one embodiment, the pipe storage device may include a plurality of storage racks.
In one embodiment, at the spar base process 6914, the manufactured pipe portions are received by the spar base, the pipe portions are joined at the spar base to form long pipe portions, and the long pipe portions are then coiled and loaded onto a vessel, ship or barge. In one embodiment, the spool base may include a semi-automated or automated welding system, an in-situ seam coating system, a non-invasive inspection and testing system, storage racks, roller systems, and/or other pipe handling equipment for the manufacture, winding, and loading of rigid pipe prior to installation.
In one embodiment, the pipe stick is wound onto a large spool on the barge (as shown in fig. 136E) and unwound as the barge reaches the operating position. In one embodiment, the coiled pipeline rod is unwound at process 6916 on a vessel, ship, or barge and the pipeline section is then deployed at process 6918. In one embodiment, the "unwind" vessel, ship, or barge may be a J-lay barge or an S-lay barge. Fig. 136E shows an S-lay and J-lay unwind barge.
In one embodiment, an S-lay barge 6942 receives stored pipeline sections from a pipeline storage device. In one embodiment, at process 6906, S-lay barge 6942 uses its onboard system to create long pipe sections. In one embodiment, at process 6906, long pipeline sections are produced on S-lay barge 6942 using automated welding systems, pipeline port-to-port systems, support clamps, purge clamps, and/or other support equipment. In one embodiment, the S-lay pipe deployment procedure is used for offshore pipeline applications. In one embodiment, the S-lay pipe deployment procedure is used in shallow and intermediate waters. In one embodiment, the S-lay pipe deployment procedure allows the pipeline to exit the vessel in a horizontal position. In one embodiment, the S-lay pipe deployment procedure provides high production rates. As shown in fig. 136C, an S-lay barge 6942 is constructed and arranged to deploy pipeline sections in an S-shaped pipeline configuration.
In one embodiment, a J-lay barge 6944 receives stored pipeline sections from a pipeline storage facility. In one embodiment, at process 6908, a J-lay barge 6944 uses its onboard system to create long pipe sections. In one embodiment, at process 6908, a long pipe section is produced on a J-lay barge 6944 using an automated welding system, a pipe docking system, a J-lay clamp, and/or other support equipment. In one embodiment, the J-lay pipe deployment procedure is used for offshore pipeline applications. In one embodiment, the J-lay pipe deployment procedure is used for deepwater operations. In one embodiment, the J-lay pipeline deployment procedure allows the pipeline to exit the laying system in a very near vertical position. This means that the pipeline is installed with much reduced stress on the pipe. As shown in fig. 136D, a J-lay barge 6944 is constructed and arranged to deploy pipeline sections in a J-pipe configuration.
Control, positioning, and communication with the internal welder system, the joint welder system, and/or the pipe cooler system when located within the pipe may be accomplished in various ways, as described herein. In yet another embodiment, the position of the system within the pipe may be detected by transmission of low frequency electromagnetic signals from coils placed adjacent, parallel to the outer surface of the pipe. This signal is detected by a pair of orthogonal receiver coils mounted on the system in the pipe, adjacent the inner surface of the pipe. The phase of the received signal relative to the transmitted signal and the ratio of the amplitudes of the two received signals are used to estimate the relative positions of the transmitter and receiver. Control of the system within the pipe (i.e., the internal welder, the joint welder, or the chiller system, etc.) and transmission of information may also be accomplished through a high frequency direct sequence spread spectrum radio link between one or more processors outside the pipe (e.g., within a computer console) and one or more processors on the system installed in the pipe. The details of this deployment can be understood from U.S. patent 6,092,406, which is incorporated herein by reference in its entirety.
In one embodiment, the internal welding systems 5004, 3001 can include welding material consuming devices. In one embodiment, the external welding system 7500 can include a welding material consuming device. In one embodiment, the welding material consuming device can be part of the wire feed assembly 5020 of the internal welding system 5004.
In one embodiment, the welding consumables may have a similar structure and operation as the devices shown as 161A-165 and described with reference to 161A-165 of the present application. For example, in one embodiment, the structure, configuration, and operation of spool 5272 (as shown in fig. 22A) used by internal welding system 5004 may be similar to spool 14480 as shown and described with reference to fig. 161A. In one embodiment, the structure, configuration, and operation of the motor of the wire feed assembly 5020 of the internal welding system 5004 may be similar to the motor 14490 as shown in and described with reference to fig. 162, 164A, and 164B. Additionally, in one embodiment, the wire feed assembly 5020 of the internal welding system 5004 can include a weight sensor configured to sense depletion of the consumable material. The structure, configuration, and operation of the weight sensor of the internal welding system 5004 may be similar to the weight sensor 14484 as shown in fig. 161C and described with reference to fig. 161C. In one embodiment, the internal welding system 5004 may include other sensors (e.g., shown in 161B) to determine the amount of consumable welding material used by the internal welding system 5004 over a given period of time.
In one embodiment, the one or more processors 5140 operatively associated with the internal welding system 5004 may be configured to determine the wire feed speed from the speed of the motor of the wire feed assembly 5020 as described elsewhere in this application. In one embodiment, the one or more processors 5140 operatively associated with the internal welding system 5004 may be configured to determine an amount of consumable welding material used by the internal welding system 5004 within a given time period and generate welding material consumption data based thereon. In one embodiment, the transmitter of the internal welding system 5004 may transmit the welding material consumption data completely wirelessly to a remote uLog processing system for further processing. In one embodiment, the remote uLog processing system may also be configured to transmit (completely wirelessly to the internal welding system, the external welding system, and/or the joint internal welding system) additional instructions regarding the operation of the internal welding system, the external welding system, and/or the joint internal welding system based on the processed welding material consumption data. For example, the instructions may include correcting slippage of a motor of a wire feed assembly of the internal welding system, the external welding system, and/or the joint internal welding system by increasing a speed of the motor of the wire feed assembly. In one embodiment, the one or more processors 5140 of the internal welding system 5004 may use the procedures shown in and described with reference to fig. 163 and 165 to determine welding material consumption data, processed welding material consumption data, and the like.
In one embodiment, the structure and operation of the welding-consuming device is described above with reference to internal welding system 5004. In one embodiment, the external welding system 7500 and the joint internal welding system 3001 can include welding consumables having similar structures and operations. That is, in one embodiment, the hubs, electronics, software, and pictures transmitted by the welding material consuming devices of the internal welding system and the external welding system are common to both devices. However, the shape and size of the welding material consuming devices of internal welding systems 5004, 3001 and external welding system 7500 may vary. In one embodiment, the welding material consuming devices of internal welding systems 5004, 3001 and external welding system 7500 can have different shaped configurations and/or different geometries. In one embodiment, the welding material consuming device may be configured to detect unauthorized coil spools used in either the internal welding systems 5004, 3001 or the external welding systems 7500.
In-situ system testing and operation
Fig. 137A illustrates a system 13700 for facilitating field system testing or operation thereof, in accordance with one or more embodiments. As shown in FIG. 137, the system 13700 can include 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 the components of the system 13700 can communicate with each other. The field system 13702 may include one or more field devices 13712, one or more verification devices 13714, one or more field computer systems 13716, or other components. Remote computer system 13704 may include one or more processors 13730, the one or more processors 13730 configured to execute one or more subsystems, such as an object contour subsystem 13732, an operations manager subsystem 13734, an operations protocol subsystem 13736, an operations monitoring subsystem 13738, an operations triggering subsystem 13740, a presentation subsystem 13742, or other components. As described below, in one or more embodiments, the 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 herein as being performed by components of remote computer system 13704, in some embodiments, these operations may be performed by components of field system 13702 (e.g., field computer system 13716) or other components of system 13700.
In one embodiment, the field system 13702 may be the field system 5000. In one embodiment, if the computer system 5138 is local to the field system 5000, the field computer system 13716 may be the local computer system 5138 and the field computer system processor 13718 may be the local computer system processor 5140. If the computer system 5138 is located remotely from the field system 5000, the remote computer system 13704 may be the remote computer system 5138 and the remote computer system processor 13730 may be the remote computer system processor 5140.
Figure 137B illustrates communication links between a remote computer system 13730, a field computer system 13716 of a field system 13702, and other components of the field system 13702, according to one or more embodiments. In one embodiment, remote computer system 13704 (or processor 13730 thereof) may communicate with one or more other components of field system 13702 via field computer system 13716 (and one or more wired or wireless communication links between field computer system 13716 and remote computer system 13704). For example, the field computer system processor 13718 may receive inspection data, input parameters, operation observation data, or other data from one or more of the other systems of the field system 13702 (or its respective processor 13720), such as the welding system 3001 (e.g., the joint internal welding system 3001), the welding system 5004 (e.g., the internal welding system 5004), the cooler system 6500 (e.g., the internal cooler system 6500), the purge and inspection system 7001, the welding system 7500 (e.g., the external welding system 7500), or other systems 13724 of the field system 13702 (e.g., the rack or other duct alignment system, other inspection systems, etc.). The in-situ computer system processor 13718 may transmit (via a transmitter) inspection data, input parameters, operation observation data, or other data to the remote computer system 13704, and in response receive a response from the remote computer system 13704 that includes profile data (e.g., pre-weld profile data, dynamic profile data, post-weld profile data, etc.), instructions for performing an operation on the object, warnings (e.g., an indication to start or stop an operation if a defect exists, etc.), or other data. In one use case, if the response includes profile data, the in-situ computer system processor 13718 may use the profile data to generate an alert (e.g., if the defect is present indicating a defect, an indication to start or stop the operation, etc.), obtain instructions for performing the operation on the object, etc. In another use case, if the response includes instructions for performing an operation on the object, the field computer system processor 13718 may transmit the instructions to the appropriate system of the field system 13702 to cause the system to perform the operation according to the transmitted instructions.
In one embodiment, it may be beneficial to utilize one or more wireless communication links to communicate one or more components of the remote computer system 13704, the field computer system 13716, the welding system 3001, the welding system 5004, the cooler system 6500, the purge and inspection system 7001, or the welding system 7500 with one another to reduce the number of communication cables in the various systems of the field system 13702 in order to reduce potential cable tangles that may delay operation or damage other components of these systems. For example, potential cable tangles that occur during rotation of an inspection device (e.g., an inspection laser, inspection camera, or other inspection device), a welding torch, or other components of these systems can be reduced in some embodiments by reducing the number of communication cables in the welding system 3001, the welding system 5004, the purge and inspection system 7001, or the welding system 7500.
Figure 137C illustrates a communication link between a remote computer system 13730 and a component of a field system 13702 without the field computer system 13716, according to one or more embodiments. In one embodiment, the remote computer system 13704 (or the processor 13730 thereof) may communicate with one or more other components of the field system 13702 via one or more wired or wireless communication links between various ones of the field systems 13702 and the remote computer system 13704 (e.g., without requiring a separate field computer system 13716). For example, the remote computer system processor 13730 may receive inspection data, input parameters, operational observation data, or other data from one or more of the systems (or their respective electronic modules) of the field system 13702, such as the welding system 3001 (e.g., the joint internal welding system 3001), the welding system 5004 (e.g., the internal welding system 5004), the cooler system 6500 (e.g., the internal cooler system 6500), the purge and inspection system 7001, the welding system 7500 (e.g., the external welding system 7500), or other systems 13724 (e.g., the internal cooler) of the field system 13702. In response, the respective system of the field systems 13702 receives one or more responses from the remote computer system 13704, the one or more responses including profile data (e.g., pre-weld profile data, dynamic profile data, post-weld profile data, etc.), instructions for performing an operation on the object, an alert (e.g., an indication to start or stop the operation if a defect exists, etc.), or other data. In one use case, for example, if one of the systems of the field system 13702 receives a response that includes instructions for performing an operation on an object, then that system may perform the operation according to the transmitted instructions.
As another example, one or more of the electronic modules 5014, 5046, 5064, 5118 or other components of the welding system 5004 may include one or more processors configured to communicate with the field computer system 13716 (or the processor 13718 thereof), the remote computer system (or the processor 13730 thereof), or other components of the welding 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 may receive data from one or more sensors or inspection devices of the welding system 5004, process the sensor or inspection data, transmit the sensor or inspection data to the on-site computer system processor 13718 or the remote computer system processor 13730, generate signals to control one or more motors or other mechanical devices of the welding system 5004 to perform one or more operations, and so forth.
As another example, one or more of the electronic modules 3126, 13722 or other components of the welding system 3001 may include one or more processors configured to communicate with the field computer system 13716 (or the processor 13718 thereof), the remote computer system (or the processor 13730 thereof), or other components of the 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 welding system 5004, process the sensor or inspection data, transmit the sensor or inspection data to the on-site computer system processor 13718 or the remote computer system processor 13730, generate signals to control one or more motors or other mechanical devices of the welding system 3001 to perform one or more operations, and so forth.
As another example, one or more of the electronics modules 6528, 13722 or other components of the cooler system 6500 may include one or more processors configured to communicate with the field computer system 13716 (or its processor 13718), the remote computer system (or its processor 13730), or other components of the cooler system 6500 over one or more wired or wireless communication links. In one case, for example, one or more of the electronic modules 6528, 13722 may receive data from one or more sensors or inspection devices of the chiller system 6500, process the sensor or inspection data, transmit the sensor or inspection data to the on-site computer system processor 13718 or the remote computer system processor 13730, generate signals to control one or more motors or other mechanical devices of the chiller system 6500 to perform one or more operations, and so forth.
As another example, one or more of the electronic modules 7032, 7036, 7040, 7064 or other components of the purge and check system 7001 may include one or more processors configured to communicate with the in-field computer system 13716 (or processor 13718 thereof), the remote computer system (or processor 13730 thereof), or other components of the purge and check system 7001 via one or more wired or wireless communication links. In one case, for example, one or more of the electronic modules 7032, 7036, 7040, 7064 may receive data from one or more sensors or inspection devices of the purge and inspection system 7001, process the sensor or inspection data, transmit the sensor or inspection data to the in-situ computer system processor 13718 or the remote computer system processor 13730, generate signals to control one or more motors or other mechanical devices of the purge and inspection system to perform one or more operations, and so forth.
As another example, one or more of the electronic modules 3126, 13722 or other components of the welding system 3001 may include one or more processors configured to communicate with the field computer system 13716 (or the processor 13718 thereof), the remote computer system (or the processor 13730 thereof), or other components of the 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 welding system 5004, process the sensor or inspection data, transmit the sensor or inspection data to the on-site computer system processor 13718 or the remote computer system processor 13730, generate signals to control one or more motors or other mechanical devices of the welding system 3001 to perform one or more operations, and so forth.
In one embodiment, a field system (e.g., field system 5000, field system 13702, etc.) may work with one or more remote computer systems (e.g., computer system 5138, remote computer 13704, etc. located remotely from field system 5000) to facilitate field testing or physical operations based thereon. The field system may include one or more components communicatively coupled to one another and/or one or more components of a remote computer system. In one embodiment, based on the inspection of the one or more objects, one or more field devices (e.g., field device 13712) of the field system may be caused to perform one or more operations. For example, a testing device (e.g., testing device 13714) of the field system may test the object. One or more processors of the field system (e.g., processor 13718 of field computer system 13716) may receive inspection data associated with an inspection of an object from an inspection device. Based on the inspection data, the processor may cause a field device of the field system to perform an operation that physically affects the object. The inspection device may include 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, an eddy current inspection device, a temperature monitor, or other inspection device. The inspection data may include laser inspection data, camera inspection data, x-ray inspection data, gamma ray inspection data, ultrasonic inspection data, magnetic particle inspection data, eddy current inspection data, temperature inspection data, or other inspection data.
In one embodiment, a processor of the field system (e.g., the processor 13718 of the field computer system 13716) may process the inspection data to generate data related to performing an operation that physically affects the object, and cause the field device to perform the operation based on the operation-related data. In one embodiment, the processor of the field system may transmit (via the transmitter) the test data to a remote computer system. In response to transmitting the verification data, the processor may receive data from the remote computer system related to performing an operation that physically affects the object. For example, the operation-related data may be generated at a remote computer system based on the verification data. After receiving the operation-related data, the processor may cause the field device to perform an operation based on the operation-related data. The processor may cause the field device to perform the operation by transmitting the operation-related data to the field device (e.g., in a format that the field device can interpret and use to perform the operation), using the operation-related data to control the field device to perform the operation, monitoring and providing dynamic updates for performing the operation (e.g., by monitoring an object during performance of the operation), or other techniques.
In one embodiment, the inspection data may be processed to automatically determine whether the object has one or more defects, whether the object is ready for the next stage of operation, or other information. For example, if one or more defects are detected based on the inspection data, the generated operation-related data may be relevant to performing an operation to address the detected defects. For another example, if it is determined that the object is ready for a next operational stage, the generated operation-related data may be related to performing an operation associated with the next operational stage.
The field devices (e.g., field device 13712) may include welding devices, coating devices, alignment devices, heating devices, cooling devices, protection devices, inspection devices, or other devices. The operation-related data may include welding-related instructions, coating-related instructions, modification-related instructions, alignment-related instructions, or other instructions or data. The welding-related instructions may include instructions related to welding a joint area between a first object and a second object (e.g., a joint area between pipes or other objects), instructions related to a wire feed speed for welding, a wire consumption, a swing width, a swing waveform, a swing amplitude, a welding time, a gas flow rate, a power level of a welding arc, a welding current, a welding voltage, a welding impedance, a welding torch travel speed, a position of a welding tip of a welding torch along a pipe axis, an angular positioning of a welding tip of a welding torch relative to a rotational plane thereof, a distance of a welding tip of a welding torch to an inner surface of a pipe to be welded, and the like, or other welding-related instructions. The coating-related instructions may include instructions for coating an object (e.g., coating a pipe or other object), instructions related to a pre-heat temperature, a coating thickness, or other coating-related instructions. The alteration-related instructions may include instructions related to enlarging at least a portion of the object, instructions related to reducing at least a portion of the object, instructions related to changing a size of at least a portion of the object (e.g., changing the size radially, changing the size proportionally, etc.), instructions related to modifying a shape of at least a portion of the object, or other alteration-related instructions. The alignment-related instructions may include instructions related to aligning at least a portion of an object with at least a portion of another object, or other alignment-related instructions.
In one embodiment, based on inspection data associated with inspection of a joint region between a first object and a second object, one or more processors of a field system (e.g., processor 13718 of field computer system 13716) may obtain data related to performing a welding operation on the joint region. For example, the processor may transmit (via the transmitter) the verification data to a remote computer system (e.g., remote computer system 13704), and in response, the processor may obtain instructions related to the weld joint region from the remote computer system. The processor may cause the field device to weld the joint region based on the welding-related instructions.
In one use case, if it is determined based on the inspection data that the first weld path layer has a defect (but is modifiable by the second weld path), the weld-related instructions may include instructions for the second weld path such that the second weld path compensates for the defect of the first weld path layer. For example, if the first weld channel layer thickness is determined to be insufficient, the weld-related instructions may include instructions for more weld time or weld line usage for the second weld channel (as compared to if the first weld channel layer thickness was determined to be sufficient). Thus, the resulting second weld channel layer may be thicker (than it would otherwise be) to compensate for the first weld channel layer being of insufficient thickness. As another example, if the first weld channel layer is determined to be too thick, the weld-related instructions may include instructions for less weld time or weld line usage for the second weld channel (as compared to when the first weld channel layer thickness is determined to be appropriate). In this way, the resulting second weld channel layer may be thinner (compared to its thickness in the other case) to compensate for the additional thickness of the first weld channel layer.
In another use case, if a defect is detected in the first weld channel layer, the weld-related instructions may not necessarily include instructions to repair or compensate for the detected defect. For example, based on the size of the defect not satisfying a predefined defect size threshold (e.g., a minimum repairable defect size for which repair is recommended), repair of the defect may not be recommended. The predefined defect size threshold may, for example, correspond to a defect size that does not have a significant negative impact on the quality of the weld. Thus, in this use case, if the defect size in the first welding channel layer is less than the predefined defect size threshold, the welding-related instructions may simply comprise instructions for the next welding channel layer as in the case where no defect is detected.
In one embodiment, based on inspection data associated with inspection of the object, one or more processors of the field system (e.g., processor 13718 of field computer system 13716) may obtain data related to coating the object. For example, the processor may transmit (via the transmitter) the inspection data to a remote computer system (e.g., remote computer system 13704), and in response, the processor may obtain instructions related to coating the object from the remote computer system. The processor may cause the field device to apply one or more coating layers to the object based on the coating-related instructions. In one use case, if it is determined based on the inspection data that the weld to the object is complete and the completed weld is within specification, the remote computer system may transmit an instruction to the processor of the field system to begin coating the object.
In one embodiment, based on inspection data associated with inspection of the object, one or more processors of the field system (e.g., processor 13718 of field computer system 13716) may obtain data related to altering the size, shape, or other aspect of the object. For example, the processor may transmit (via the transmitter) the verification data to a remote computer system (e.g., remote computer system 13704), and in response, the processor may obtain instructions related to the altered object from the remote computer system. The processor may cause the field device to enlarge at least a portion of the object, reduce at least a portion of the object, radially change a size of at least a portion of the object, alter a shape of at least a portion of the object (e.g., machine a new bevel on an end of a pipe or perform a shape alteration), or perform other alterations to the object based on the alteration-related instructions.
In one embodiment, based on inspection data associated with inspection of the object, one or more processors of the field system (e.g., processor 13718 of field computer system 13716) may obtain data related to aligning the object. For example, the processor may transmit (via the transmitter) the inspection data to a remote computer system (e.g., remote computer system 13704), and in response, the processor may obtain instructions from the remote computer system related to aligning the object. The processor may cause the field device to align at least a portion of the object with at least a portion of another object based on the alignment-related instructions. In one use case, for example, where the object is a pipe and analysis of the inspection data by the remote computer system indicates an alignment error, the alignment-related instructions received from the remote computer system may include instructions to resolve the alignment error (e.g., an angular error resulting in a gap between the pipes, a positional error resulting in a mistaking problem, etc.) that alter the position of at least one of the pipes.
In one embodiment, based on inspection of a plurality of objects, one or more operations may be caused to be performed on one or more objects. In this way, for example, inspection data from an inspection of a plurality of objects may be used to perform an analysis of the object as a whole. In some cases, this analysis may be otherwise incomplete if isolated to inspection data from a single object. For example, while the individual pipes of a pipeline may each be within specification, the pipeline or a portion thereof (including a plurality of the individual pipes) as a whole may be outside specification. As another example, while individual pipes of a pipeline may be ready for a next stage of operation, the pipeline or pipeline portion as a whole may not be ready for the next stage of operation. By using inspection data from an inspection of each of the pipes or pipe sections of the pipeline, a more complete analysis of the pipe or pipe section as a whole may be performed.
In one embodiment, one or more processors of the field system (e.g., processor 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, the processor may cause a field device of the field system to perform an operation that physically affects the one or more objects. The first verification data and the second verification data may each include at least one of: laser inspection data, camera inspection data, x-ray inspection data, gamma-ray inspection data, ultrasonic inspection data, magnetic particle inspection data, eddy current inspection data, temperature inspection data, or other inspection data. The inspection of the first object and the inspection of the second object may be performed by the same inspection device or different inspection devices.
In one embodiment, a processor of the field system (e.g., the processor 13718 of the field computer system 13716) may process the first inspection data and the second inspection data to generate data related to performing an operation that physically affects the object, and cause the field device to perform the operation based on the operation-related data. In one embodiment, the processor of the field system may transmit the first inspection data and the second inspection data to a remote computer system (e.g., remote computer system 13704). In response to transmitting the first inspection data and the second inspection data, the processor may receive data from a remote computer system related to performing an operation that physically affects the object. For example, the operation-related data may be generated at the remote computer system based on the first verification data and the second verification data. After receiving the operation-related data, the processor of the field system may cause the field device to perform an operation based on the operation-related data.
In one embodiment, the operation-related data (based on which the operation is performed on the object) may additionally or alternatively be based on one or more input parameters of one or more operations performed on one or more objects (e.g., the object, another object, etc.). For example, a field device of a field system may perform an operation prior to inspection of an object. Input parameters of previously performed operations, inspection data associated with inspection of the object, or other data may be transmitted to a remote computer system. After receiving the transmitted data, the remote computer system may generate operation-related data based on the input parameters, the inspection data, or other data. For example, if a defect is detected based on the inspection data, the input parameters may be analyzed in conjunction with the detected defect to determine a cause of the defect (e.g., the actual output does not match the theoretical output of the input parameters), and operation-related data may be generated such that the operation-related data may be used to perform an operation to repair or compensate for the detected defect or the cause of the defect.
In one use case, if it is determined that the first weld path layer from the welding operation is not thick enough (based on inspection data associated with inspection of the first weld path layer), the input parameters of the welding operation may be taken into account to determine the cause of the first weld path layer's insufficient thickness. For example, if it is determined that insufficient weld time or weld line is the cause of the insufficient thickness, then weld-related instructions for the second weld pass may be generated to include input parameters (e.g., more weld time, more line usage, etc.) calibrated to compensate for the insufficient thickness of the first weld pass layer or the cause of its determination.
Processing of data from field systems
In one embodiment, a computer system (e.g., computer system 5138, remote computer system 13704, field computer system 13716, etc.) may work with one or more field systems (e.g., field system 5000, field system 13702) to facilitate field testing or physical operations based thereon. The computer system may include one or more processors or other components communicatively coupled to each other and/or one or more components of one or more field systems. The computer system may be a local computer system with respect to at least one of the field systems or a remote computer system with respect to at least one of the field systems. In one embodiment, a processor of a computer system may receive inspection data associated with an inspection of an object from a field system. The processor may process the inspection data to generate data related to performing an operation that physically affects the object. The processor may transmit the operation-related data to the field system to cause the field system to perform an operation that physically affects the object. For example, the field system may perform an operation based on the operation-related data. As described herein, the operation-related data may include welding-related instructions, coating-related instructions, alteration-related instructions, alignment-related instructions, or other instructions or data.
In one embodiment, a processor of a computer system may receive (via a receiver) inspection data associated with inspection of a plurality of objects from one or more field systems and generate data related to performing an operation of an object that physically affects at least one of the field systems based on the inspection data. The processor may transmit the operation-related data to the field system to cause the field system to perform an operation that physically affects the object. The inspection data associated with the inspection of each object may include at least one of: laser inspection data, camera inspection data, x-ray inspection data, gamma-ray inspection data, ultrasonic inspection data, magnetic particle inspection data, eddy current inspection data, temperature inspection data, or other inspection data. The inspection of the plurality of objects may be performed by the same inspection apparatus or different inspection apparatuses.
In one embodiment, the operation-related data (based on which the operation is performed on the object) may additionally or alternatively be based on one or more input parameters of one or more operations performed on the object. For example, a field device (e.g., field device 13712) of a field system may perform an operation prior to inspection of an object. The processor of the computer system may obtain input parameters of previously performed operations, inspection data associated with inspection of the object, or other data from the field system or other source. The processor of the computer system may generate operation-related data based on the obtained data. For example, if a defect is detected based on the inspection data, the input parameters may be analyzed in conjunction with the detected defect to determine a cause of the defect (e.g., the actual output does not match the theoretical output of the input parameters), and operation-related data may be generated such that the operation-related data may be used to perform an operation to repair or compensate for the detected defect or the cause of the defect.
In one embodiment, the operation-related data (based on which the operation is performed on the object) may additionally or alternatively be based on observations of one or more operations performed on one or more other objects. In one embodiment, a processor of a computer system may monitor one or more operations on one or more objects. For example, the processor may monitor operation by one or more inspection devices, such as one or any combination of an inspection laser, an inspection camera, an x-ray radiographic inspection device, a gamma ray inspection device, an ultrasonic inspection device, a magnetic particle inspection device, an eddy current inspection device, a temperature monitor, or other inspection devices. During such monitoring, the processor may obtain data relating to observations of the operation, such as observations of one or more field devices during performance of the operation, observations of objects during performance of the operation, observations of environmental conditions during performance of the operation, or other observations. The processor may compare the observations to determine situations that may be the cause of the defect, and may generate operation-related data for subsequent operations to avoid or mitigate such defects. In one embodiment, the processor of the computer system may compare one or more sets of observations of an operation performed on one or more objects determined to have a defect (after performing the operation) with one or more other sets of observations of the same operation performed on one or more other objects that do not have a defect to determine a condition that may result in a defect (as described in further detail elsewhere herein). In one embodiment, the determination of such conditions may be stored and used (e.g., in conjunction with the determination of such conditions occurring in other field systems) (i) to generate and select one or more operating protocols for subsequent operation (as described herein) to prevent or reduce defects; (ii) enabling earlier detection of defects in a process (e.g., by active monitoring while performing an operation, dynamic inspection during an operation, etc., as described herein); or (iii) provide other advantages to produce a better product for current and future customers.
For example, analysis of inspection data for multiple welds and operational observations of these welds may show that the lack of fusion is significantly more likely to occur when the weld voltage is reduced by more than 0.5V to below the weld voltage input parameter while the torch is welding between the 2 o 'clock and 4 o' clock positions on the pipe. In contrast, the welding voltage may be reduced by 1.2V to below the welding voltage input at other locations on the pipe without causing the defect of lack of melting. Based on these observations, the processor of the computer system may generate and send new welding input parameters that instruct the welding device to increase the welding voltage by 0.7V when the welding torch is between the 2 o 'clock and 4 o' clock positions. As another example, if the analysis shows that the weld voltage drop condition results in a lack of fusion when the torch is welding downhill (but not when welding uphill), the new weld input parameters generated may indicate that the welding device is only achieving a weld voltage increase when the torch is welding downhill. As another example, if the analysis shows that the reduced weld voltage condition results in a lack of fusion at the outer weld (but not at the inner weld), the generated new weld input parameters may indicate to the outer welding device to effect the weld voltage increase.
In one embodiment, a processor of a computer system may obtain inspection data associated with inspection of one or more objects and compare the inspection data to a predefined quality profile of the object. Based on the comparison, the processor may determine whether the object has one or more defects, whether the object is ready for the next stage of operation, or other information. For example, if one or more defects are detected based on the inspection data, the generated operation-related data may be relevant to performing an operation to address the detected defects. For another example, if it is determined that the object is ready for a next operational stage, the generated operation-related data may be related to performing an operation associated with the next operational stage.
For example, the predefined quality profile may include one or more size criteria, shape criteria, conformance criteria, alignment criteria, temperature criteria, color criteria, or other criteria. In one use case, the predefined quality profile of a pipe of the pipeline may include one or more acceptable ranges for a pipe inner diameter, a pipe outer diameter, a pipe thickness, a size of a joint area between the pipe and another pipe to which the pipe is welded or to be welded, a height of the weld in the pipe interior, a height of the weld on the pipe exterior, a temperature of the weld material or pipe (e.g., during a welding operation), a color of the weld material or pipe during the welding operation (e.g., which may indicate a temperature of the weld material or pipe), or other criteria. The predefined quality profile may correspond to a particular quality level, such as a "golden-home" quality (e.g., a high quality level), a minimum required quality level, and so on.
In one embodiment, a processor of a computer system may provide inspection data associated with an inspection of one or more objects, one or more analysis results from an analysis of the inspection data, or other data for presentation to a user (e.g., an operator, inspector, manager, or other user). In one embodiment, the processor may receive user input from a user indicating a defect associated with at least one of the objects. For example, the user may specify the location of the defect on the object and what the defect is. Based on the specified defects, the processor may generate operation-related data that may be used to cause the field system to perform an operation to repair or compensate for the defects associated with the object.
In one embodiment, one or more operational triggers may be provided to address a situation that results in one or more defects (e.g., in an object, group of objects, protrusion, etc.). For example, although the same input parameters are used for a particular operation, field devices performing operations with these input parameters may perform operations differently from one another, which may cause an object (operated on by one field device) to have a defect while another object (operated on by another field device) may not have a defect. These differences in results may be caused by: one or more of the actual inputs to the field device are different than the expected inputs, one or more of the actual outputs of the field device are different than the expected outputs, one or more imperfections in the object on which the field device is operating, one or more actual operating conditions are different than acceptable operating conditions (e.g., environmental conditions, misalignment or misalignment of objects, etc.), or other circumstances.
In one embodiment, a processor of a computer system may monitor one or more operations on one or more objects. During such monitoring, the processor may obtain data relating to observations of the operation, such as observations of one or more field devices during performance of the operation, observations of objects during performance of the operation, observations of environmental conditions during performance of the operation, or other observations. The processor may compare the observations to one another to generate one or more operational triggers. After such triggers are implemented, one or more field systems may cause one or more operations to be performed in response to one or more subsequent observations that satisfy respective ones of the triggers. The triggers may include one or more triggers or other triggers that result in operations that prevent or otherwise reduce the defects.
In one embodiment, based on data relating to observations of operations, a processor of a computer system may compare a first set of observations of an operation performed on an object determined to have a defect (after the operation was performed) with one or more other sets of observations of the same operation performed on one or more other objects that do not have a defect. After the comparison, the processor may determine one or more differences between the first set of observations and the other sets of observations. Based on the difference, the processor may generate one or more triggers associated with one or more operations (e.g., operations to prevent defects or other operations). For example, if there is a common difference between the first set of observations and each of the other sets of observations, it may be that the observed case corresponding to the common difference causes a defect. Thus, if those conditions are observed during subsequent operations, one or more operations for addressing those conditions may be implemented to prevent the defect from occurring (e.g., by aborting the subsequent operations until the condition no longer occurs, by modifying input parameters of the subsequent operations to compensate for the condition, by generating an alert indicative of the condition, etc.).
In one embodiment, based on data associated with observations of operations, a processor of the computer system may compare a second set of observations of the same operation performed on another object determined to have a defect (after the operation was performed) with other sets of observations of the same operation performed on other objects that do not have a defect. After the comparison, the processor may determine one or more differences between the second set of observations and the other sets of observations. For example, the processor may then 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 differences common to the first set of observations and the second set of observations (e.g., similarities between the common differences common to the first set of observations and the second set of observations and the observations of the other sets for other objects that are not defective). Based on the difference common to the first and second sets, the processor may generate one or more triggers associated with one or more operations (e.g., operations for preventing defects or other operations).
In one use case, by comparing one or more sets of observations of a welding operation for a root pass (for one or more joint regions between pipes), a processor of a computer system may determine that at least one set of observations of a welding operation (that produces a defect in its root pass) has a common difference from other sets of observations of a welding operation that produces a root pass without defects. For example, if the common difference includes some deviation between one or more measured inputs and input parameters for the welding operation, the processor may generate one or more triggers that activate one or more operations for resolving the deviation when such deviation is detected. For example, subsequent welding operations for the root pass may be monitored, and if a deviation from the input parameters used by the welding device for the root pass welding operation occurs, the generated trigger may cause its associated operation to be performed to account for the deviation (e.g., modify the input parameters to cause the actual inputs of the welding operation to be within the expected input ranges associated with the unmodified input parameters, generate an alert to be provided to an operator or other individual or system, stop the welding operation, etc.). In other use cases, one or more similar types of triggers may be generated for addressing conditions during coating operations, preheating operations, cooling operations, alignment operations, protection operations, inspection operations, or other operations, respectively.
In another use case, during the monitoring of the subsequent operations on the object, a condition corresponding to a common observation with the object having defects can be detected. In response, an operational trigger for the situation may cause an operation associated with the operational trigger to be performed on the object. For example, a processor of a computer system may modify one or more input parameters of a subsequent operation or another operation performed after the subsequent operation. The processor may, for example, modify input parameters of subsequent operations during the course of the subsequent operations, modify input parameters of other subsequent operations before the other subsequent operations, or perform other modifying operations associated with the operation trigger. The modified input parameters may include one or more welding parameters, coating parameters, alignment parameters, modification parameters, or other parameters. As another example, the processor may stop the subsequent operation (e.g., suspend the subsequent operation until further notice), generate an alert indicating the situation during the subsequent operation (e.g., generate and transmit an alert to the field system to perform the subsequent operation, provide an alert to a manager, field operator, or other personnel, etc.), or perform other operations associated with the operation trigger. In this way, for example, the aforementioned operational triggers and/or active monitoring may enable earlier detection of defects in the process and prevent or reduce defects to provide more efficient and effective operation and better product for current and future customers.
Operating protocol and operations based thereon
In one embodiment, one or more operation protocols for performing one or more operations may be generated based on inspection of one or more objects. For example, a processor of a computer system (e.g., computer system 5138, remote computer system 13704, in-field computer system 13716, etc.) may receive inspection data associated with an inspection of an object (e.g., an inspection before performing one or more operations that physically affect the object, an inspection during performance of an operation, an inspection after performing an operation, etc.) from an in-field system (e.g., in-field system 5000, in-field system 13702, etc.). The processor may generate an operation protocol (associated with at least one operation type of the operation) based on the inspection data and one or more input parameters for performing the operation. The operating protocol may include, for example, a welding protocol, a coating protocol, an alignment protocol, a change protocol, or other protocol. The one or more parameters of the operating protocol may include one or more welding parameters, coating parameters, alignment parameters, modification parameters, or other parameters.
In one embodiment, the processor of the computer system may select an operation protocol for performing subsequent operations similar to at least one of the operations (physically affecting the object). The processor may generate data related to performing a subsequent operation based on at least one input parameter of the operating protocol. The processor may transmit the operation-related data to the field system to cause the field system to perform a subsequent operation. For example, the field system may perform subsequent operations based on the operation-related data.
In one embodiment, based on the inspection data, a processor of the computer system may detect a defect associated with the object. In response to the defect detection, the processor may generate the operating protocol such that the operating protocol includes a set of input parameters having at least one input parameter different from the set of input parameters used to perform the operation. For example, a predefined operating protocol may be used to perform an operation on an object. If a defect of the object is detected based on the inspection of the object, the predefined operating protocol may be modified to avoid similar defects when the predefined operating protocol is used for one or more subsequent operations similar to the operation that may result in the detected object defect. The modified operating protocol may be stored as a new predefined operating protocol, replacing a previous version of the predefined operating protocol, etc.
In one use case, a predefined welding operation protocol may be used to perform a welding operation to weld two pipes together, wherein the predefined welding operation protocol may include input parameters relating to: wire feed speed, wire consumption, swing width, swing waveform, swing amplitude, welding time, gas flow rate, power level of the welding arc, welding current, welding voltage, welding impedance, welding torch travel speed, position of the welding tip of the welding torch along the pipe axis, angular positioning of the welding tip of the welding torch relative to its plane of rotation, distance of the welding tip of the welding torch to the inner surface of the pipe to be welded, or other parameters. For example, if it is determined that the welding operation produces a weld channel layer of insufficient thickness, the predefined welding operation protocol may be modified to allow for more welding time, more wire usage (e.g., increasing wire feed speed), or other changes to the input parameters of the predefined welding operation protocol. Thus, when the modified operating protocol is subsequently used to perform similar operations on two similar pipes, the modification of the input parameters may prevent the under-thickness problem.
In one embodiment, based on the inspection data, the processor of the computer system may determine whether the quality of one or more aspects of the object resulting from the operation (physically affecting the object) meets or exceeds a quality criterion indicated by the predefined quality profile. For example, the processor may generate an operating protocol in response to the quality of the aspect of the object meeting or exceeding a quality criterion indicated by the predefined quality profile, such that the operating protocol includes one or more input parameters (for performing the operation). The predefined quality profile may correspond to a particular quality level, such as a "golden-home" quality (e.g., a high quality level), a minimum required quality level, and so on. If the quality of the aspect of the object meets or exceeds the quality criteria indicated by the predefined quality profile, the input parameters (for performing the operations that produce such results) may be used to generate an operating protocol (e.g., such that the operating protocol includes some or all of the input parameters). Thus, for example, an operating protocol may be used to perform one or more subsequent operations similar to the operation that produced such a result, such that the subsequent operations produce similar quality.
As another example, if the quality of the aspect of the object does not meet the quality criteria (as indicated by the predefined quality profile), the processor may generate the operating protocol such that the operating protocol does not include one or more input parameters (for performing operations that result in the verified state of the object). In one use case, if a predefined operating protocol (including input parameters for performing an operation) is selected for performing at least one of the operations and the quality of the aspect of the resulting object does not meet the required minimum quality level, one or more input parameters of the predefined operating protocol may be modified to avoid subsequent unsatisfactory results when the predefined operating protocol is used to perform a subsequent operation.
In one embodiment, a processor of a computer system may obtain inspection data associated with an inspection of one or more objects and compare the inspection data to a predefined mass profile of the object to determine whether the mass of one or more aspects of the object meets or exceeds a quality criterion indicated by the predefined mass profile. For example, based on the comparison, the processor may determine whether the object has one or more defects, whether the object is ready for the next stage of operation, or other information. As another example, in response to the quality of the aspect of the object exceeding a quality criterion indicated by the predefined quality profile, the processor may generate a new quality profile based on the inspection data, wherein the new quality profile indicates the new quality criterion based on the inspection data. The new mass profile may be stored, for example, in a database for use in analyzing one or more aspects resulting from one or more subsequent operations.
In one embodiment, a processor of a computer system may provide inspection data associated with an inspection of one or more objects, one or more analysis results from an analysis of the inspection data, or other data for presentation to a user (e.g., an operator, inspector, manager, or other user). In one embodiment, the processor may receive user input by a user indicating a quality level (e.g., a low quality level, a high quality level, etc.) of one or more aspects of the object resulting from one or more operations. In response to the user input, the processor may generate a new quality profile associated with the indicated quality level, wherein the new quality profile indicates a new quality criterion based on the inspection data. The new mass profile may be stored, for example, in a database for use in analyzing one or more aspects resulting from one or more subsequent operations.
In one embodiment, a processor of a computer system may generate one or more operating protocols based on data related to input parameters for performing one or more operations, data related to observations of the operations, inspection data associated with inspection (e.g., before, during, or after the operations) of an object on which the operations are performed, or other data. For example, the processor may analyze the inspection data to determine whether the objects have defects and which of the objects have defects. The processor may then compare one or more sets of observations of the operation performed on the one or more objects determined to have a defect (after the operation is performed) with one or more other sets of observations of the same operation performed on one or more other objects that are not defective to determine a condition that may lead to a defect (as described in further detail elsewhere herein). Based on the comparison, the processor may generate an operating protocol such that when the operating protocol is used for one or more subsequent operations (e.g., subsequent operations that are the same as or similar to the operations performed and observed), the operating protocol avoids or otherwise addresses the situation (which may have resulted in a flaw).
For another example, if input parameters for performing an operation on one or more objects are observed to differ from input parameters for performing an operation on one or more other objects, the processor may compare the observations to one another to determine whether the differences in the input parameters are likely to cause a defect. For example, the observations may be compared to determine common differences between input parameters for performing operations on objects with resulting defects and input parameters for performing operations on objects without defects. Based on the common difference, the processor may generate an operating protocol such that the operating protocol avoids including input parameters that may cause a defect. The generated operating protocol may be stored such that the operating protocol may be used in one or more subsequent operations (e.g., subsequent operations that are the same as or similar to the operations performed and observed). For example, in one use case with respect to a welding protocol, analysis of inspection data for multiple welds and operational observations of those welds may show that the lack of fusion defect is significantly more likely to occur when the welding voltage is reduced by more than 0.5V to below the welding voltage input parameter while the torch is welding between the 2 o 'clock and 4 o' clock positions on the pipe. In contrast, the welding voltage may be lowered by 1.2V to below the welding voltage input at other locations on the pipe without causing the defect of lack of melting. Based on these observations, the processor of the computer system may generate a welding protocol that includes new welding input parameters that indicate that the welding voltage needs to be increased by 0.7V when the welding torch is between the 2 o 'clock and 4 o' clock positions.
Further exemplary flow charts
Fig. 138 illustrates a flow diagram of a method 13800 for facilitating field testing and physical operations based thereon by a field system (e.g., one of the field systems 13702), in accordance with one or more embodiments. The process operations of the methods presented below are intended to be illustrative and non-limiting. For example, in some embodiments, the method may be implemented using one or more additional operations not described and/or without one or more of the operations discussed. Additionally, the order in which the process operations of the method are illustrated (and described below) is not intended to be limiting. In some embodiments, the methods may be implemented at least by one or more processing devices (e.g., a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and/or other mechanisms for electronically processing information). The processing device may include one or more devices that perform some or all of the operations of the described methods in response to instructions stored electronically on an electronic storage medium. The processing device may include one or more devices configured by hardware, firmware, and/or software to be specifically designed for performing one or more of the operations of the method.
In one embodiment, an object (13802) may be scanned. For example, the object may be scanned before, during, or after an operation performed on the object that physically affects the object to derive the inspection data. According to one or more embodiments, operation 13802 may be performed by an inspection device the same as or similar to the inspection device 13714. For example, the inspection device may include an inspection laser, an inspection camera, an x-ray radiographic inspection device, a gamma ray inspection device, an ultrasonic inspection device, a magnetic particle inspection device, an eddy current inspection device, a temperature monitor, or other inspection device. The inspection data may include laser inspection data, camera inspection data, x-ray inspection data, gamma ray inspection data, ultrasonic inspection data, magnetic particle inspection data, eddy current inspection data, temperature inspection data, or other inspection data.
In one embodiment, inspection data associated with a scan of an object may be obtained (13804). In accordance with one or more embodiments, operation 13804 may be performed by a field computer system that is the same as or similar to field computer system 13716.
In one implementation, the verification data may be transmitted to a remote computer system (e.g., remote computer system 13720) (13806). In accordance with one or more embodiments, operation 13806 may be performed by a field computer system the same as or similar to field computer system 13716.
In one embodiment, data related to performing an operation that physically affects the object may be obtained from a remote computer system in response to transmitting the inspection data (13808). For example, the operation-related data may be derived from the verification data. As another example, the operation-related data may be derived by the remote computer system from inspection data, other inspection data associated with a scan of another object, input parameters for performing an operation on the respective object prior to the scan, or other data. According to one or more embodiments, the operations 13808 may be performed by a field computer system that is the same as or similar to the field computer system 13716.
In one embodiment, based on the operation-related data, a field device of the field system may be caused to perform an operation that physically affects the object (13810). In accordance with one or more embodiments, operation 13810 may be performed by a field computer system that is the same as or similar to field computer system 13716.
In one embodiment, referring to fig. 138, the operation-related data may include welding-related instructions, such as instructions related to: wire feed speed, wire consumption, swing width, swing waveform, swing amplitude, weld time, gas flow rate, power level of the welding arc, weld current, weld voltage, weld impedance, weld torch travel speed, position of the welding tip of the welding torch along the pipe axis, angular position of the welding tip of the welding torch relative to its plane of rotation, distance of the welding tip of the welding torch to the inner surface of the pipe to be welded, or other instructions. Based on the welding-related instructions, the field device of the field system may be caused to perform a welding operation on the first object and the second object (e.g., weld two pipes together, weld two other objects together, etc.).
In one embodiment, referring to fig. 138, the operation-related data may include coating-related instructions, such as instructions related to pre-heat temperature, coating thickness, or other instructions. Based on the coating-related instructions, a field device of the field system may be caused to apply one or more coating layers to the object.
In one embodiment, referring to FIG. 138, the operation-related data may include an alignment-related instruction. Based on the alignment-related instructions, the field devices of the field system may be caused to align the objects (e.g., align two pipes for welding, align other objects with each other, etc.).
In one embodiment, referring to FIG. 138, operating on related data may include altering related instructions. Based on the alteration-related instructions, the field device of the field system may be caused to alter the object, such as to enlarge at least a portion of the object, reduce at least a portion of the object, change a size of at least a portion of the object, modify a shape of at least a portion of the object, or other alteration.
FIG. 139 illustrates a flow diagram of a method 13900 for facilitating field testing and physical operations based thereon by a computer system, according to one or more embodiments. The process operations of the methods presented below are intended to be illustrative and non-limiting. For example, in some embodiments, the method may be implemented using one or more additional operations not described and/or without one or more of the operations discussed. Additionally, the order in which the process operations of the method are illustrated (and described below) is not intended to be limiting. In some embodiments, the methods may be implemented at least by one or more processing devices (e.g., a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and/or other mechanisms for electronically processing information). The processing device may include one or more devices that perform some or all of the operations of the described methods in response to instructions stored electronically on an electronic storage medium. The processing device may include one or more devices configured by hardware, firmware, and/or software to be specifically designed for performing one or more of the operations of the method.
In one embodiment, inspection data associated with the scanning of the object may be obtained from a field system (13902). In accordance with one or more embodiments, operation 13902 may be performed by an object contour subsystem that is the same as or similar to object contour subsystem 13732. For example, the inspection data may include laser inspection data, camera inspection data, x-ray inspection data, gamma ray inspection data, ultrasonic inspection data, magnetic particle inspection data, eddy current inspection data, temperature inspection data, or other inspection data.
In one embodiment, one or more input parameters for one or more operations performed on an object may be obtained (13904). For example, the operation performed on the object may be an operation that physically affects the object and is performed on the object prior to scanning of the object (upon which the inspection data is based). The input parameters may be input parameters (e.g., welding parameters, coating parameters, or other input parameters) for performing an operation on the object. According to one or more embodiments, operation 13904 may be performed by an operation monitoring subsystem that is the same as or similar to operation monitoring subsystem 13738.
In one embodiment, the inspection data and the input parameters may be processed to generate data related to performing an operation that physically affects the object (13906). For example, the operation-related data may include one or more of the types of operation-related data described above with reference to fig. 138 (e.g., welding-related instructions, coating-related instructions, etc.). In accordance with one or more embodiments, operation 13906 may be performed by an operations manager subsystem that is the same as or similar to operations manager subsystem 13734.
In one embodiment, the operation-related data may be transmitted to the field system to cause the field system to perform an operation, wherein the operation is performed based on the operation-related data (13908). For example, the operations that may be caused to be performed by the field system may include one or more of the types of operations (causing the field devices of the field system to perform) described above with reference to fig. 138. In accordance with one or more embodiments, operation 13908 may be performed by an operations manager subsystem that is the same as or similar to operations manager subsystem 13734.
Fig. 140 illustrates a flow diagram of a method 14000 for facilitating field testing and physical operations based thereon by a computer system, in accordance with one or more embodiments. The process operations of the methods presented below are intended to be illustrative and non-limiting. For example, in some embodiments, the method may be implemented using one or more additional operations not described and/or without one or more of the operations discussed. Additionally, the order in which the process operations of the method are illustrated (and described below) is not intended to be limiting. In some embodiments, the methods may be implemented at least by one or more processing devices (e.g., a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and/or other mechanisms for electronically processing information). The processing device may include one or more devices that perform some or all of the operations of the described methods in response to instructions stored electronically on an electronic storage medium. The processing device may include one or more devices configured by hardware, firmware, and/or software to be specifically designed for performing one or more of the operations of the method.
In one embodiment, a defect associated with the object may be detected based on inspection data associated with the scan of the object (14002). For example, the scan may be performed after an operation performed on the object using a first set of input parameters (e.g., welding parameters, coating parameters, or other input parameters). Inspection data may be obtained from the field system, where the inspection data may include laser inspection data, camera inspection data, x-ray inspection data, gamma ray inspection data, ultrasonic inspection data, magnetic particle inspection data, eddy current inspection data, temperature inspection data, or other inspection data. In accordance with one or more embodiments, operation 14002 may be performed by an object contour subsystem that is the same as or similar to object contour subsystem 13732.
In one embodiment, an operation protocol associated with an operation type of an operation (performed on an object using a first set of input parameters) may be generated (14004). For example, the operating protocol may be generated such that the operating protocol includes a second set of input parameters that is different from the first set of input parameters (e.g., for performing operations that may cause defects). For example, in one use case, a first set of input parameters and inspection data may be analyzed to determine which parameters are likely to cause a defect, and those parameters may be modified (determined to be likely to cause a defect) to generate a second set of input parameters for the operating protocol. After generation, the operation profile may be stored in a database (e.g., an operation protocol database or other database) for subsequent operations. In accordance with one or more embodiments, operation 14004 may be performed by an operating protocol subsystem that is the same as or similar to operating protocol subsystem 13736.
In one embodiment, an operating protocol may be selected for performing a subsequent operation similar to the operation performed on the object using the first set of input parameters (14006). For example, if the previous operation was a welding operation for a root pass, the subsequent operation may also be a welding operation for a root pass. As another example, if the previous operation was a welding operation for a hot aisle, the subsequent operation may also be a welding operation for a hot aisle. In accordance with one or more embodiments, operation 14006 may be performed by an operating protocol subsystem that is the same as or similar to operating protocol subsystem 13736.
In one embodiment, data related to performing a subsequent operation may be generated based on at least one parameter of the operating protocol (14008). In accordance with one or more embodiments, operation 14008 may be performed by an operations manager subsystem that is the same as or similar to operations manager subsystem 13734.
In one embodiment, the operation-related data may be transmitted to the field system to cause the field system to perform a subsequent operation, wherein the subsequent operation is performed based on the operation-related data (14010). In accordance with one or more embodiments, operation 14010 may be performed by an operations manager subsystem that is the same as or similar to operations manager subsystem 13734.
FIG. 141 illustrates a flow diagram of a method 14100 for facilitating field testing and physical operations based thereon by a computer system, in accordance with one or more embodiments. The process operations of the methods presented below are intended to be illustrative and non-limiting. For example, in some embodiments, the method may be implemented using one or more additional operations not described and/or without one or more of the operations discussed. Additionally, the order in which the process operations of the method are illustrated (and described below) is not intended to be limiting. In some embodiments, the methods may be implemented at least by one or more processing devices (e.g., a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and/or other mechanisms for electronically processing information). The processing device may include one or more devices that perform some or all of the operations of the described methods in response to instructions stored electronically on an electronic storage medium. The processing device may include one or more devices configured by hardware, firmware, and/or software to be specifically designed for performing one or more of the operations of the method.
In one embodiment, a quality of one or more aspects of an object may be determined based on inspection data associated with a scan of the object (14102). For example, the scan may be performed after an operation performed on the object using a set of input parameters (e.g., welding parameters, coating parameters, or other input parameters). Inspection data may be received from the field system, where the inspection data may include laser inspection data, camera inspection data, x-ray inspection data, gamma ray inspection data, ultrasonic inspection data, magnetic particle inspection data, eddy current inspection data, temperature inspection data, or other inspection data. In accordance with one or more embodiments, operation 14102 may be performed by an object profiling subsystem that is the same as or similar to object profiling subsystem 13732.
In one embodiment, in response to the quality exceeding a quality criterion (indicated by a predefined quality profile), an operation protocol (14104) associated with an operation type of the operation (performed on the object using the set of input parameters) may be generated. For example, the operating protocol may be generated such that the operating protocol includes one or more parameters of the set of input parameters (for performing the operation). As another example, the operating protocol may be generated such that the operating protocol includes all of the set of input parameters. After generation, the operation profile may be stored in a database (e.g., an operation protocol database or other database) for subsequent operations. In accordance with one or more embodiments, operation 14104 may be performed by an operating protocol subsystem that is the same as or similar to operating protocol subsystem 13736.
In one embodiment, an operating protocol may be selected for performing a subsequent operation (14106) similar to the operation performed on the object using the first set of input parameters. In accordance with one or more embodiments, operation 14106 may be performed by an operating protocol subsystem that is the same as or similar to operating protocol subsystem 13736.
In one embodiment, data related to performing a subsequent operation may be generated based on at least one parameter of the operating protocol (14108). In accordance with one or more embodiments, operation 14108 may be performed by an operations manager subsystem that is the same as or similar to operations manager subsystem 13734.
In one embodiment, the operation-related data may be transmitted to the field system to cause the field system to perform a subsequent operation, wherein the subsequent operation is performed based on the operation-related data (14110). In accordance with one or more embodiments, operation 14110 may be performed by an operations manager subsystem that is the same as or similar to operations manager subsystem 13734.
FIG. 142 illustrates a flow diagram of a method 14200 for facilitating field testing and physical operations based thereon by a computer system in accordance with one or more embodiments. The process operations of the methods presented below are intended to be illustrative and non-limiting. For example, in some embodiments, the method may be implemented using one or more additional operations not described and/or without one or more of the operations discussed. Additionally, the order in which the process operations of the method are illustrated (and described below) is not intended to be limiting. In some embodiments, the methods may be implemented at least by one or more processing devices (e.g., a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and/or other mechanisms for electronically processing information). The processing device may include one or more devices that perform some or all of the operations of the described methods in response to instructions stored electronically on an electronic storage medium. The processing device may include one or more devices configured by hardware, firmware, and/or software to be specifically designed for performing one or more of the operations of the method.
In one embodiment, one or more operations performed on one or more objects may be monitored (14202). In accordance with one or more embodiments, operation 14202 may be performed by an operation monitoring subsystem that is the same as or similar to operation monitoring subsystem 13738.
In one embodiment, data related to the observation of the operation may be obtained based on the monitoring (14204). For example, observation-related data may include data related to observations of one or more field devices during performance of an operation, observations of objects during performance of an operation, observations of environmental conditions during performance of an operation, or other observations. In accordance with one or more embodiments, operation 14204 may be performed by an operation monitoring subsystem that is the same as or similar to operation monitoring subsystem 13738.
In one embodiment, one or more sets of observations of an operation (performed on one or more objects determined to have a defect) may be compared (14206) with one or more other sets of observations of the operation (performed on one or more other operations that do not have a defect). In accordance with one or more embodiments, operation 14206 may be performed by an operating protocol subsystem that is the same as or similar to operating protocol subsystem 13736.
In one embodiment, one or more common differences between the set of observations (corresponding to defective objects) and the other set of observations (corresponding to objects that are not defective) may be determined based on the comparison (14208). In accordance with one or more embodiments, operation 14208 may be performed by an operating protocol subsystem that is the same as or similar to operating protocol subsystem 13736.
In one embodiment, one or more operational triggers may be implemented based on a common difference (14210). For example, after implementing an operation trigger based on one of the common differences, the operation trigger may cause the associated operation to be performed when a condition corresponding to the common difference occurs in a subsequent operation. In accordance with one or more embodiments, operation 14210 may be performed by an operating protocol subsystem that is the same as or similar to operating protocol subsystem 13740.
In one embodiment, a universal cloud recording system (also referred to herein as "uog" or "uog system" or "uCloud") is a system that seamlessly collects welding data to provide quality control and management, welding data recording, task and project management, security and inspection control and management, real-time welding activity monitoring and data reporting, and visualization of software, hardware, equipment, and telecommunications networks. The uog 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 uog system may use software technology, mobile device and desktop computer technology, telecommunications technology, and other technologies in products, equipment, systems, processes, and methods to achieve high quality welding, inspection, control, management, and security results. The uLog system may be used onshore, offshore, vessel-based, platform-based, structure-based, or other construction conditions. In an embodiment, the uLog may process bluetooth communications and data may be transmitted to the uLog for processing by bluetooth or any other wireless means.
In an embodiment, the uLog has tools to seamlessly collect weld data and/or weld data logs. The uLog system may use welding data and other pipeline configurations and related data in its many and varied embodiments to produce one or more of the following: analysis results, field reports, control data, quality control data, automatically generated regulatory reports, daily summaries, data archiving, welding records, material usage data, quality control records, and project management records.
In embodiments, the uLog may be used to maintain and/or generate process assessment records ("PQR") and data related thereto. The uLog function may also be used to document, develop, maintain, and manage welding process specifications ("WPS").
The uog may enable a user to view, record, track, measure, and analyze log data regarding one or more welding and/or welding activities and/or pipeline configuration and/or coating activities and/or inspection activities and/or management activities. By using the uLog and its analysis functions, the user can achieve improved weld quality and assess the welding process results. In many and varied implementations thereof, the uog may have the functionality to process data in real time or based on historical data. This allows the user to make decisions in real time and/or based on historical data. In embodiments, the uLog may provide real-time data to a user regarding any aspect of welding, coating, inspection, pipe handling, project management, pipeline configuration, and/or configuration activities in progress, and enable real-time quality control welding and/or welding activities and/or other activities related to pipeline configuration. In another embodiment, the uLog may also provide functionality relating to construction management, project management, billing, inventory and material management, and financial control and auditing of both finance and materials. The uLog may also provide functionality relating to human resource management and time logging, as well as salary accounting and support.
Without limitation, various embodiments of the present disclosure may be implemented, for example, as a computer system, method, cloud-based service, or computer program product. Accordingly, various embodiments may take the form of an entirely hardware embodiment, an entirely software embodiment (e.g., one or more computer applications to be implemented on a mobile device, such as an "App" (or "App") and/or an application to be implanted on a desktop computer), or an embodiment combining 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) embodied in the storage medium. Various embodiments may take the form of web-implemented computer software. Any suitable computer readable storage medium may be utilized including, for example, hard disks, compact disks, DVDs, optical storage devices, solid state storage devices, and/or magnetic storage devices.
Various embodiments are described below with reference to schematic, block, image, and flowchart illustrations of methods, apparatus (e.g., systems) and computer program products. It will be understood that each block of the block diagrams and flowchart illustrations, and combinations of blocks in the block diagrams and flowchart illustrations, respectively, can be implemented by computer program instructions. These computer program instructions may be loaded onto a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions which execute on the computer or other programmable data processing apparatus create means for implementing the functions specified in the flowchart block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture that can be configured to implement the function specified in the flowchart block or blocks. The computer program instructions may also be loaded onto 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 such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart block or blocks.
Accordingly, blocks of the block diagrams and flowchart illustrations support combinations of means for performing the specified functions, combinations of steps for performing the specified functions and program instructions for performing the specified functions. It will also be understood that each block of the block diagrams and flowchart illustrations, and combinations of blocks in the block diagrams and flowchart illustrations, can be implemented by special purpose hardware-based computer systems that perform the specified functions or steps, or combinations of special purpose hardware and other hardware that execute suitable computer instructions. But also by dedicated software and devices running dedicated software and/or applications. The entire system may be accessible from a variety of computer platforms, including mobile devices.
FIG. 143 includes an image of a land-based pipeline. The uLog can be used for the manufacture of any pipeline in any construction environment. The construction environment may be onshore, offshore, both onshore and offshore, underwater, subsea, on a factory, on a vessel, on a barge, on a platform, on a structure, in space, or in any other construction environment. For example, uog may be used for control of pipeline welding.
Fig. 144 shows a weld station 14410 according to an embodiment of the disclosure. The uLog may be used in conjunction with the weld station 14410. The uLog may process data from the weld station 14410. The welding station may include a welding machine or welding system 14412, a welder 14414, or an automated or robotic welding system. In an embodiment, the welding machine or welding system 14412 is an orbital welding machine. An example of a welding machine or welding system 14412 is described in U.S. patent No. 3,974,356 to Nelson et al, 8/10 1976, the entire contents of which are incorporated herein by reference in their entirety. The welding station 14410 may be controlled by a computer system 14416 to control the welding process and also to obtain data regarding the welding process. The uLog implemented on computer system 14416 may control a welding station 14410 including welding machine 14412, and may also process data from a workpiece 14418, such as a pipe, and/or regarding work or welds applied to a workpiece (e.g., a pipe) 14418.
Diagram 145 shows a plurality of line welding stations 14410 (line welding extensions 14420) according to an embodiment of the present disclosure. The uLog may be used on the pipeline weld extension 14420. The uLog may process data from one or more welding stations 14410 in the pipeline weld extension 14420. In an embodiment, the uLog may process data from a number or number of weld stations 14410. There is no limitation on the position of the welding stage 14410. Line 14418 may be very long and one or more stations may be located anywhere without limitation. Further, the uog supports simultaneous processing of data from multiple projects and/or activities and/or tasks and/or people. The uLog user experts may be used across projects and may also be used within projects. The uLog allows a user to work on data from one or more projects simultaneously or sequentially, in real time, or based on history.
FIG. 146 is a schematic diagram of a system having multiple welding stations 14410 in communication with multiple control and log collection stations (computer systems) 14416, according to an embodiment of the present disclosure. In an embodiment, welding data may be collected at log collection stage 14416 associated with welding stage 14410. The control and log collection stage 14416 may process data for one or more welding and/or welding stages 14410. Data collection and/or processing may begin with the pipeline configuration, welding station equipment, operators, welders, or other data entry means. In non-limiting embodiments, device processors, embedded processors, computers, sensors, process control devices, wired or wireless analog and digital devices, and handheld data processors may be used to collect, transmit, and/or process welding station and/or welding system data. In an embodiment, one or more technicians may control the welding stage 14410 and the control and log collection stage 14416. There is no limit to the number of log collection stations 14416 that can be used with a uLog. The log collection stage 14416 is used with the welding stage 14410 in the welding system 14422.
FIG. 147 is a schematic diagram of a system having a plurality of welding stations 14410 in communication with a plurality of control and log collection stations 14416 according to another embodiment of the present disclosure. In an embodiment, welding data may be collected from each welding station 14410 or welding system 14422. In another embodiment, welding data may be collected from multiple welding stations or welding systems 14410. There is no limit to the number of welding stations 14410 and/or welding systems 14422.
Fig. 148 is a schematic diagram of a welding station 14410 communicating with a wireless network 14424 via a wireless connection (e.g., WiFi connection) 14426, according to an embodiment of the disclosure. For example, the welding station 14410 may be equipped with wireless communication capabilities, such as bluetooth, WiFi, cellular communication, satellite phone, or other wireless means. By way of non-limiting example, the welding station 14410 may have one or more of a welding process computer, server, or processing unit 14416 that may collect and process welding system data. As shown in fig. 148, the welding station 14410 includes two welding machines or welding systems 14412. In an embodiment, the welding system 14412 includes an orbital welding system. One of the welding machines 14412 is a Clockwise (CW) welding machine or system and the other welding machine 14412 is a counterclockwise (CCW) welding machine or system.
Fig. 149 is a schematic diagram of a plurality of job sites 14430 communicating with a cloud server 14432 over a global network (internet) according to an embodiment of the present disclosure. The uLog may be configured based on local, regional, project, or global scope. There are no geographical limitations to the implementation of uog. One or many job points 14430 may be networked with uLog. In an embodiment, users, staff, managers, engineers, departments, companies, experts, workers, customers, and many others may be networked to the uLog. Each job site 14430 includes a welding bench 14410 that is operated by a welding worker 14414 (shown in fig. 144), a mentor 14434, and a welding engineer 14436. Each job site 14430 is configured to communicate with cloud servers 14432 through a dedicated communication line or communication channel 14440 or through the internet 14442. Cloud server 14432 is accessible by system administrator 14438 and engineer 14439. A storage 14433 in communication with the cloud server may be provided for storing welding data.
The diagram 150 is a schematic diagram of a plurality of welding stations 14410 in communication with an intermediary computing device 14450 operated by a technician (referring to the technician 14452, the inspector 14454, the engineer 14456, etc.) via a communication channel or communication line 14458, according to an embodiment of the present disclosure. For example, each welding station 14410 may communicate with one or more of the intermediate computing devices 14450. Similarly, each intermediate computing device 14450 is configured to communicate with one or more of the welding stations 14410. The intermediary computing device 14450 is, in turn, configured to communicate with a cloud server 14432 over the internet 14442. Portions of the uLog program are configured to run on cloud server 14432, other portions of the uLog program are configured to run on intermediate computing device 14450, and yet other portions are configured to be implemented on welding station computer/server 14416. Each part or component of the uog operates in conjunction with other parts or components to provide seamless management of the overall system. In an embodiment, the uLog may optionally have differentiated global network capabilities and propagation network capabilities. In another embodiment, all capabilities are fully integrated; and in yet another embodiment, all capabilities may be indifferent.
FIG. 151 is a schematic diagram of a plurality of welding stations 14412 communicating with an intermediate computer system 14450 (operated by an engineer, quality and technical terminal) through a wireless (e.g., WiFi) communication channel 14426 to a wireless communication network 14424, according to an embodiment of the present disclosure. The intermediary computer system may be any type of computing device for implementing data entry, processing, transmission, input, output, and other functions, including a tablet, a telephone, a smart phone, a PDA, and/or other wireless device. The intermediate computer runs the uLog program and may be operated by engineers, quality controls, users, supervisory technicians, and others. In an embodiment, a uLog running at an intermediate computer 14450 coordinates the welding station computers 14416 located at each welding station 14410 to provide data, process data, and transmit data or information.
Fig. 152 is a schematic diagram of a plurality of welding stations 14410 communicating with an intermediate computer system 14450 through a wireless (e.g., WiFi) communication channel 14426 into a wireless communication network 14424, according to an embodiment of the disclosure. Fig. 152 shows an extended network configuration. The intermediate computer system 14450 has wireless capabilities, such as WiFi or cellular (3G, 4G, etc.), allowing it to communicate wirelessly with any of the welding stations 14410. The intermediate computer 14450 may be any type of mobile wireless device, such as a smartphone, tablet, or PDA, that may connect anywhere in the wireless network 14424. In an embodiment, the uLog program or system may use a mesh network to process data through a mesh wireless (e.g., WiFi) network 14424. For example, the welding station server 14416 of the welding station 14410 may communicate with the uLog device 14450 through the mesh wireless network 14424 and may connect anywhere within the mesh network 14424. In an embodiment, mesh networking may be used in an extended network configuration.
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 engineers 14456, inspector 14454, lead technician 14452, etc.), which in turn are in communication with a cloud server 14432, according to an embodiment of the present disclosure. Fig. 153 shows a data flow diagram of the overall network configuration. In an embodiment, the overall network configuration may be a global network configuration. The overall network configuration may be used by managers, engineers, inspectors, mechanics, lead mechanics, welding engineers, welders and welding stations, among others. In embodiments, the uLog overall network configuration may optionally have global network capabilities and differentiated data flows that extend network capabilities. In another embodiment, all capabilities are fully integrated without differentiation. For example, similar to the configuration shown in diagram 150, each welding station 14410 may 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 intermediary computing device 14450 is, in turn, configured to communicate with a cloud server 14432 over the internet 14442. Portions of the uLog program are configured to run on cloud server 14432, other portions of the uLog program are configured to run on intermediate computing device 14450, and yet other portions are configured to be implemented on welding station computer/server 14416. Each part or component of the uLog program or system operates in conjunction with other parts or components to provide seamless management of the overall system. In an embodiment, the uLog may optionally have differentiated global network capabilities and propagation network capabilities. In another embodiment, all capabilities are fully integrated; and in yet another embodiment, all capabilities may be indifferent.
Diagram 154 illustrates an exemplary graphical user interface ("GUI") of a "home screen" 14460 of a cloud-based universal data log (uLog) application implemented by a computer system at a welding station 14410, at an intermediate computer system 14450, or at a cloud server 14432, according to embodiments of the present disclosure. In embodiments, the uLog provides a variety of features for data retrieval, data analysis, data analytics, data mining, data logging, and reporting. GUI 14460 includes a plurality of icons 14461-14468. Each icon when activated (e.g., by a mouse click or by finger touch) opens an application. For example, icon 14461 is associated with application management configured to be operated by a manager for setting administrative features of the uLog. Icon 14462 is associated with a welding parameter configured for inputting the welding parameter. Icon 14463 is associated with the function "log". Icon 14464 is associated with the function "report". Icon 14465 is associated with the function "job settings". Icon 14466 is associated with the function "analytics". Icon 14468 is associated with uploading and saving data on the cloud (i.e., saving data on cloud server 14432 or storage 14433). Thus, as can be appreciated, the uLog universal logging functionality can include, but is not limited to, processing data and information about: management, welding parameters, logs, records, reports, job settings, inspections, quality control, painting, pipe handling, user and/or management diagnostics, analytics, and data for local processing and/or processing by cloud-based means.
The scope of the present disclosure encompasses methods and means for implementing the disclosed pipeline welding and construction support, and encompasses any article of manufacture, product, means, and method for producing and using any software, application, computer-executable code, programming, logic sequence, or other form of electronic or automated means to implement and/or use the methods herein. Such articles of manufacture, and means include, by way of example and not limitation, software application products provided on a fixed medium such as a magnetic disk, or in physical memory, or in a memory stick, or as a software application product, or as an application provided for digital download, or provided by other means. This application expressly encompasses installed, uninstalled, compiled, and uncompiled versions of any software product or equivalent product that can be used, implemented, installed, or otherwise activated to use, implement, and/or practice the methods disclosed herein. Except in its conventional and customary sense, reference to "computer-readable program code means" is intended to be broadly construed to cover any kind and type of computer-readable program code, executable code, software-as-a-service, web service, cloud service or cloud-based process that can be employed to manufacture, use, sell, implement, participate in, generate, run, or operate the methods disclosed herein, embedded applications, applications provided on a fixed medium such as a disk or in physical memory or in flash memory or in a memory stick or as a software application product or as a digital download, or software application products provided on programmable hardware, or other devices. The present application should be construed broadly and not limited to any delivery device or any form of product that provides or uses, implements and/or practices the computer readable program code products, means and/or methods disclosed herein. In embodiments, all methods herein may be generated and provided to a user as a software product, software application, computer-readable program code means, or any other article of manufacture or device that may be used to implement any, some, or all of the results, calculations, and/or numerical methods disclosed herein.
In an embodiment, a user may set up a job locally or in the cloud. In the cloud-based example, the user may use and/or inherit the job-related information from the cloud for retrieval by or push to the user's device and or machine (e.g., computer 14416 associated with welding machine 14412). Setting up a job on or through the cloud can activate device 14416 to inherit job-related information from the cloud for pushing to the device and/or machine 14416. In another embodiment, the uLog provides a single point of data integrity maintenance. Machine-to-cloud (M2C) and cloud-to-machine (C2M) data storage and retrieval are also functions provided by uCloud.
In an embodiment, a centralized location may be used in which details of a job client may be automatically entered, processed, and maintained or retrieved by the uLog. The uLog may also use a distributed approach for data management and processing. The uLog may create and connect job specific parameter files to be deployed on jobs managed with proper authorization with assigned user privilege levels. This job-related information may be inherited by the assigned user and pushed to a computer 14416 (cloud-to-machine; "C2M") associated with the welding machine 14412. Changes made to job-related information are collected from computers 14416 associated with the welding machine 14412 and synchronized (synchronized) back (machine to cloud; "M2C") to the cloud (i.e., cloud server 14432). Cloud server 14432 provides a single point where the uLog processes some or all of the data.
The uog may process, record, analyze, and use data from one, more, or all of the following types of devices: welding machines, pipe bending apparatus, pipe handling apparatus, end preparation apparatus, clamps, bedding and/or crushing apparatus, dual coupling apparatus and/or systems, weighing apparatus and/or systems, conveying apparatus and/or systems, pipelaying (1 aycage) apparatus and construction/management systems. The uLog may also be or work with an Enterprise Resource Planning (ERP) system.
The uog may use and/or process data from any one or more of the following types of welding equipment. Such welding equipment may be, for example but not limited to: manual welding equipment, automatic welding equipment, external welding machines, internal welding machines, single torch welders, dual torch welders, multi torch welders, high throughput welding systems, inspection systems, internal inspection systems, external inspection systems.
The uog may use and/or process data for any one or more of the following types of elbow devices: the pipe bending machine comprises a pipe bending machine, a wedge-shaped mandrel, a hydraulic wedge-shaped mandrel, a plug mandrel, a hydraulic plug mandrel, a pneumatic mandrel and a pneumatic wedge-shaped mandrel. The uog may use and/or process data from any one or more of the following types of pipeline processing equipment:
Figure BDA0002971521410003121
Devices (CRC-Evans corporation, houston, texas), vehicles, construction vehicles, and devices adapted to generate data for use or processing. The uog may use and/or process data from any one or more of the following types of devices: bend kits and dies, angle measurement devices and apparatus, compressors, supports, hangers and/or supports, degaussing devices, tires, wheels, and track wheels.
The uog may use and/or process data from any one or more of the following types of devices: an end preparation station for enlarging a platform on a pipe bevel, an alignment station for pipe alignment and external welding, a cap filling station for applying an external weld cap, an internal welding station for applying an internal weld, a powered trailer or vessel with a diesel generator and weld rectifier, a pipe skid and support for inter-station transfer pipes, an internal pneumatic alignment fixture and pipe butt machine, a sub-arc welding machine, and a processing apparatus.
The uog may also use and/or process data from any one or more of the following types of devices: pipelaying equipment, pipeline handling, double coupling, combination coating equipment, onshore equipment, offshore equipment, deepwater equipment, shallow water equipment, roller units, conveyors, pipeline transfer equipment, support frames, support units, roller modules, longitudinal conveyor roller modules, pipeline elevators, pipeline supports, roller-type pipeline supports (PSA and PSF), pipeline transfer carriages, PTC-V pipeline transfer carriages, stern tube supports, adjustable height pipeline supports, SPSA roller-type stern tube supports, TPSA rail-type pipeline supports, cross-conveyors, walking beam-type conveyors, and TV-C-W cross-conveyors.
The uog may use and/or process data from any one or more of the following types of processes and methods: welding, pipe welding, pipeline welding, coating, co-coating in-situ, inspection, quality assurance, non-invasive testing, heat treatment, management, marine management, onshore management, managed service, welding support, spool base management, and microalloying.
In an embodiment, the uLog may be used to deploy daily job statistics from the cloud and from the mobile device. Creation of PQR and/or WPS and/or daily reports may be done from the mobile platform and/or on the cloud or by other means. Analyzing the collected data on the cloud and mobile device provides feedback to the control system to improve quality and defect prediction. In an embodiment, the uLog provides an integrated pipe coupling marker, synchronized with the data log. The uLog may also use a single point capture of data logs, provide machine setup information, and handle software corrections.
The uLog may also perform automatic error reporting of machine state, automatic time stamping of job locations on job records, and performing synchronized capture of job-related parameter change annotations from all users for a given project. In addition, the uLog can also generate a unified report of project-related data from a single point to the customer.
Fig. 155 illustrates an exemplary GUI of a "field log" screen displaying an application of cloud-based universal data logging (uLog) of voltage versus time at one welding station, according to an embodiment of the disclosure. In an embodiment, the uLog performs centralized data capture of data from all pipe welding processes, coating related machines, and performs centralized data capture of each type of data related to such machines and activities. A summary of the current site activity for welding, coating and inspection may be generated. Reporting various parameters in a table, the parameters including: event number, timestamp, area identification, inclination of the welding device or welding system, travel speed of the welding device, lead volt or voltage applied to the wire, lead ampere (a) or current applied to the wire, lead speed or wire speed, etc. For example, various parameters including lead wire speed (i.e., wire speed) and welding device speed (travel speed), among other parameters, may be reported in tabular and/or graphical form. In addition, the voltage applied to the wire may also be displayed in a table and/or as a graph versus time.
Optionally, uLog may support electronic signing of PQR/WPS documents. Optionally, the uLog may handle system parameter versioning and rollback. In an embodiment, the uLog also has functionality for deploying daily job statistics from the cloud and/or mobile device. For non-limiting embodiments, the uLog may perform data management and may provide a report to the user regarding the number of welds completed over a given period of time (e.g., hourly, daily, weekly, etc.), and may report the amount or other measurements of consumables (e.g., welding material) used over a given period of time (e.g., hourly, daily). The uLog may also generate job and error reports.
In an embodiment, the uLog may send an email and/or SMS (text message) or other notification to the appropriate regulatory body. The uLog may also be used for financial functions, accounting audits, time logging, and other administrative tasks. For example, the uLog may provide invoices to customers in a timely manner. In embodiments, invoices may be generated based on the number of welds or based on the use and/or waste of consumables. The uLog provides a rating system and supports efficient invoicing and billing for pipeline welding projects.
The uLog may also be used to automatically re-supply materials and/or equipment and/or other resources or inventory related to the project. Many and varied functions of the uLog disclosed herein can reduce job interruptions, downtime, waste, and other negative occurrences during construction.
Fig. 156 illustrates an exemplary GUI of an "acquire log" screen of an application displaying a cloud-based universal data log (uLog) of welding data parameters including welding event type, time, area, welding travel speed (travel speed of welding system), wire travel speed (wire speed), according to an embodiment of the present disclosure. Graph 156 shows various parameters reported on the table, including: a weld identification or type number, an event number, a timestamp, a zone identification, a slope of the welding device or welding system, a travel speed of the welding device, a lead volt or voltage applied to the wire, a lead ampere (a) or current applied to the wire, and a lead speed (speed of the wire). In an embodiment, the uog may automatically timestamp the job location on the job record. In other embodiments, the data log may be time stamped and may reflect a time zone, as shown in the table depicted in the diagram 156. Timestamps can be synchronized from GPS and/or based on data presented and/or pushed to the uLog so that the log reflects the time zone in which they were captured.
Fig. 157 illustrates an exemplary GUI of an abstract reporting screen displaying an application of a cloud-based universal data record (uLog) including various welding parameters of welding time, welding station identification number, welding arc voltage, and the like, according to an embodiment of the present disclosure. In an embodiment, the uLog may create and/or generate PQR and/or WPS and/or summary reports and/or daily reports that are all done from the mobile platform and on the cloud. The PQR, WPS, summary and daily reports may be generated manually or automatically. The uLog may generate one, more, or all of these types of reports on a scheduled, temporary, or simultaneous basis. The uog provides the benefit of handling generic and consistent data. Reports may be generated at the same or different locations and/or output devices using the same collected data.
The reported rule may be established on the uog, and may be configurable. In an embodiment, the key data for a given item may be synchronized on the cloud. The uLog supports the creation of project rating binders that will be sent to the user and/or the user's client and/or other recipients at the end of an approved electronic signature-attached rating process. The uLog reduces the time and expense of creating these reported and approved documents.
Fig. 158 illustrates an exemplary GUI of a "save data on log" screen of an application displaying various cloud-based universal data records (ulogs), according to an embodiment of the present disclosure. The uLog provides a data storage service of unlimited nature. Pipeline construction is global and its items may be geographically dispersed. In addition, pipeline construction may be performed in harsh environments and climates. The uLog allows data from anywhere a user and/or device may be located to be stored and protected. The data may also be synchronized or otherwise processed. For example, data may be saved to the cloud from jobs, logs, welding stations, welding parameters, reports, and job locations. In embodiments, location data may be saved in addition to technical and/or administrative data.
Fig. 159 illustrates an exemplary GUI of an "analytics" screen of an application displaying a cloud-based universal data record (uLog) for selecting two icons of the type of analysis performed (e.g., trend, moving average), according to an embodiment of the present disclosure. In embodiments, the uLog analysis may process and provide data trends, moving averages, and/or any type of data processing desired by the user. In an embodiment, the uLog may have a pipeline data cloud recording, reporting, and analysis system. For example, analytics may be implemented on the collected data to provide feedback to the control system to improve the quality and fault prediction of welding and/or construction equipment, activities, and operations. In an embodiment, data may be collected through the cloud and/or one or more mobile devices. In an embodiment, the uLog supports the simultaneous capture of job-related parameter change annotations from all users for a given project. In another embodiment, the uog may monitor, analyze, and report current field activity and provide field summary data and summary reports of welding, coating, and inspection activities. The uog system may perform system parameter versioning and rollback. The uog system may also enable single point capture of data logs, machine setup information, and software corrections. In yet another embodiment, the integrated pipe coupling marker may be implemented and synchronized with the data log.
Fig. 160 illustrates an exemplary GUI of a "welding parameters" screen displaying an application of a cloud-based universal data record (uLog) for two various mechanisms for selecting a type of function to be performed (e.g., obtain Welding Parameters (WP), set Welding Parameters (WP), view welding parameters WP..), according to an embodiment of the present disclosure. In embodiments, the uog cloud-based record may perform any of the following activities and/or processes: obtaining welding parameters, setting welding parameters, viewing and processing welding parameter annotations, viewing and processing welding parameter transfers, and rolling back welding parameters. In embodiments, the uLog may comprise any, multiple, or all of the following: pipeline mile reward function, pipe mile function, uLog function, M2C function, and C2M function.
If a welder changes the wire spool too quickly before most of the wire is consumed, the welder or welding technician may waste wire. Furthermore, if the spool runs out of wire during the welding process, the welding process may be interrupted, resulting in downtime and defect repair. One way to address these problems in the present embodiment is to rely on the wire feed motor speed to determine the wire speed and, therefore, the length of wire consumed over a period of time. However, this approach may introduce errors due to slippage or incorrect starting weight of the wire on the wire feed motor wheel. Therefore, determining the length of the line based on the motor speed may not be accurate. In addition, an incorrect starting weight may result in the user believing that there is sufficient wire in the spool for performing the weld (e.g., if the initial or starting weight is overestimated), while in fact the amount of wire remaining in the spool is insufficient to complete the weld. To address this deficiency, the device is used to measure the weight of the wire spool in real time while the motor is pulling the wire. By measuring the weight of the spool, the user or welder can determine whether enough wire remains in the spool to complete the weld before starting the weld. Thus, the weight of the wire can be determined at all times, which substantially eliminates uncertainty due to spool slippage or unknown starting weight. Further, the weight may be compared to the wire feed speed to determine if the wire is fed at a preset speed.
Fig. 161A schematically depicts an example of wire spool 14480 configured to carry wire in accordance with an embodiment of the present disclosure. Fig. 161B schematically depicts a side view of hub transducer 14482 configured to measure the weight of spool 14480, according to an embodiment of the present disclosure. Fig. 161C depicts another side view of the hub transducer showing the positioning of the transducer element or strain sensor/strain gauge 14484 measuring weight strain when spool 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 the hub 14482, the weight of the spool will exert a force on the shaft 14482A of the hub 14482, which in turn exerts a strain on the lateral hub 14482B. A strain sensor 14484 is provided on the lateral hub 14482B to sense the strain imposed by the weight of the spool. An example of a strain sensor that may be used to measure strain is a piezoelectric element. The strain sensor 14484 converts the strain force into a measured voltage. Thus, by measuring the voltage, the weight of spool 14482 can be determined. In an embodiment, a temperature sensor (not shown) may be provided in the hub and positioned to capture the temperature of the hub in order to apply corrections to the strain sensor measurements for a wide temperature range.
Diagram 162 schematically depicts an arrangement in which motor assembly 14490 pulls a weld line 14486 in wire spool 14480 mounted to hub 14482 for feeding line 14482 to a welding device (not shown), according to an embodiment of the present disclosure. Wire 14486 is pulled by motor assembly 14490. In an embodiment, the rotational speed of the motor assembly (used to determine wire speed) may be measured by sensor 14492. In an embodiment, the motor assembly uses a motor with sufficient rotational speed (revolutions per minute or RPM measured by sensor 14492) to achieve a desired feed rate of wire to the welding device. In another embodiment, the rotation of the motor assembly may be varied according to the desired wire feed (wire speed) speed as measured by sensor 14492. Motor assembly 14490 is configured to supply or feed wire 14486 to welding device 14500 for welding work piece 144101 (e.g., a pipe, etc.). The speed of the welding device 14500 is measured by a speed sensor 14502. Speed sensor 14502 is also configured to measure various parameters of the weld or weld data.
Fig. 164A and 164B depict enlarged side cross-sectional views of motor assembly 14490 according to embodiments of the present disclosure. As shown, the motor assembly includes a motor 14491 and a feed wheel 14493. The motor 14491 engages the feed wheel 14493 to rotate the feed wheel 14493. Motor assembly 14490 also includes a nip roller 14495, which nip roller 14495 contacts feed wheel 14493. A tension spring 14497 is provided to bias the nip roller 14495 toward the feed wheel 14493. Lead 14486 is interposed between feed wheel 14493 and nip roller 14495. Thus, nip roller 14495 pushes wire 14486 such that wire 14486 contacts feed wheel 14493. Thus, rotation of feed wheel 14493 and nip roll 14495 as indicated by the arrow in FIG. 164B will theoretically translate into linear movement of line 14486 as indicated by the arrow. In an embodiment, gear teeth are provided on feed wheel 14493 to catch wire 14486 by friction and force wire 14486 to move. However, a situation may occur in which the line 14486 is not completely caught by the feed wheel 14493. In this case, the line 14486 may slip because although the feed wheel 14493 rotates, this rotation of the feed wheel 14493 is not translated into an accurate linear movement of the line 14486. This may occur, for example, when the cogs on feed wheel 14493 wear out (thereby not providing sufficient friction to catch wire 14486) or when nip roller 14495 wears out (thereby not applying sufficient pressure or force on wire 14486 to push wire 14486 against feed wheel 14493), or when tension spring 14497 loses its preload (thereby causing nip roller 14495 to not apply sufficient pressure or force on wire 14486), or when nut 14499 securing feed wheel 14493 is loosened (thereby causing the feed wheel to not catch wire 14486), or any combination thereof. As shown in fig. 164A, the motor assembly 14490 includes a speed sensor 14492, the speed sensor 14492 being configured and arranged to measure the speed of rotation of the motor 14491. An output 14498 is provided for inputting data into and outputting data from motor assembly 14490, the data including the speed of motor 14491. Data from the output 14498 is sent to a computer 14416 associated with the welding station 14410.
Fig. 165 is a diagram of a welding system configuration depicting the interconnection of various components of the system, in accordance with an embodiment of the present disclosure. As shown in fig. 165, the rotational speed of motor assembly 14490 is measured by a rotational speed sensor (RPM sensor) 14492. In addition, the weight of wire spool 14480 is measured by weight sensor 14484 in hub transducer 14482. The speed of the welding device 14500 is measured by a speed sensor 14502. All parameters or data measured by the rotational speed sensor 14492, weight sensor 14483, and speed sensor 14502 are input to the computer 14416 at the welding station 14410. In an embodiment, computer 14416 may be managed by an intermediary computer 14450. The intermediate computer 14450 may be a wireless device, such as a tablet, mobile device, smart phone, laptop, and the like. Thus, intermediate computer 14450 may access data at computer 14416, including data from RPM sensor 14492, weight sensor 14484, and speed sensor 14502. Intermediate computer(s) 14450 also communicate (e.g., wirelessly) with cloud server(s) 14432, where data from computer(s) 14416 may be stored and/or further processed. In embodiments of the present disclosure, no intermediate computer is used. In this case, computer 14416 is directly connected (e.g., wirelessly) to cloud server 14432.
As stated in the preceding paragraph, in some embodiments, due to potential slippage, the measurement of the speed of the motor assembly (e.g., the speed of feed wheel 14493) may not be sufficient to provide an accurate amount of wire used or consumed by the welding machine or system alone. In fact, even if the rotation of the feed wheel 14493 is accurately measured, the rotation of said wheel will theoretically translate into a movement and therefore a certain length. However, due to the slip, the wire is not moved, and therefore the length determined based on the rotation or rotational speed of the wheel does not correspond to the actual wire length. Thus, the weight of the wire spool can also be measured. In an embodiment, the weight of the new and unused spool is about 15kg (15000 grams). In an embodiment, the weight of the reel spool is measured with an accuracy of about 100 grams over 15000 grams, i.e. an accuracy of about 0.7%. Thus, the weight provides a relatively good measurement method of determining the amount of wire remaining in the wire spool. In an embodiment, the weight of the spool is periodically captured or measured and time stamped to record and transmit to the uLog each time the spool rotation stops. An indicator such as a buzzer or a light flashing may indicate to the welder that it is time to refill another spool. Further, in one embodiment, the welding machine may not perform a welding operation in such a case. The indicator may indicate a weight threshold at which a complete weld cannot be completed.
In an embodiment, an RF module is also provided to read the spool serial number, the manufacturing weight of the spool, the spool type, the item name, and any details fed on the RF tag mounted on the spool. This data can be passed over the cloud through the uLog with any additional necessary details. If the old spool is reused, the system compares the serial number to the database of spools already in use and extracts the last available weight from the cloud and compares it to the new weight reading before beginning operation. A buzzer or indicator light is available on the system to indicate to the operator that details on the RF tag have been read and transmitted over the CAN. Using an RF system would eliminate the need to track the number of spools used, their serial numbers, and further any manual accounting work required to identify the workstation at which these spools are used. If the wrong composition/diameter wire is delivered, the system can identify this from the RF tag properties, thereby alerting the operator to the deviation. This can be very imperceptible if the system is completely manual.
In an embodiment, the difference DW between the weight W1 measured at time T1 and the weight W2 measured at a later time T2 may be calculated. The weight difference DW (where DW ═ W1-W2) corresponds to the weight of the wire consumed during the welding process. This weight difference DW can be compared to the theoretical weight TW. The theoretical weight TW can be obtained using the rotational speed R of the motor or the linear speed S of the wire (the linear speed S depends on the rotational speed R). The theoretical weight TW may be calculated using the following equation (1).
TW (T2-T1) × S × (wire diameter) 2 × (density of wire material) × pi/4 (1)
It is assumed that the theoretical weight TW should be equal to the measured weight DW if there is no slip. On the other hand, if slippage occurs during the period between time T1 and time T2, the theoretical weight TW will be greater than the measured weight DW, in which case the ratio R between the theoretical weight TW and the measured weight DW is greater than 1(R ═ TW/DW > 1), and/or the difference Δ between the theoretical weight TW and the measured DW is greater than zero (Δ ═ TW-DW > 0). Thus, if after a certain period of time or a certain number of measurements, it is noted that a difference between the measured weight and the theoretical/calculated weight still exists, the speed of motor assembly 14490 may be adjusted or compensated so as to make the calculated/theoretical weight substantially equal to the measured weight. Thus, the measured weight is compared with the theoretical weight (determined from the wire feed speed) to determine whether the wire is fed at the preset feed speed. In one embodiment, this determination may be implemented locally on the welder side or by using a uLog system at cloud server 14432.
Fig. 163 is a flow chart depicting a process of comparing a measured weight to a theoretical weight determined based on a line feed speed, in accordance with an embodiment of the present disclosure. As can be appreciated from the above paragraph, the process begins at S10 with measuring a first weight W1 of the spool of wire at a first time (T1). The process further includes measuring a second weight W2 of the spool at a second time T2 after a certain time elapses from the time T1 (T2 > T1) at S12. The process also includes, at S14, calculating a difference between the first measured weight W1 and the second measured weight at time T2. The process includes calculating a theoretical weight based on the line feed speed at S16. At S18, the theoretical weight based on the wire feed speed is compared to the calculated weight difference, and if the theoretical weight is greater than or less than the calculated weight difference is processed at S18, the speed of the motor assembly pulling the wire is adjusted at S20. After adjusting the speed of the motor assembly, the process is repeated after another increment of time. If the theoretical weight is the same as the calculated weight difference, the process is repeated without adjusting the speed of the motor assembly, also after another time increment. This process is repeated at a plurality of time increments in order to monitor and/or correct for any potential slippage of motor assembly 14490.
This process may be implemented locally by a uLog system at computer 14416 associated with the welding station 14410, or by a uLog system at cloud server 14432, or by a uLog system at intermediary computer 14450 described in the paragraphs above.
In an embodiment, it may be desirable to monitor the use of wires at different welding stations 14410 to assess the overall efficiency of the welding system. This would allow, for example, predictive indication of the amount of reels needed on a large project based on prior knowledge. For example, the use of the reel may be uploaded to the uLog system for storage and processing by cloud server 14432. For example, each of welding stations 14410 may upload usage data for the wire spool to the uog system to a cloud server using the previously described network configuration, and based on historical usage of the spool amount of wire spool and using Machine Learning Algorithms (MLAs), the uog system may predict the average future usage of the spool (or amount of wire). For example, based on usage patterns on certain welding parameters, the uLog system may determine a threshold at which a complete weld cannot be completed. Thus, the uLog system may use an indicator (e.g., a buzzer, a flashing light, etc.) to alert the operator that the wire in the spool has run out and that a full weld cannot be completed based on theoretical thresholds determined using a machine learning algorithm. For example, cloud server 14432 running the uLog may be configured to provide feedback to one or more of the plurality of welding station computers 14416 to alert the welder that a complete weld cannot be completed based on theoretical thresholds determined using machine learning algorithms.
In another embodiment, when there is a difference (W2-W1) between the theoretical weight determined based on wire feed speed (measured by sensor 14492) and the measured weight, where W2 and W1 are measured by weight sensor 14484, instead of adjusting the speed of motor assembly 14490, the speed (or travel speed) of welding device 14500 can be adjusted to match the speed V obtained from measured weights W2-W1.
As can be appreciated from the above paragraphs, there is provided a welding system that includes a plurality of welding stations 14410. Each welding station 14410 includes a welding station computer 14416 and a welding system 14412 in communication with the welding station computer 14416. Each welding station 14410 includes one or more sensors 14492, 14502 configured to measure welding data including wire speed data (measured by speed sensor 14492), as depicted in, for example, fig. 162. The system also includes a plurality of wireless devices 14450 that communicate with one or more of the welding station computers 14450 to receive welding data including measured lead speed data. The system also includes a cloud server 14432 in communication with the wireless device 14450, the cloud server 14432 configured to process welding data including the lead speed data and configured to determine an amount of consumable welding material used by the plurality of welding stations 14410 over a given period of time. Cloud server 14432 is configured to communicate the amount of consumable wire used to one or more of the wireless devices.
In an embodiment, the welding data further comprises travel speed data of the welding system. In an embodiment, the wireless device 14450 is configured to also receive travel speed data for the welding system. In an embodiment, cloud server 14432 is also configured to process travel speed data.
As can be appreciated from the above paragraphs, there is also provided a welding system having a welding station that includes a welding station computer and a welding system in communication with the welding station computer. The welding system includes a welding material supply 14480, a welding device 14500, and a welding supply motor assembly 14490 that moves welding material 14486 in welding supply material 14480 to the welding device. The welding system also includes a weighing device 14482 operatively connected to the weld station computer 14416 and configured to measure a weight of the supply of welding material 14480 and to communicate the weight of the supply of welding material 14480 to the weld station computer 14416, and a sensor 14492 operatively connected to the supply of welding motor assembly 14490 and the weld station computer 14416 for communicating a speed of the supply of welding motor assembly 14490 to the weld station computer 14416 in the form of speed data. The weld station computer 14416 is operatively connected to the weld supply motor assembly 14490 and is configured to control the speed of the motor assembly 14490 based on the weight data.
As can be appreciated from the above paragraphs, there is provided a welding system comprising a plurality of welding stations 14410, each welding station 14410 comprising a welding station computer 14416 and a welding system 14500 in communication with the welding station computer 14416, each welding station 14410 comprising one or more sensors 14492, the one or more sensors 14492 configured to measure welding data including lead speed data. The welding system also includes a plurality of wireless devices 14450 that communicate with one or more of the welding station computers 14416 to receive welding data including measured wire speed data. Each welding station computer 14416 is configured to process welding data, including lead speed data, for the welding system 14500 with which it communicates. The welding station computer 14416 is also configured to determine an amount of consumable welding material used by the welding system 14500 over a given period of time, and to generate consumption data based thereon.
In an embodiment, each welding station 14410 further includes a motor 14490 for moving the wire at a wire speed, wherein the wire speed data is determined based on the speed of the motor 14490, and each welding station 14410 further includes a weight sensor 14484 that senses depletion of the weight of the consumable material. The weight sensor 14484 provides an output signal to the weld station computer 14416. The output signals are used by the weld station computer 14416 to determine consumption data. In an embodiment, weld station computer 14416 uses the consumption data to control the speed of motor 14490. In an embodiment, the system further includes a cloud server 14432 for receiving the consumption data along with the lead speed data to correlate the consumption data with the lead speed data.
FIG. 166 illustrates a system overview that can be used with a wide variety of test and inspection devices, means, processes and methods. In the general example of fig. 166, a pipeline 16610 may be constructed by joining multiple pipe sections together by annular welds, as required by a main company 16670. This construction may be done by the owner company 16670, a third party, or other parties. During the construction process, non-invasive tests and inspections may be performed to ensure that the pipeline does not fail within its specified service within the quality control parameters. To support this goal, for example, one or more welds (such as ring welds) may be inspected and tested by one or more testing means, processes, or methods (such as ultrasonic testing or radiographic testing).
For example, the field welder 16650 may place a testing device (such as imaging device 16620) on the pipeline adjacent each annular weld. A testing device (which may be an imaging device) may collect data regarding the internal structure of the annular weld for analysis. This data may be any type of data desired for analysis by an inspector or other person or required for any computer processing. For example, if an ultrasonic testing method or a radiographic testing method, or both, are used, one or more signals may be transmitted to the pipeline and/or the weld (such as an annular weld), and data and information responsive to such signals may be collected, processed, and analyzed by one or more computers and/or one or more persons.
In embodiments, responses to the signals may be received, processed, digitized, compressed, transmitted, and transmitted (16625) to a separate device or receiver (or the device and receiver may be separate from the testing device that generated the signals and/or received the responses; and the device and receiver may be remotely located or located at a remote facility 16630). Herein, a device, facility, or computer that receives data from a test unit and is separate or separable from the test unit is referred to as a "remote entity". A remote entity broadly encompasses any device, facility or person or other that can receive, use, sense, process or convert any data from a test unit. The scope of this term can range in width from a memory device (such as a memory stick) to a distributed control system, cloud-based processor, cell phone, smart phone, computer, digital processor, receiver, capability, enterprise-wide control system, or remote facility or remote central processing facility, or other device, person, or location. In an embodiment, the remote entity may be a remote facility, which may be a computing, processing and monitoring center. A remote entity (such as a remote facility) may be networked, wirelessly networked, cloud-based, hybrid cloud-based, or located at a physical facility or associated with a person, company, capability, use, entity, or otherwise. In embodiments, the remote entity may be owned and/or controlled by any desired person, customer, company, organization, inspector, third party, operator, worker, or otherwise.
In an embodiment, a remote entity (such as a remote facility) may use a computer to process test and/or inspection data (such as compression data) to determine the size, shape, location and orientation of any defects present in the weld and/or pipe. The test data and/or test data or analysis results may be transmitted (16635) to the test specialist 16640, which the test specialist 16640 may examine the data or confirm the analysis results, or otherwise use all or a portion of the data provided to the test specialist 16640. Herein, "test data" and "non-invasive test data" are used synonymously. For example, the results or results confirmed by the inspection specialist may be communicated (16645) to field worker 16650. This supports a defect repair process that repairs defects or manages welds and pipelines. Optionally, the results of the validation may be transmitted to quality assurance inspector 16660 and proprietary company 16670.
The techniques, processes, means and methods used herein can be extended to and used for pipeline testing and inspection. The devices, processes and apparatus disclosed herein have a range of applications that extends well beyond welding.
Fig. 167 illustrates an embodiment of a system that can be used with any of a wide variety of testing methods and with many types of devices. As shown in fig. 167, in embodiments, one or more ring welds may be inspected. The annular weld 167110 securing the pipeline 167100 together may be inspected and the pipeline may then be placed in service. One field crew 167500 or a plurality of field crew 167500 may travel along a pipeline having one or more of the ring welds 167110. They may stop at each annular weld and use the imaging device 167200 to capture images of the respective internal structures of one or more of the annular welds 167110. The number of ring welds 167500 to be inspected may range from 1 to a very large number (such as 5 million).
The inspection data and images may be generated, processed, recorded, detected, digitized, compressed and transmitted locally or to a remotely located facility (such as a remotely located central facility 167300). At the remotely located central facility 167300, the computer 167310 may process the inspection data and images (which may be digital images or other data images or data sets) to determine the size, shape, orientation, and location of any defects present in the weld under test. The computer may also identify which defects are significant enough and/or large enough to have a significant impact on pipeline integrity by executing the computer executable code using computer executable logic. If defects are identified by computer processing, one or more defects may be transmitted to an inspection expert 167400, which may confirm the presence and significance of the computer-identified defects 167400.
Alternatively, the inspector may directly review the inspection data and draw conclusions from the inspector's training and experience. Optionally, the inspector's conclusion may be confirmed by a computer process.
The validation results (whether computer generated or human generated) may then be transmitted to field workers 167500 by computer means or by telephone so that the weld can be repaired. The test results may also be sent to a quality assurance tester 167600, a company 167700 that owns the pipeline, or other interested or predetermined party.
In an embodiment, pipeline 167100 may be constructed by joining multiple pipe sections 167120A, 167120B together by annular welds 167110, as required by master company 167700. To ensure that the pipeline does not fail in service, the builder or others desire to verify the annular weld by non-invasive means. These means may include magnetic particle inspection, dye penetrant inspection, ultrasonic testing, and X-ray radiography. Both ultrasound testing and x-ray radiography are data intensive imaging methods.
The analysis work to evaluate test and/or inspection data requires one or more trained technicians 167400, 167520 and specialized imaging equipment 167200. A usable imaging device may have an emitter 167210, a receiver 167220, and an analog-to-digital (A/D) converter 167230. One or more field workers 167520 may transport imaging apparatus 167200 along a pipeline to a weld by supporting truck 167530 or other vehicle.
The imaging device may be of any useful type, such as an ultrasound type or a radiography type.
At the section joint, a field worker may place an imaging device on or near the pipeline adjacent to the annular weld 167110. The field worker may activate the imaging device. The emitter portion may send a signal (167215) into the pipe segment and/or the ring weld. The signal may be an ultrasonic sound wave pulse in the case of an ultrasonic test or x-ray radiation in the case of x-ray radiography.
In the case of ultrasonic testing, the ultrasonic pulse may be reflected from the boundary of the change in density of the annular weld 167110. The boundary between metal and air gives the strongest reflection. The reflected pulses may be detected by a receiver. The receiver may measure the intensity of the reflected pulse (167222) and may generate an electronic signal proportional to the intensity of the reflected pulse. In an embodiment, the emitter and the receiver may have a plurality of elements. Optionally, the emitter elements may be selectively activated to target the ultrasound pulse to a specific location.
In the case of x-ray radiography, the intensity of the x-rays is attenuated by the material in the pipe sections and the annular weld. The receiver may measure the intensity of radiation passing through the material (167224).
In an embodiment, the image forming apparatus may be mounted to a motor-driven carriage that is movable at a constant rate along the annular weld. The A/D converter may digitize the signal (167226) from the receiver and may compress the digitized data. The compressed imaging data and the carriage position (167235) may be transmitted to a computer 167310 at a remote entity, such as a remote facility 167300. The transmission may be by cable, transport of physical media, wireless, network, cloud, radio transmission, or otherwise.
In the non-limiting example of fig. 167, at a remote facility 167300, a computer 167310 may analyze the data (167235). The analysis may be performed in one or more steps. For example, the compute engine 167320 may identify a signal (167222, 167224) that may indicate the presence of an anomaly in the ring weld 167110. An exception signal (167325) may be communicated to the AI engine 167330. The AI engine may be a computer running computer executable code, relational logic, and/or artificial intelligence programming. The AI engine can determine the size, shape, orientation, and location of the defect (167335) that caused the exception signal (167325). The AI engine may execute computer executable program code using rule-based logic to determine which defects are significant to the integrity of the pipeline and must be repaired, which are not significant. The computer 167310 may send data describing the zero or more defects (167335) to an inspection technician 167400, a quality assurance inspector 167600, an owner company 167700, and field personnel 167500, or otherwise.
In an embodiment, the inspection technician may choose to review (167215) the data (167335) before the data (167335) is transmitted to a quality assurance inspector, an owner company, field personnel, or otherwise. The inspection technician may also change the identification of the defect from salient to non-salient or vice versa, or otherwise modify or annotate any results generated by a computer or otherwise. Defect data (167335) associated with the significant defect may be transmitted to field personnel 167500. The data may be transmitted to one or more field workers 167520. One or more field workers may mark the location and size of the significant defect on the weld and/or pipeline (167525) for repair by repair welder 167510 or other repair. Alternatively, the data may be transmitted directly to the repair welder 167510 or otherwise.
Figure 168 shows an ultrasonic testing embodiment. As shown in fig. 168, in an embodiment, one or more annular welds may be inspected by ultrasonic testing. The annular weld 168110 securing the pipeline 168100 together may be inspected, after which the pipeline may be placed in service. One field crew 168500 or a plurality of field crew 168500 may travel along the pipeline with one or more of the annular welds 168110. They may stop at each annular weld and use the ultrasonic testing apparatus 168200 to capture images of the internal structure of the weld. These images may be digitized, compressed, and transmitted to a remote facility (such as a remotely located central facility 168300). At the remotely located central facility, the computer 168310 may process inspection data (such as ultrasonic data, image data, or images) to determine the size, shape, orientation, and location of any defects present in the weld under test. The number of ring welds 168110 tested may range from 168 to a very large number (such as 5 million).
The computer may also identify which defects are significant enough and/or large enough to have a significant impact on pipeline integrity by executing the computer executable code using computer executable logic. If defects are identified by computer processing, one or more of the defects may be transmitted 168400 to inspection expert 168400, which may be an ultrasonic testing expert, who may confirm the presence and significance of the computer-identified defects.
Alternatively, the inspector may directly review the inspection data and draw conclusions from the inspector's training and experience. Optionally, the inspector's conclusion may be confirmed by a computer process.
The confirmation result (whether computer generated or human generated) may then be transmitted by computer means or by telephone to field personnel 168500 so that the weld can be repaired. The test results may also be sent to a quality assurance tester 168600, a company 168700 that owns the pipeline, or other interested or predetermined party.
In the embodiment of fig. 168, line 168100 is constructed by joining multiple pipe sections 168120a, 168120B together by annular welds 168110 under the requirements of main company 168700. To ensure that the pipeline does not fail in service, it is desirable to inspect the annular weld by non-invasive means. These means may include magnetic particle inspection, dye penetrant inspection, ultrasonic testing, and X-ray radiography. Ultrasonic testing is a data intensive imaging method. It requires one or more trained technicians 168400, 168520 and specialized imaging equipment 168200.
The imaging device may have an emitter 168210, a receiver 168220, and an a/D converter 168230. One or more field workers 168520 may transport imaging equipment 168200 along the pipeline by way of a support truck 168530 or other vehicle. The field worker may place the imaging apparatus on the pipeline adjacent the annular weld 168110, at the annular weld to be tested. The field worker may activate the imaging device. The emitter portion may send ultrasonic pulses (168215) into the pipe segment and the annular weld. The pulses may be transmitted at a rate of 1Hz to 20,000 Hz. The frequency of the ultrasonic waves may vary from 0.5MHz to 23 MHz. The ultrasonic pulse may be reflected from a boundary of density change in the ring weld 168110 or in the pipe. The boundary between metal and air gives the strongest reflection. The reflected pulses may be detected by a receiver. The receiver measures the intensity of the reflected pulse (168222) and generates an electronic signal proportional to the intensity. The emitter and the receiver may have a plurality of elements. The emitter elements may be selectively activated to target the ultrasonic pulses to specific locations.
The image forming apparatus is mounted to a motor-driven carriage that is movable at a constant rate along an annular weld. The A/D converter can digitize the signal (168226) from the receiver and can compress the digitized data. The compressed imaging data and the carriage position (168235) may be transmitted to a remote entity, such as a computer 168310 optionally at a remote facility 168300. The transmission may be by cable, transport of physical media, wireless, network, cloud, radio transmission, or otherwise.
In the embodiment of fig. 168, at remote facility 168300, computer 168310 may analyze the data (168235). The analysis can be performed in multiple steps. The calculation engine 168320 may identify a signal that may indicate the presence of an anomaly in the ring weld 168110 (168222). An exception signal (168325) is communicated to the AI engine 168330. The AI engine may determine the size, shape, orientation, and location of the defect (168335) that caused the anomaly signal (168325). The AI engine may determine which defects are significant to the integrity of the pipeline and must be repaired. Computer 168310 sends data (168335) describing zero or more defects to inspection technician 168400, quality assurance inspector 168600, proprietor 168700, field personnel 168500, or others.
Optionally, the inspection technician may receive the data directly and perform an analysis other than AI. Optionally, in this case, the inspection technician may use the AI to check or confirm the results of the inspection technician.
Optionally, the inspection technician may choose to review (168405) the data (168335) before the data (168335) is transmitted to a quality assurance inspector, an owner company and/or field personnel, or otherwise. The inspection technician may also change the identification of the defect from prominent to non-prominent or from non-prominent to prominent.
Defect data (168335) associated with the significant defect may be communicated to field personnel 168500. The data may be transmitted to one or more field workers 168520. One or more field workers may mark the location and size of the significant defect on the pipeline (168525) for subsequent repair by repair welder 168510. Alternatively, the data may be transmitted directly to repair welder 168510.
Fig. 169 shows a radiographic testing embodiment. As shown in fig. 169, in an embodiment, one or more annular welds may be inspected by radiographic testing. The annular weld 169110 securing the pipeline 169100 together may be inspected and the pipeline may then be placed in service. One field crew 169500 or a plurality of field crew 169500 may travel along the pipeline with one or more of the annular welds 169110. They may stop at each annular weld 169110 and use the x-ray device 1699200 to acquire data and/or capture images of the internal structure of each annular weld 169110.
The inspection data and/or images may be digitized, compressed, and transmitted to a remote facility (such as a remotely located central facility 169300). At the remotely located central facility, the computer 169310 may process inspection data (such as ultrasonic data, image data, or images) to determine the size, shape, orientation, and location of any defects present in the weld under test. The number of ring welds 169110 examined may range from 1 to a very large number (such as 5 million).
The computer may also identify which defects are significant enough and/or large enough to have a significant impact on pipeline integrity by executing the computer executable code using computer executable logic. If a defect is identified by the computer process, one or more defects may be transmitted to inspection expert 169400, which may be a radiographic testing expert 169400, which may confirm the presence and significance of the computer-identified defect.
Alternatively, the inspector may view the inspection data directly and draw conclusions from the inspector's experience. Optionally, the inspector's conclusion may be confirmed by a computer process.
The confirmation results (whether computer generated or human generated) may then be transmitted by computer means or by telephone to field worker 169500 so that the weld can be repaired. The test results may also be sent to a quality assurance tester 169600, a company 169700 that owns the pipeline, or other interested or predetermined party.
In an embodiment, as shown in fig. 169, the pipeline 169100 may be constructed by joining multiple pipe segments 169120a, 169120B together by annular welds 169110 under the requirements of the main company 169700. To ensure that the pipeline does not fail in service, it is desirable to inspect the annular weld by non-invasive means. These means may include magnetic particle inspection, dye penetrant inspection, ultrasonic testing, and x-ray radiography. Both ultrasound testing and x-ray radiography are data intensive imaging methods. They require one or more trained technicians 169400, 169520 and a specialized imaging device 169200. The imaging device may be composed of an emitter 169210, a receiver 169220, and an a/D converter 169230. One or more field workers 169520 may transport imaging apparatus 169200 along the pipeline via support truck 169530. At each segment connection, a field worker may place an imaging device on or near the pipeline adjacent the annular weld 169110. The field worker may activate the imaging device. The emitter portion may send x-ray radiation (169215) into the tube segment and the annular weld. The intensity of the x-rays may be attenuated by the material in the tube segments and the annular weld. The receiver may measure the intensity of radiation passing through the material (169224).
The image forming apparatus may be mounted to a motor-driven carriage that is movable at a constant rate along the annular weld. The a/D converter may digitize the signal 169226 from the receiver and may compress the digitized data. The compressed imaging data and the carriage position (169235) may be transmitted to a computer 169310 at the remote facility 169300. The transmission may be by cable, transport of physical media, or radio transmission.
In the example shown in fig. 169, at remote facility 169300, computer 169310 may analyze the data (169235). The analysis may be performed in multiple steps. The calculation engine 169320 may identify a signal (169224) that may indicate the presence of an anomaly in the annular weld 169110. An exception signal (169325) may be communicated to the AI engine 169330. The AI engine may determine the size, shape, orientation, and location of the defect (169335) that caused the anomaly signal (169325). The AI engine may determine which defects are significant to the integrity of the pipeline and must be repaired. Optionally, these steps may be performed by an inspection technician with or without AI support based on test and/or inspection data.
In the embodiment of fig. 169, computer 169310 may send data describing zero or more defects (169335) to inspection technician 169400, quality assurance inspector 169600, proprietor company 169700, and field personnel 169500, or otherwise. The inspection technician may choose to review (169405) the data (169335) before the data (169335) is transmitted to a quality assurance inspector, owner company, and/or field personnel. The inspection technician may also change the identification of the defect from prominent to non-prominent or from non-prominent to prominent.
Defect data (169335) associated with the significant defect may be communicated to field personnel 169500.
The data may be transmitted to one or more field workers 169520. One or more field workers may mark the location and size of the significant defect on the pipeline (169525) for subsequent repair by repair welder 169510. Alternatively, the data may be transmitted directly to the repair welder 169510.
In one embodiment, a computer system may include a first device having a processor to process pipeline configuration data, wherein the first device transmits the pipeline configuration data to a cloud-based memory and the pipeline configuration data is processed by the cloud-based processor.
In one embodiment, the pipeline configuration data includes welding data, pipe treatment data, coating data, inspection data, or other data.
In one embodiment, the first device comprises an apparatus of a welding station, an apparatus of a pipeline weld expansion operation, an automated welding tool, a system for visual welding, an inspection system, or other device.
In one embodiment, first data may be transmitted from a first device to a second device, wherein the first data includes data regarding a pipeline configuration. The first data may be processed by a cloud-based network device.
In one embodiment, the first data (transmitted from the first device to the second device) may include welding data, pipe processing data, coating data, inspection data, management data, or other data.
In one embodiment, a computer program product for welding support may comprise: computer readable program code means providing welding data to a computer memory; computer readable program code means for providing data from the data set including the pipeline data to the memory; and computer readable program code means for processing the weld data and the pipeline data to provide a recorded output.
In one embodiment, a computer program product for welding support may include program executable code for rule based logic to process welding data via welding support program code, program executable code for rule based logic to process welding data via verification program code, program executable code for rule based logic to process welding data via supervisor program code or quality control program code, or other program executable code.
In one embodiment, a welding system may include 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 welding station includes one or more sensors and the one or more sensors are configured to measure welding data including lead speed data. A system for welding may include: a plurality of wireless devices in communication with one or more of the welding station computers to receive welding data including measured wire speed data; and a cloud server in communication with the wireless device. The cloud server is configured to process welding data including the lead speed data and is configured to determine an amount of consumable welding material used by the plurality of welding stations over a given time period. The cloud server is configured to communicate the amount of consumable welding material used to one or more of the wireless devices.
In one embodiment, the welding system may include an orbital welder. For example, orbital welders may include Clockwise (CW) and counterclockwise (CCW) welding systems.
In one embodiment, the measured welding data may also include travel speed data of the welding system. In one embodiment, the plurality of wireless devices are configured to also receive travel speed data for the welding system. In one embodiment, the cloud server is further configured to process travel speed data.
In one embodiment, if the current in the welding system is high, the welding station computer instructs the welding system to slow the speed of the welding system or to control the position of the welding torch in the welding system.
In one embodiment, a system for welding may include a welding station. The welding station may include a welding station computer and a welding system in communication with the welding station computer. The welding system may include a welding material supply, a welding device, and a welding supply motor assembly to move the welding material to the welding device. In one embodiment, the system for welding may further comprise: a weighing device operatively connected with the weld station computer and configured to measure a weight of the supply of weld material and to transmit the weight of the supply of weld material to the weld station computer in the form of weight data; and a sensor operatively connected with the weld supply motor assembly and the weld station computer for communicating the speed of the weld supply motor assembly in the form of speed data to the weld station computer. The weld station computer is operatively connected to the weld supply motor assembly and is configured to control a speed of the motor assembly based on the weight data.
In one embodiment, the welding device may comprise an orbital welding machine. In one embodiment, the supply of welding material includes a wire spool configured to carry the wire. In one embodiment, the weighing device comprises a hub transducer, wherein the hub transducer is configured to carry a spool. In one embodiment, the weighing device includes a strain sensor mounted on a hub of the hub transducer. In one embodiment, the strain sensor is configured and arranged to sense strain exerted by the weight of the spool. In one embodiment, the motor assembly includes a motor and a feed wheel operatively connected to the motor. In one embodiment, the motor assembly includes a nip roller configured to push the wire into contact with the feed wheel such that rotation of the feed wheel causes movement of the wire. In one embodiment, the feed wheel is configured to rotationally engage the line to move the line.
In one embodiment, the welding station computer is configured to measure a weight difference between a weight of the supply of welding material measured at a first time and a weight of the supply of welding material measured at a second time after the first time, the weight difference corresponding to the measured weight of welding material consumed between the first time and the second time. In one embodiment, the weld station computer is configured to calculate a theoretical weight of the weld material consumed based on a rotational speed of the weld supply motor assembly. In one embodiment, the welding station computer is configured to calculate a difference or ratio or both between the measured weight of the welding material and a theoretical weight of the consumed welding material. In one embodiment, the weld station computer is configured to compare the measured weight of the weld material to a theoretical weight of the consumed weld material, and if there is a difference, the weld station computer indicates that slippage is occurring and controls the speed of the motor assembly to adjust the rotational speed of the motor assembly. In one embodiment, the welding station computer is configured to repeat the comparison between the measured weight of the welding material and the theoretical weight of the welding material consumed at a plurality of time increments.
In one embodiment, a welding system may include a cloud server in communication with a welding station computer, wherein the cloud server is configured to process a speed of a welding supply motor assembly and a weight of a welding material supply received from the welding station computer to store historical data regarding welding material usage.
In one embodiment, the cloud server is further configured to process the speed of the welding supply motor assembly and the weight of the welding material supply received from a plurality of welding station computers associated with the plurality of welding stations to store historical data regarding welding material usage at each of the plurality of welding stations. In one embodiment, the cloud server is configured to predict an average future use of the welding material based on historical data and using a machine learning algorithm. In one embodiment, the cloud server is configured to determine a threshold of welding material needed to complete a complete weld based on the usage pattern and historical data. In one embodiment, the cloud server is configured to provide feedback to one or more of the plurality of welding station computers to alert the welder that a complete weld cannot be completed based on theoretical thresholds determined using a machine learning algorithm.
In one embodiment, the welding station computer is configured to control the speed of the welding device to adjust the speed of the welding device to match a speed obtained from the measured weight of the supply of welding material.
In one embodiment, a first weight of the supply of welding material at a first time may be measured using a weight measuring device. The second weight of the supply of weld material may be measured using the weight measuring device at a second time after the first time. A difference in measured weight between the first weight and the second weight may be calculated using a computer, where the difference in measured weight corresponds to the measured used weld material. The theoretical weight of the welding material that has been used is calculated using a computer based on the speed of the motor assembly that feeds the welding material to the welding device. The theoretical weight of the used soldering material can be compared with the measured weight of the used soldering material by means of a computer. The speed of the motor assembly may be adjusted by the computer to correct for slippage of the motor assembly.
In one embodiment, the measuring of the first weight, the measuring of the second weight, the calculating of the difference in weight corresponding to the measured used welding material, the calculating of the theoretical weight of the used welding material, the comparing of the theoretical weight of the used welding material to the measured weight of the used welding material at a plurality of time increments, and the adjusting of the speed of the motor assembly when slippage of the motor assembly occurs may be repeated.
In one embodiment, a welding system may include a plurality of welding stations, wherein each welding station includes a welding station computer and a welding system in communication with the welding station computer, each welding station includes one or more sensors, and the one or more sensors are configured to measure welding data including lead speed data. The system for welding may also include a plurality of wireless devices in communication with one or more of the welding station computers to receive welding data including measured wire speed data. Each welding station computer is configured to process welding data including the lead speed data for the welding system with which it is in communication, and the welding station computer is configured to determine an amount of consumable welding material used by the welding system over a given period of time and generate consumption data based thereon.
In one embodiment, each welding station of the welding system may include a motor for moving the wire at a wire speed, wherein the wire speed data is determined based on the speed of the motor, each welding station further including a weight sensor that senses depletion of weight of the consumable material, the weight sensor providing an output signal to the welding station computer, and the welding station computer using the output signal to determine the consumption data. In one embodiment, the weld station computer uses the consumption data to control the speed of the motor.
In one embodiment, a welding system may include a cloud server for receiving consumption data along with lead speed data to correlate the consumption data with the lead speed data.
In one embodiment, a system for pipeline testing may include a testing device adapted to generate non-invasive test data about at least a portion of a weld. The testing device may communicate non-invasive test data to a second device adapted to receive the non-invasive test data. The testing device may be adapted to operate remotely from the device analyzing non-invasive test data.
In one embodiment, the testing device is adapted to transmit non-invasive test data for wireless communication. In one embodiment, the testing device is adapted to transfer non-invasive test data to a recording medium that is not permanently connected to the testing device. In one embodiment, the testing device is adapted to transmit non-invasive test data to an external digital recording device.
In one embodiment, a system for non-invasive line testing may comprise: an imaging device adapted to generate non-invasive test data relating to a portion of a welded conduit; and a remote processing device adapted to receive and process inspection data relating to the portion of the welded pipe.
In one embodiment, the remote processing device is adapted to analyze the pipeline data. In one embodiment, the remote processing device is adapted to analyze the welding data. In one embodiment, the remote processing device is adapted to execute computer executable code to identify a significant weld defect from the non-invasive test data.
In one embodiment, the remote processing device is adapted to execute computer executable code of an algorithm to identify a significant weld defect from the non-invasive test data. In one embodiment, the remote processing device is adapted to execute artificial intelligence computer executable code to identify significant weld defects from the non-invasive test data. In one embodiment, the remote processing device is adapted to execute computer executable code of the rule-based logic to identify a significant weld defect from the non-invasive test data.
In one embodiment, the non-invasive test data may include one or more of the following: the location, size, orientation, shape, and significance of any defects that cause anomalies in the non-invasive test data. In one embodiment, non-invasive test data may be analyzed without human computational or analytical intervention. In one embodiment, the non-invasive test data may be analyzed in part by computer analysis and in part by human work.
In one embodiment, a method of non-invasive line testing may comprise: providing an imaging device; generating non-invasive test data; providing means for providing non-invasive test data for analysis; and providing non-invasive test data for analysis at a location of the apparatus remote from and adjacent to the test portion of the conduit.
In one embodiment, the method may further comprise providing non-invasive test data for analysis at a location remote from the test portion of the pipeline and the support vehicle. In one embodiment, the method may further comprise providing for analysis at a location remote from the test portion and any computer adjacent to the test portion or test location adjacent to the pipe.
In one embodiment, the method may further comprise processing the digital NDT data at a location substantially remote from the location where the data was collected. In one embodiment, the method may further comprise transmitting the NDT data to a location substantially remote from the location where the data was collected by wireless data transmission. In one embodiment, the method may further comprise transmitting the NDT data to a location substantially remote from the location where the data was collected by the transport of the physical medium. In one embodiment, the method may further comprise transmitting the NDT data over a data transmission cable to a location substantially remote from the location where the data is collected. In one embodiment, the method may further comprise transmitting the NDT data to a location substantially remote from the location where the data was collected by a combination of methods.
In one embodiment, the method may further comprise transmitting results of the analysis performed at the substantially remote location to a location where the data is collected. In one embodiment, the method may further comprise communicating the results of the analysis performed at the substantially remote location to an expert at another substantially remote location.
In one embodiment, the method may further comprise analyzing the digitally automated ultrasonic test data. In one embodiment, the method may further comprise transmitting the automated ultrasonic test data by wireless data transmission to a location substantially remote from the location where the data was collected; and processing the digitally automated ultrasonic test data at a location substantially remote from the location at which the data is collected. In one embodiment, the method may further comprise transmitting the automated ultrasonic test data to a location substantially remote from the location where the data was collected by transportation of the physical medium.
In one embodiment, the method may further comprise transmitting the automated ultrasonic test data to a location substantially remote from the location where the data was collected via a data transmission cable. In one embodiment, the method may further comprise transmitting the automated ultrasonic test data to a location substantially remote from the location where the data was collected by a combination of methods. In one embodiment, the method may further comprise using a computer algorithm to identify significant weld defects from the automated ultrasonic test data.
In one embodiment, the method may further comprise processing the digital radiography data at a location substantially remote from the location at which the data is collected. In one embodiment, the method may further comprise transmitting the digital radiographic data by wireless data transmission to a location substantially remote from the location where the data was collected. In one embodiment, the method may further comprise transferring the digital radiographic data to a location substantially remote from the location where the data was collected by transportation of the physical medium. In one embodiment, the method may further comprise transmitting the digital radiographic data over a data transmission cable to a location substantially remote from the location where the data is collected.
In one embodiment, the method may further comprise transmitting the digital radiographic data by a combination of methods to a location substantially remote from the location where the data was collected. In one embodiment, the method may further comprise using a computer algorithm to identify significant weld defects from the digital radiography data.
In one embodiment, a system for pipeline construction may include a system for recording welding data in real time, wherein the welding data is provided for analysis by a computerized device and/or by a subject matter expert. In one embodiment, the welding data includes welding data, pipe treatment data, coating data, inspection data, management data, or other data. In one embodiment, the system may further include a system for aggregating all available weld data into a single data set having all data about each associated weld or suitable for analysis by computerized devices and/or subject matter experts.
In one embodiment, the system may further include machine readable code that executes the rule-based program logic to identify correlations between different data about the weld and to identify defects in the weld. In one embodiment, the system may further include machine readable code that executes rule-based program logic to identify correlations between the same data about different welds and the presence or absence of defects in those welds.
In one embodiment, a system for aligning and welding two sections of a pipe together may include a welding mechanism for applying a weld to a face seam of the two sections. The welding mechanism may include an articulating welding torch, a laser sensor for reading the profile of the face joint, and an electronic controller for receiving information signals from the laser sensor to control the position and/or orientation of the welding torch. The system may further include an alignment mechanism for regulating the orientation of the longitudinal axis of at least one of the segments relative to the other. The welding mechanism may further include: a bracket for fixing the position of the welding mechanism in the pipe; and a welding portion rotatable within the pipe relative to the support portion. The welding torch and the laser sensor may be rotatably supported by the welding portion such that the welding torch follows the laser sensor along the face seam during welding.
In one embodiment, the welding mechanism may further comprise a camera for optically sensing the face seam. In one embodiment, the articulation of the torch head on the torch may comprise one of: radial translational movement toward and away from the face joint, translational movement in the direction of the longitudinal axis of the segment, pivotal movement relative to the welding mechanism about an axis parallel to the longitudinal axis of the pipe segment, and pivotal movement relative to the welding head about an axis perpendicular to the longitudinal axis of the pipe segment.
In one embodiment, the alignment mechanism regulates the orientation of the at least one segment by external contact with the at least one segment. In one embodiment, the electronic controller receives signals from the laser sensor to direct the alignment mechanism to adjust the relative position of the pipe segments based on predetermined alignment parameters.
In one embodiment, the welding mechanism is rotated within and relative to the interior of the two-section face seam such that the welding torch follows the laser sensor, and the laser sensor provides continuous face seam profile data to the electronic controller, which in turn continuously guides the positioning of the welding torch.
In one embodiment, the camera follows the welding torch along the weld joint path, and the camera sends a signal to the console display to allow an operator to inspect an image of a portion of the weld.
In one embodiment, a method of aligning and welding two sections of a pipe together may comprise: placing the first tube segment on an alignment device; inserting an internal welding machine having a laser and a welding torch into the first pipe segment; substantially aligning the second pipe segment with the first pipe segment and the internal welding machine; clamping exterior portions of the first and second pipe segments to adjust an axial position of the internal welding machine to substantially align with the face seams of the first and second pipe segments; adjusting, by an alignment device, a relative alignment of the first and second pipe segments based on a signal from the internal welder; starting a root welding cycle in which a laser scans a face joint, a welding torch follows the laser, and a position of the articulating welding torch is controlled using output from the laser, wherein the position and orientation of the welding torch relative to the face joint is controlled to produce a quality weld; determining a face seam profile from the laser; releasing the alignment device and removing the internal welding machine from the open pipe section end; and repositioning the next sequential tube segment on the external alignment mechanism in preparation for welding the next joint.
In one embodiment, the method may further comprise: providing a rotation mechanism on which the laser and the torch are rotated to perform an initial scan of the face seam by the laser sensor; and generating a signal from the rotating laser to guide alignment of the first and second conduits by the alignment device before welding begins.
In one embodiment, an Internal Heat Exchanger (IHEX) for pipeline welding may include: a drive system configured to move the IHEX into a position within at least one pipe section near a weld joint location with another pipe section; a cooling portion comprising a cooling structure configured to selectively cool one or more interior surface portions of at least one conduit portion; and a controller in communication with the cooling structure and configured to activate the cooling portion when the IHEX is at the location within the at least one conduit portion.
In one embodiment, the IHEX may further comprise a connection member configured to secure the IHEX to the inner joint 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 in forward and reverse directions within the at least one pipe section. In one embodiment, the drive system may comprise a cable and winch system, wherein the winch is configured for anchoring at a location outside the at least one conduit portion and the cable extends between the winch and a support structure of the IHEX comprising the controller and the cooling portion.
In one embodiment, the controller is also in communication with a remote control device to facilitate selective activation of the cooling portion by the remote control device. In one embodiment, the cooling section comprises: at least one nozzle configured to spray a coolant toward an inner wall surface portion of the at least one conduit portion; and a coolant supply configured to deliver coolant to the at least one nozzle.
In one embodiment, the IHEX may further comprise a frame including a first portion having a coolant supply, an intermediate portion having a cooling portion, and a third portion having a controller. In one embodiment, the coolant supply source may comprise a coolant pump located remotely from the cooling portion such that the coolant pump is located outside the at least one conduit portion when the cooling portion is disposed within the at least one conduit portion, and the coolant pump is connected to the at least one nozzle by at least one fluid conduit. In one embodiment, the at least one nozzle comprises a plurality of nozzles arranged in a plurality of rows, and the rows are arranged around a perimeter of the central support member of the cooling portion.
In one embodiment, the cooling portion includes a plurality of fin members extending radially outward from and spaced around a periphery of a central support member of the cooling portion. In one embodiment, the at least one fin member includes at least one channel extending through the fin member, and the cooling portion further includes at least one fan controllable by the controller and adjacent to and aligned with the at least one fin member to direct air flow through the at least one channel of the at least one fin member.
In one embodiment, the at least one fin member includes a hollow shell having an inlet and an outlet, and the cooling portion further includes a circulating coolant flow circuit to selectively flow coolant through the hollow shell of the at least one fin member.
In one embodiment, the IHEX may include one or more temperature sensors disposed at one or more locations along the IHEX and in communication with the controller. One or more temperature sensors measure temperature at one or more locations within the at least one duct section and provide measured temperature information to the controller, and the controller is configured to selectively control activation and operation of the cooling section based on the measured temperature information.
The technology disclosed herein addresses a significant technical problem of how to test, verify and ensure the quality of thousands of welds in a pipeline system by using reliable and technically sophisticated equipment and methods. In an embodiment, a system for pipeline testing may have testing apparatus adapted to generate non-invasive test data ("NDT") regarding at least a portion of a weld or an entire weld. The testing device may communicate non-invasive test data to a second device adapted to receive the non-invasive test data. The testing device may be adapted to operate remotely from the device analyzing non-invasive test data. A system for pipeline testing may have a testing device adapted to transmit non-invasive test data for wireless communication. A system for pipeline testing may have a testing device adapted to transmit non-invasive test data to a recording medium that is not permanently connected to the testing device. A system for pipeline testing may have a testing device adapted to transmit non-invasive test data to an external digital recording device. A system for non-invasive pipeline testing may have: an imaging device adapted to generate non-invasive test data relating to a portion of a welded conduit; a remote processing device adapted to receive and process inspection data regarding the portion of the welded pipe. A system for non-invasive pipeline testing may have a remote processing device adapted to analyze pipeline data. A system for non-invasive pipeline testing may have a remote processing device adapted to analyze welding data. A system for non-invasive pipeline testing may have a remote processing device adapted to execute computer executable code to identify significant weld defects from non-invasive test data. The system for non-invasive pipeline testing may have a remote processing device adapted to execute computer executable code of an algorithm to identify significant weld defects from non-invasive test data. A system for non-invasive pipeline testing may have a remote processing device adapted to execute artificial intelligence to identify significant weld defects from non-invasive test data. The system for non-invasive pipeline testing may have a remote processing device adapted to execute computer executable code of the rule-based logic to identify one or more significant weld defects from the non-invasive test data. The identified weld defects may be of different types, such as plugged, missing material, material properties, brittleness, density, thickness, air bubbles, gas bubbles, and others. A system for non-invasive pipeline testing may have non-invasive test data such as one or more of the following: the location, size, orientation, shape and significance of any defects that cause anomalies in the scan. A system for non-invasive pipeline testing may have non-invasive test data that may be analyzed by the system automatically and without human computational or human analytical intervention. In an embodiment, a method of non-invasive line testing may have the steps of: providing an imaging device; generating non-invasive test data; providing means for providing non-invasive test data for analysis; and providing non-invasive test data for analysis at a location of the apparatus remote from and adjacent to the test portion of the conduit. A method for non-invasive pipeline testing may have the step of providing non-invasive test data for analysis at a location remote from the test portion of the pipeline and the supporting vehicle. The method for non-invasive pipeline testing may have the step of providing non-invasive test data for analysis at a location remote from the test portion and any computer adjacent to the test portion or test location of the pipeline. The method of non-invasive pipeline testing may have the step of processing the digital NDT data at a location substantially remote from the location at which the data is collected. The method of non-invasive pipeline testing may have the step of transmitting the NDT data by wireless data transmission to a location substantially remote from the location from which the data was collected. The method of non-invasive pipeline testing may have the step of transmitting the NDT data through the transport of the physical medium to a location substantially remote from the location where the data was collected. The method of non-invasive pipeline testing may have the step of transmitting the NDT data over a data transmission cable to a location substantially remote from the location where the data is collected. The method of non-invasive pipeline testing may have the step of transmitting the NDT data to a location substantially remote from the location where the data was collected by a combination of methods. The method of non-invasive pipeline testing may have the steps of: the results of the analysis performed at the substantially remote location are transmitted to the location where the data is collected. The method of non-invasive pipeline testing may have the step of communicating the results of the analysis performed at a substantially remote location to an expert at another substantially remote location. The method of non-invasive pipeline testing may have the step of analyzing digital automated ultrasonic test data (also referred to as digital "AUT" data). The method of non-invasive pipeline testing may have the step of processing digitally automated ultrasonic test data at a location substantially remote from the location at which the data is collected. The method of non-invasive pipeline testing may have the step of processing digitally automated ultrasonic test data by wireless data transmission at a location substantially remote from the location at which the data is collected. The method of non-invasive pipeline testing may have the step of transmitting automated ultrasonic test data by wireless data transmission to a location substantially remote from the location where the data is collected. The method of non-invasive pipeline testing may have the step of transmitting automated ultrasonic test data to a location substantially remote from the location where the data was collected by transport of the physical medium. The method of non-invasive pipeline testing may have the step of transmitting automated ultrasonic test data over a data transmission cable to a location substantially remote from the location where the data is collected. The method of non-invasive pipeline testing may have the step of transmitting automated ultrasonic test data to a location substantially remote from the location where the data was collected by a combination of methods. The method of non-invasive pipeline testing may have the step of using computer algorithms to identify significant weld defects from automated ultrasonic test data. The method of non-invasive pipeline testing may have the step of processing the digital radiography data at a location substantially remote from the location at which the data is collected. The method of non-invasive pipeline testing may have the step of transmitting the digital radiographic data by wireless data transmission to a location substantially remote from the location where the data is collected. The method of non-invasive pipeline testing may have the step of transmitting the digital radiographic data by transport of the physical medium to a location substantially remote from the location where the data is collected. The method of non-invasive pipeline testing may have the step of transmitting the digital radiographic data over a data transmission cable to a location substantially remote from the location where the data is collected. The method of non-invasive pipeline testing may have the step of transmitting the digital radiographic data by a combination of methods to a location substantially remote from the location where the data was collected. The method of non-invasive pipeline testing may have the step of using a computer algorithm to identify significant weld defects from digital radiography data. In an embodiment, a universal cloud recording system ("uLog") disclosed herein may have a computer system including a first device having a processor that processes pipeline configuration data, which may transfer the pipeline configuration data to a cloud-based memory. The pipeline configuration data may be processed by a cloud-based processor. The uLog may process any one or more pipeline configuration data, such as, but not limited to: welding data, pipe processing data, coating data, and inspection data. The uog may process data from any one or more of the following devices and/or apparatuses: a welding station, a pipeline welding extension operation, a welding tool, an automatic welding tool, a manual welding tool, a system for visual welding, a single torch automatic welder or welding machine, a dual torch automatic welder or welding machine, an external welder or welding machine, an internal welder or welding machine, an inspection system, a smartphone, a cellular phone, a Personal Data Assistant (PDA), a laptop, a tablet, a computer, a digital device, a wireless device, and equipment used by a welder, a mechanic, a worker, an inspector, a coating applicator, and/or an administrator. The uog may use a method of data management performed on a computer, the method comprising the steps of: transferring first data from a first device to a second device, the first data being data relating to a pipeline configuration; and processing, by the cloud-based network device, the first data. The data that may be transmitted by the first device and/or processed by the second device and/or processed by the network of the uLog may be any one or more of the following: welding data, pipe processing data, coating data, welding data, inspection data, heat treatment data, and management data or other pipeline related configuration and/or management data. In an embodiment, the method of data management by uog may comprise further method steps of processing the first data and/or data by a network device, which may be a wired network device or a wireless network device. In another embodiment, the method of data management by uog may comprise the further method step of processing the first data and/or data by a network device, the network device being a wireless network device, a telecommunication device or a WiFi device. In yet another embodiment, the method of data management by uog may include the further method step of processing the first data by a network device, the network device being a cloud-based network device. In an embodiment, the uLog may be a computer program product for welding support, the computer program product having: computer readable program code means providing welding data to a computer memory; computer readable program code means for providing data from the data set including the pipeline data to the memory; and computer readable program code means for processing the weld data and the pipeline data to provide a recorded output and/or an output resulting from execution of the program logic and/or the analytical method. In an embodiment, the computer program product for welding support may also have program executable code for rule-based logic to process the welding data with the welding support program code. In another embodiment, the computer program product for welding support may also have program executable code for rule-based logic for processing welding data by examining the program code. In yet another embodiment, the computer program product for welding support may also have program executable code for rule-based logic for processing welding data through supervisor code or quality control program code. The system for pipeline construction may have a system for recording welding data in real time. The welding data is provided for analysis by computerized means and/or by subject matter experts. The system for pipeline configuration may use welding data having one or more of welding torches, pipe processing data, coating data, inspection data, and management data. The system for pipeline construction may also have a system for aggregating all available weld data into a single data set having all data about each relevant weld or suitable for analysis by computerized devices and/or subject matter experts. The system for pipeline construction may also have machine readable code executing rule-based program logic to identify correlations between different data about a weld and identify defects in this weld. The system for pipeline construction may also have machine readable code executing rule-based program logic to identify correlations between the same data for different welds.
In an embodiment, a universal cloud recording system ("uLog") disclosed herein may have a computer system including a first device having a processor that processes pipeline configuration data, which may transfer the pipeline configuration data to a cloud-based memory. The pipeline configuration data may be processed by a cloud-based processor. The uLog may process any one or more pipeline configuration data, such as, but not limited to: welding data, pipe processing data, coating data, and inspection data. The uog may process data from any one or more of the following devices and/or apparatuses: a welding station, a pipeline welding extension operation, a welding tool, an automatic welding tool, a manual welding tool, a system for visual welding, a single torch automatic welder or welding machine, a dual torch automatic welder or welding machine, an external welder or welding machine, an internal welder or welding machine, an inspection system, a smartphone, a cellular phone, a Personal Data Assistant (PDA), a laptop, a tablet, a computer, a digital device, a wireless device, and equipment used by a welder, a mechanic, a worker, an inspector, a coating applicator, and/or an administrator.
The uog may use a method of data management performed on a computer, the method comprising the steps of: transferring first data from a first device to a second device, the first data being data relating to a pipeline configuration; and processing, by the cloud-based network device, the first data. The data that may be transmitted by the first device and/or processed by the second device and/or processed by the network of the uLog may be any one or more of the following: welding data, pipe processing data, coating data, welding data, inspection data, heat treatment data, and management data or other pipeline related configuration and/or management data. In an embodiment, the method of data management by uog may comprise the further method step of processing the first data and/or data by a network device, which may be a wired network device or a wireless network device. In another embodiment, the method of data management by uog may comprise the further method step of processing the first data and/or data by a network device being a wireless network device, a telecommunication device or a WiFi device. In yet another embodiment, a method of data management by a uog may include additional method steps of processing first data by a network device that is a cloud-based network device. In an embodiment, the uLog may be a computer program product for welding support, the computer program product having: computer readable program code means providing welding data to a computer memory; computer readable program code means for providing data from the data set including the pipeline data to the memory; and computer readable program code means for processing the weld data and the pipeline data to provide a recorded output and/or an output resulting from execution of the program logic and/or the analytical method.
In an embodiment, the computer program product for welding support may also have program executable code for rule-based logic to process the welding data with the welding support program code. In another embodiment, the computer program product for welding support may also have program executable code for rule-based logic for processing welding data by examining the program code. In yet another embodiment, the computer program product for welding support may also have program executable code for rule-based logic for processing welding data through supervisor code or quality control program code. The present patent application, in its several aspects and embodiments, addresses the problems discussed above and significantly advances welding technology, pipe handling, coating, pipeline construction, management, and inspection technologies.
Although the present patent application has been described in detail for purposes of illustration, it is to be understood that such detail is solely for that purpose and that the application is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. Furthermore, it is to be understood that this application contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.

Claims (37)

1. A pipe cooling system comprising:
a frame configured to be positioned within at least one of a plurality of welded pipes secured together via a welded joint;
a plurality of rollers configured to rotatably support the frame;
a drive motor driving the plurality of rollers to move the frame within the at least one duct;
a braking system that resists movement of the frame at a desired location within the at least one conduit;
one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system;
a cooler carried by the frame, the cooler including a fan configured to blow a cooling gas within the at least one duct and in a direction toward a weld joint to facilitate cooling of the weld duct; and
one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe.
2. The pipe cooling system of claim 1, wherein the braking system comprises one or more clamps that clamp circumferentially spaced locations on the inner surface of the welded pipe.
3. The duct cooling system of claim 1, wherein the braking system includes a wheel lock that prevents rotation of the plurality of rollers.
4. A pipe cooling system comprising:
a frame configured to be positioned within at least one of a plurality of welded conduits;
a plurality of rollers configured to rotatably support the frame;
a drive motor driving the plurality of rollers to move the frame within the at least one duct;
a braking system that resists movement of the frame at a desired location within the at least one conduit;
one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system;
a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; and
One or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe;
wherein the cooler comprises a heat exchanger carrying a cooling fluid therein, the heat exchanger having a tube contacting surface that contacts an inner surface of the welded tube to facilitate cooling of the welded tube.
5. The pipe cooling system of claim 4, further comprising a heat exchanger motor configured to move the heat exchanger radially outward such that the pipe contact surface engages the inner surface of the welded pipe after the frame is positioned at a desired location within the welded pipe.
6. The duct cooling system of claim 1, wherein the blower blows air to facilitate cooling of the welded duct.
7. The duct cooling system of claim 1, wherein the one or more battery cells carried by the frame are configured to provide power to the cooler.
8. The duct cooling system of claim 1, wherein the one or more processors are communicatively connected to the brake system, the drive motor, and/or the cooler through one or more wired or wireless connections.
9. The duct cooling system of claim 1, wherein the one or more processors are communicatively connected to a brake system, the drive motor, and/or the cooler by one or more wireless connections, and wherein the one or more wireless connections include: a Wi-Fi connection, a bluetooth connection, a Near Field Communication (NFC) connection, or a cellular connection.
10. A pipe cooling system comprising:
a frame configured to be positioned within at least one of a plurality of welded conduits;
a plurality of rollers configured to rotatably support the frame;
a drive motor driving the plurality of rollers to move the frame within the at least one duct;
a braking system that resists movement of the frame at a desired location within the at least one conduit;
one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system;
A cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct;
one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe; and
a temperature sensor to sense a temperature of the welded pipe, the temperature sensor in operable communication with the one or more processors, the one or more processors to send operating instructions to the chiller based on signals received from the temperature sensor.
11. The pipe cooling system of claim 10, wherein the one or more processors operate the cooler until the sensor and the processor determine that the temperature of the welded pipe is below a threshold temperature.
12. A pipe cooling system comprising:
a frame configured to be positioned within at least one of a plurality of welded conduits;
a plurality of rollers configured to rotatably support the frame;
A drive motor driving the plurality of rollers to move the frame within the at least one duct;
a braking system that resists movement of the frame at a desired location within the at least one conduit;
one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system;
a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; and
one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe;
wherein the one or more processors are communicatively connected to a remote computer system and configured to transmit the pipe cooling data to the remote computer system.
13. The pipe cooling system of claim 12, wherein the pipe cooling data transmitted by the one or more processors includes cooling time profile information including changes in pipe temperature over time.
14. The pipe cooling system of claim 12 wherein the remote computer system contains pipe cooling data from other welding systems and calculates an expected time required until the temperature of the welded pipe is below a threshold.
15. The pipe cooling system of claim 14, wherein the expected time is sent to the one or more processors.
16. The duct cooling system according to claim 15, further comprising a user interface, wherein the expected time and/or duct temperature is sent to the user interface by the one or more processors.
17. The pipe cooling system of claim 14, wherein the expected time is calculated based at least in part on a size of the welded pipe.
18. A pipe cooling system comprising:
a frame configured to be positioned within at least one of a plurality of welded conduits;
a plurality of rollers configured to rotatably support the frame;
a drive motor driving the plurality of rollers to move the frame within the at least one duct;
a braking system that resists movement of the frame at a desired location within the at least one conduit;
One or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system;
a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; and
one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe;
wherein the one or more processors are configured to calculate an expected time required until the temperature of the welded pipe is below a threshold temperature, wherein the calculation is based at least in part on the size of the welded pipe.
19. The duct cooling system according to claim 18, wherein the calculation is further based on a cooling energy output of the chiller.
20. The duct cooling system according to claim 19, wherein the cooling energy output is based on information received from the remote computer system.
21. The pipe cooling system according to claim 19, wherein said cooling energy output is predetermined.
22. A pipe cooling system comprising:
a frame configured to be positioned within at least one of a plurality of welded conduits;
a plurality of rollers configured to rotatably support the frame;
a drive motor driving the plurality of rollers to move the frame within the at least one duct;
a braking system that resists movement of the frame at a desired location within the at least one conduit;
one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system;
a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; and
one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe;
wherein the one or more processors are communicatively connected to a remote computer system and configured to transmit coolant consumption data.
23. The duct cooling system of claim 1, wherein the cooling gas comprises air, and wherein the cooler comprises at least one fan configured to force air through an interior surface of the welded duct.
24. A pipe cooling system comprising:
a frame configured to be positioned within at least one of a plurality of welded conduits;
a plurality of rollers configured to rotatably support the frame;
a drive motor driving the plurality of rollers to move the frame within the at least one duct;
a braking system that resists movement of the frame at a desired location within the at least one conduit;
one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system;
a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; and
one or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe;
Wherein the cooling gas comprises air, and wherein the cooler comprises at least one fan configured to force air through a heat exchanger element of the duct cooling system.
25. The duct cooling system of claim 23, wherein the at least one fan is in communication with the one or more processors to facilitate selective operation of the at least one fan during cooling of the welded duct.
26. A pipe cooling system comprising:
a frame configured to be positioned within at least one of a plurality of welded conduits;
a plurality of rollers configured to rotatably support the frame;
a drive motor driving the plurality of rollers to move the frame within the at least one duct;
a braking system that resists movement of the frame at a desired location within the at least one conduit;
one or more battery units carried by the frame, the one or more battery units configured to power the drive motor and the braking system;
a cooler carried by the frame, the cooler configured to blow a cooling gas within the at least one duct to facilitate cooling of the welded duct; and
One or more processors operatively connected with the drive motor, the braking system, and the cooler, the one or more processors operating the cooler to reduce the temperature of the weld pipe;
wherein the cooling gas comprises air, and wherein the cooler comprises at least one fan configured to force air through an interior surface of the welded pipe,
wherein the duct cooling system further comprises a temperature sensor that senses a temperature of the welded duct, the temperature sensor being in operable communication with the one or more processors, the one or more processors sending operating instructions to the at least one fan based on signals received from the temperature sensor.
27. The duct cooling system of claim 26, wherein the one or more processors operate the at least one fan until the temperature sensor and the one or more processors determine that the temperature of the welded duct is below a threshold temperature.
28. The pipe cooling system of claim 24, wherein the heat exchanger element of the pipe cooling system comprises a fin, and
Wherein the fins are configured to extend radially outward from a central longitudinal axis of the frame to be in direct thermal contact with an inner surface of the welded conduits at or near a welded joint between the welded conduits to thereby cool the inner surface of the welded conduits.
29. The duct cooling system of claim 28, wherein the at least one fan is configured to provide a flow of air through the fins to cool the fins and thereby force heat through convective air flow from the fins.
30. The duct cooling system of claim 28, wherein the at least one fan is configured to be operated at a variable operating speed so as to selectively control fan speed and corresponding air flow rate through the fins differently and on demand during cooling of the welded duct.
31. The duct cooling system of claim 28, wherein the at least one fan is configured to be operated to provide a flow of cooling air through the fins at one or more desired flow rates, and
wherein the fins are configured to draw heat from the inner surface of the welded conduit, and wherein the forced airflow provided by the at least one fan removes heat from the fins.
32. The duct cooling system of claim 28, wherein the fin includes a curled outer surface portion that generally corresponds in shape to an inner surface of the welded duct, the fin extending toward the inner surface.
33. The tube cooling system according to claim 28, wherein said fins are constructed of a material having a suitable thermal conductivity to promote a high heat transfer rate from the interior surface of said welded tube.
34. The duct cooling system of claim 27, wherein the fin includes an open channel therein that extends through the fin in the longitudinal direction, and
wherein the at least one fan is positioned in close proximity to an end of the fin and aligned with the open channels of the fin to provide a flow of air through the open channels of the fin to cool the fin.
35. The duct cooling system of claim 1, wherein the frame is positioned at a junction between two adjacent ducts such that the frame has portions that are simultaneously disposed in two different ducts.
36. The duct cooling system of claim 35, wherein the braking system is configured to inhibit movement of the frame at the joint such that the portion of the frame is secured to the two different ducts.
37. The pipe cooling system of claim 1, wherein the one or more processors are configured to operate the chiller to reduce the temperature of the welded pipe to a predetermined level.
CN202110266287.2A 2015-03-26 2015-11-24 Pipeline cooling system Pending CN113001070A (en)

Applications Claiming Priority (9)

Application Number Priority Date Filing Date Title
PCT/US2015/022665 WO2015148765A1 (en) 2014-03-28 2015-03-26 Internal pipeline cooler
USPCT/US2015/022665 2015-03-26
US201562175201P 2015-06-12 2015-06-12
US62/175,201 2015-06-12
US201562189716P 2015-07-07 2015-07-07
US62/189,716 2015-07-07
USPCT/US2015/047603 2015-08-28
PCT/US2015/047603 WO2016033568A1 (en) 2014-08-29 2015-08-28 Method and system for welding
CN201580080511.1A CN107614193A (en) 2015-03-26 2015-11-24 System and method for the pipeline section of welded pipeline

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CN202110266287.2A Pending CN113001070A (en) 2015-03-26 2015-11-24 Pipeline cooling system
CN202011391383.1A Pending CN112589320A (en) 2015-03-26 2015-11-24 Spin welding system

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