GB2531709A - Apparatus and method - Google Patents

Abstract

Apparatus 100 for performing a cutting operation on an inner wall of a pipeline from within the pipeline, the apparatus being propellable longitudinally along and within the pipeline, wherein the apparatus comprises, (e.g. in a dedicated drill module) thereof: cutting means 440 for performing the cutting operation on the pipeline from therewithin, drive means 410a, 410b for driving the cutting means 440 so as to perform the cutting operation when in a cutting relationship with the pipeline inner wall to be cut, and displacement means (460a, 460b; 462a, 462b; 468a, 468b) for advancing or retracting the cutting means 440 into or from the said cutting relationship with the pipeline inner wall. The drive means may comprise one or more electrical motor(s) driving the cutting means by way of gears. The means for advancing and retracting may comprise plates (460a, 460b; 462a, 462b) having inclined slots (470a, 470b; 472a, 472b) which cooperate with pins (468a, 468b) when axially moved by fluid actuators (420a, 420b)

Description

APPARATUS AND METHOD

TECHNICAL FIELD

The present invention relates to pipelines, especially but not exclusively to apparatus for use in the maintenance or installation of pipelines. More particularly, though not exclusively, the invention relates to apparatus for use in performing a drilling or other cutting operation on an inner wall of a pipeline.

BACKGROUND

Maintenance, upgrading and replacement of ageing utilities pipeline infrastructures are major issues facing utilities companies such as water and gas utilities companies. Pipeline networks typically include main supply pipelines (also referred to as the "'mains" supply) and consumer service connection pipelines. The consumer service connection pipelines are connected to the main supply pipelines typically by means of a T-connection, to deliver a supply of fluid such as water or gas to a consumer's premises from the main supply pipeline.

Utilities supply pipelines are typically located underground, presenting substantial access issues when maintenance, upgrading or replacement is required.

Ageing pipelines are vulnerable to failure and leakage of fluid from pipelines is a known hazard particularly in the case of gas leakage.

One solution to reducing the cost of replacement of pipelines is to install replacement pipeline within pre-existing pipeline, including the main pipeline and consumer service connection pipeline, leaving the pre-existing main pipeline and pre-existing consumer service connection pipeline in place. The replacement main pipeline has an external diameter that is smaller than the internal diameter of the pre-existing main pipeline, allowing it to fit within the pre-existing main pipeline infrastructure. Similarly, the replacement consumer service connection pipeline has a diameter that is smaller than the pre-existing consumer service connection pipeline. The replacement main pipeline may be referred to as a "main pipeline liner" or "mains liner" because it effectively lines the pre-existing main pipeline. Similarly the replacement consumer service connection pipeline may be referred to as a "service connection liner" since it effectively lines the pre-existing consumer service connection pipeline. The consumer service connection pipeline may be of the Serviflex (RTM) type, being a twin wall corrugated flexible polyethylene liner pipe supplied by Radius Systems Ltd, South Normanton, Alfreton, Derbyshire, UK.

In known methods of replacement pipeline installation, the replacement pipeline is installed within the pre-existing pipeline by pulling the replacement pipeline through the pm-existing pipeline. Connection of the replacement consumer service connection pipeline to the replacement main pipeline is made by excavating ground above the location at which the pre-existing service connection pipeline connects to the pre-existing main pipeline.

Installer personnel may then remove a portion of the pre-existing main pipeline and pre-existing service connection pipeline in order to expose the replacement pipelines that have been installed therein. A T-connector is then installed on the replacement main pipeline and the replacement service connection pipeline coupled to the replacement main pipeline via the T-connector. The T-connector is typically attached to the main pipeline by forming an electrofusion bond between the T-connector and the main pipeline in a known manner.

In methods of installing a replacement pipeline within a pre-existing pipeline it is frequently necessary to utilise an apparatus, often a remote-controlled apparatus such as a "pig" or "robot", that is insertable into and propellable along the pipeline in order to carry out one or more operations on an inner wall of the pipeline. Such operations often include a cutting operation, especially a drilling operation for the purpose of forming a hole or aperture through the pipeline wall in order to make a necessary consumer service connection thereto. For example, having drilled a necessary hole or aperture in the replacement pipeline wall from therewithin, a connector device (such as the above-mentioned T-connector) may be inserted therein and the new consumer service connection then completed. Other cutting operations, such as removal of burrs, or bevelling or chamfering of a cut wall forming a hole or aperture, may in some instances also need to be performed.

Such "pigs" or "robots" are often designed to be as small and lightweight as possible, and to that end it is common practice to provide such apparatuses with a multi-strand or multi-tube tether or umbilical cable via which it is linked to an above-ground control station and sources of electrical power, operational control signals, supplies of pressurised fluid to onboard pneumatic and/or hydraulic systems, and suchlike.

In practice however it is difficult to design such pigs or robots which are able to carry out drilling or other cutting operations with efficiency and accuracy, especially in terms of being controllable so as to be able to drill holes or apertures, or perform other cutting operations, in or on an inner pipeline wall at accurately defined locations and with precision in terms of the hole/aperture formed or other cut made. Indeed, known attempts at providing such apparatus have hitherto failed to successfully address such shortcomings.

It is an aim of the present invention to address disadvantages associated with the prior art such as those discussed above.

SUMMARY OF THE INVENTION

Embodiments of the invention may be understood with reference to the appended claims.

Aspects of the present invention provide an apparatus or robot, a system and a method.

In one aspect of the invention for which protection is sought there is provided apparatus for performing a cutting operation on an inner wall of a pipeline from within the pipeline, the apparatus being propellable longitudinally along and within the pipeline, wherein the apparatus comprises: cutting means for performing the cutting operation on the pipeline from therewithin, drive means for driving the cutting means so as to perform the cutting operation when in a cutting relationship with the pipeline inner wall to be cut, and displacement means for advancing or retracting the cutting means into or from the said cutting relationship with the pipeline inner wall.

In many embodiments of the invention the displacement means may preferably be constructed and arranged to advance or retract the cutting means in a direction generally transverse to the longitudinal axis of the pipeline.

As used herein the terms "longitudinally" and "longitudinal", and variants thereof in the same context, with respect to the pipeline mean generally or approximately parallel to the longitudinal axis of the pipeline, in particular at or adjacent the particular location or region within the pipeline to which the term is being applied. The terms "generally transverse" and "generally transversely", and variants thereof in the same context, as used herein with respect to directions relative to the longitudinal axis of the pipeline, mean generally or approximately perpendicular to the pipeline longitudinal axis at or adjacent the particular location or region therewithin to which the term is being applied. Moreover, this meaning of the terms "generally transverse" and "generally transversely" is intended to be construed broadly and to encompass directions at angles either side of 90°, e.g. up to around 10 or 20 or 30 or 40 or 50 or 60 or 70 or 80° either side of 90°, with respect to the pipeline longitudinal axis at or adjacent the particular location or region therewithin to which the term is being applied.

Some embodiments of the invention may be configured for operation in pipelines having a diameter of lm or less, optionally in the range from about 10mm to about lm. Some embodiments may be configured for operation in pipelines having a diameter in the range from about 50mm to about 200mm, optionally from about 50mm to about 100mm, optionally in the range from about 75mm to about 90 mm.

Embodiments of the present invention are especially applicable to cutting operations performed on one or more walls of a replacement pipeline to be inserted within, or having already been inserted within, or in the process of being inserted in, a pre-existing pipeline.

In embodiments of the present invention the cutting operation which is to be carried out by the cutting means may be any operation involving cutting of an inner wall of the pipeline or a portion of the pipeline wall which has already been cut in a previous cutting operation.

The cutting operation may be selected from one or more of any of the following: - drilling of a hole or aperture, of any shape, through the pipeline wall; - partial drilling-or cutting-through of an inner surface or wall of the pipeline; - thermal or high-pressure punching of a hole or aperture through the pipeline wall; - bevelling, chamfering, de-burring or other shaping or finishing of one or more edges of a hole or aperture formed in the pipeline wall.

In many practical embodiments the cutting operation may preferably comprise at least the drilling-through of a wall of the pipeline to form a hole or aperture therein, especially in an overall method of providing a consumer service connection thereto.

In some embodiments of the invention the apparatus may be constituted by a robot which forms part of an overall system, including control means for controlling operation of the cutting means, drive means and displacement means.

Accordingly, in another aspect of the invention for which protection is sought there is provided a system for performing a cutting operation on an inner wall of a pipeline from within the pipeline, wherein the system comprises: a robot which is propellable longitudinally along and within the pipeline, the robot comprising: cutting means for performing the cutting operation on the pipeline from therewithin, drive means for driving the cuffing means so as to perform the cutting operation when in a cuffing relationship with the pipeline inner wall to be cut, and displacement means for advancing or retracting the cutting means into or from the said cutting relationship with the pipeline inner wall; and the system further comprises control means for controlling actuation and operation of the robot.

In another aspect of the invention for which protection is sought there is provided a method of performing a cuffing operation on an inner wall of a pipeline from within the pipeline, the method comprising: providing an apparatus or robot according to the first aspect of the invention or any embodiment thereof; inserting the apparatus or robot into the pipeline and propelling it therealong to a desired site of operation; and operating the displacement means to advance the cuffing means into cutting relationship with the pipeline inner wall, and operating the drive means to drive the cutting means to perform the cuffing operation in or on the pipeline inner wall.

In embodiments the steps of operating the displacement means and operating the drive means may be carried out either substantially simultaneously or sequentially in any order, i.e. it is possible to operate the drive means either before or after, or even simultaneously with, operating the displacement means.

In some embodiments the method may further comprise: operating the displacement means to retract the cutting means from the said cutting relationship with the pipeline inner wall.

In practical embodiments of the invention the apparatus may be constructed and configured so as to comprise a plurality of operational modules, e.g. arranged longitudinally or sequentially in the apparatus, each module comprising an operational device for performing a given respective task or operation on or in the pipeline, with one of the said modules being a drilling module comprising the cutting means, drive means and displacement means of the apparatus of the first aspect of the invention or any embodiment thereof.

By way of example, such operational modules may be constructed, arranged and/or configured for carrying out any of the following operations (which list is to be considered as non-exhaustive): - a traction or drive operation, e.g. for moving the apparatus with respect to one or more walls of the pipeline, e.g. for propelling the apparatus along the pipeline or manoeuvring or aligning it (e.g. rotating it about the longitudinal axis of the pipeline and/or moving it longitudinally) therewithin into a desired positon for performing one or more other operations; - a surveying operation, e.g. for observing or detecting a particular condition of or location in the pipeline in order to diagnose or prepare for one or more other operations; - a drilling operation, e.g. for drilling a hole or aperture (of any shape) in a wall of the pipeline for the purpose of forming a service connection, such as a consumer utility service connection, thereto, or for part drilling-or cutting-through the pipeline wall or for bevelling, chamfering, de-burring or other shaping or finishing of one or more edges of a hole or aperture formed in the pipeline wall; - an insertion operation, e.g. for physically inserting one or more connection or other components, e.g. a T-connector, into an aperture formed by a drilling operation; - a welding operation, e.g. for completing an insertion operation or effecting a repair or service connection operation; - a repair operation, e.g. for repairing a wall of the pipeline or a service connection thereto; -a testing operation, e.g. for pressure-testing a pipeline subsequent to an insertion, welding or repair operation; - a cleaning operation, e.g. for cleaning an internal wall or surface of the pipeline or clearing debris or waste material from within the pipeline, including swarf from a drilling or other cutting operation.

Actuation of the one or more operational devices may be effected by any suitable actuation means, preferably under control of control means, for example part of an overall control system of the apparatus or system. Such control means may be located at least partly on or in the apparatus itself, or it may be located at least partly at ground level and connected to the apparatus via a tether or umbilical cable.

In embodiments of the invention the cutting means may comprise a drill or dill bit, or any other suitable cutting tool for performing a desired cutting operation. A given drill or tool may for example be constructed and/or configured for effecting a single such cutting operation, or it may be constructed and/or configured for effecting a plurality of different cutting operations, either simultaneously or sequentially. The drill, drill bit or other cutting tool may have a size, especially a diameter, and shape to suit the cutting operation it is to perform. Practical examples of suitable drills, drill bits and various cutting tools are well known in the art.

In embodiments the cutting means may be mounted or carried on a carriage, which enables it to be moved by displacement by the displacement means into or out of its cutting relationship, especially its cutting position, with respect to the pipeline wall, as or when required. The cutting means may be mounted on or in the carriage by any suitable mounting means, which may include locking means for anchoring the cutting means securely in positon thereon or therein. Examples of suitable mounting means are well known in the art.

The cutting means is drivable to effect its cutting operation on or in the pipeline wall by the drive means. Any suitable drive means may be employed. Examples include one or more electric (AC or DC) motors. Other types of motor or drive device may however be used, e.g. one or more pneumatic or hydraulic motors. For driving a given cutting means, it is possible to use one, two or possibly even more than two motors or other drive means, optionally working in series or in parallel. For example, in some embodiments it may be particularly useful to provide a pair of electric (e.g. DC) motors both driving the cutting means in a parallel, but reversed-orientation, arrangement, with each motor driving the cutting means through a respective gearbox, gear train or gearing arrangement. In this manner an increased level of torque, e.g. double the torque of a single motor, can be applied to the cutting means, whilst at the same time helping to reduce asymmetrical forces acting on the apparatus by the operating motors.

Specific examples of motor and gearbox arrangements will be described further hereinbelow with reference to some specifically described and illustrated embodiments of the invention.

In preferred embodiments the displacement means are constructed and/or configured and/or operable to advance or retract the cutting means into or from its cutting relationship with the pipeline wall as or when actuated to do so, preferably by actuation means. Thus in some embodiments the displacement means may preferably comprise: transposition means for allowing the cutting means, especially the carriage on which it is mounted in preferred embodiments, to move towards (advanced) or away from (retracted) the pipeline wall; and actuation means for effecting said movement of the cutting means towards or away from the pipeline wall.

The movement of the carriage carrying the cutting means may preferably be in a transverse direction with respect to the pipeline longitudinal axis (as defined hereinabove). Such movement may be provided by virtue of the carriage being slidably mounted on at least one rod, pin, bearing or other sliding device permitting said transverse movement of the carriage relative to the remainder of the apparatus and thus the pipeline wall under actuation of the actuation means.

The actuation means which effects movement of the carriage towards or away from the pipeline wall may for example comprise one or more pressurised fluid devices, e.g. one or more pneumatic or hydraulic devices, which preferably operate(s) via fluid displacement from one or more cylinders or other reservoirs of the relevant fluid. Suitable such devices may include one or more compressed gas devices, e.g. devices operated by compressed air.

In preferred embodiments the actuation means, especially the one or more pressurised fluid devices, may comprise one or more supplies of the pressurised fluid, e.g. carried in one or more reservoirs or tanks, which are provided on or in the apparatus itself, especially so that they are carried by the apparatus as it travels along the pipeline to any site at which it is to conduct its cutting operation. Conveniently the one or more pressurised fluid supply reservoirs may be carried in a dedicated module of a modular apparatus, of which the drill module containing the primary components of embodiments of the invention may be another module, with appropriate connecting pipework, tubes or conduits as well as any necessary valve arrangements and/or pressure-regulating devices (for providing compressed fluid at an appropriate pressure to where it is needed) being provided internally of the overall modular apparatus.

This arrangement therefore avoids the need, as is often found with prior art apparatuses, to provide a source of the pressurised fluid for operating the various actuation means as an element of the tether or umbilical cable linking the apparatus to a ground-based control station. By placing the supply of the pressurised fluid onboard the apparatus, it is possible to improve response times and/or actuation or operational speeds of the relevant one or more actuation, e.g. pneumatic-or hydraulic-operated, means used to effect and control the displacement of the carriage carrying the cutting means. Furthermore, it also enables a reduction in size, weight, and complexity of any tether or umbilical cable that is employed to provide power, control signals and/or other services to the apparatus from ground level whilst the apparatus is within the pipeline.

In practical implementation of such embodiments of the invention there may be provided externally of the apparatus charging means, or filling or replenishing or loading means, for charging the one or more pressurised fluid supply reservoirs, preferably from a general source thereof outside the apparatus, especially from ground level, e.g. whilst the apparatus is present within the pipeline. Such charging means may be substantially permanently linked to the apparatus, e.g. via an element of the tether or umbilical cable, so as to enable the one or more reservoirs to be charged as or when required whilst the apparatus remains within the pipeline, or alternatively (and in a possibly more preferred arrangement) such charging means may not be permanently linked to the apparatus such that the or the respective reservoir may be rechargeable or refillable only when the apparatus is removed from the pipeline, e.g. upon completion of a particular operation or series of operations, for which a single charge or fill of pressurised fluid is sufficient. This may thus avoid the need for a permanent fluid supply connection from a ground supply source to the apparatus, which can thereby circumvent typically disadvantageous consequences of poor flow characteristics associated with small diameter tubing, which typically is needed for any fluid connection embodied in a tether or umbilical cable.

In embodiments the actuation means may comprise any number of compressed fluid devices operating on the carriage to move it as or when required. In some preferred embodiments two such compressed fluid devices may be provided, working in a tandem or parallel arrangement. This may usefully enhance the accuracy and responsive of the displacement operation as the carriage carrying the cutting means is advanced or retracted to or from its cutting position.

The transposition means, forming part of the displacement means, may in preferred embodiments be constructed and arranged for permitting movement of the cutting means, especially the carriage on which it is mounted in preferred embodiments, in a transverse direction relative to the pipeline longitudinal axis. Such permitted movement may preferably be substantially only in said transverse direction.

In one practical example form the transposition means may comprise at least one slider mechanism, comprising: a slider member connected to, and advanceable or retractable in a longitudinal direction by, one or more, preferably a respective, actuation means (e.g. pressurised fluid device), the slider member containing a slot or channel therein, the slot or channel having a length dimension oriented so as to be non-perpendicular and non-parallel relative to the longitudinal axis of the pipeline; and a pivot member attached to or carried on or with the carriage carrying the cutting means, the pivot member being engaged with the slot or channel so as to be slidable therein upon advancement or retraction of the slider member by the actuation means, whereby upon said advancement or retraction of the slider member by the actuation means, the pivot member slides in the said slot or channel in the slider member to move the carriage in the said transverse direction relative to the pipeline longitudinal axis.

In a more preferred arrangement of the above slider mechanism there are provided a pair of slider members, each connected to, and advanceable or retractable in opposite longitudinal directions by respective ones of a pair of oppositely oriented actuation means (e.g. a pair of oppositely oriented pressurised fluid devices), wherein each said slider member contains a respective slot or channel therein, the respective slots or channels in the slider members each having a respective length dimension oriented at a substantially equal but opposite angle (each relative to the other) either side of 90° relative to the longitudinal axis of the pipeline, and wherein the slider members are positioned adjacent one another such that the pivot member is engaged with both slots or channels of both slider members so as to be slidable in both slots or channels simultaneously upon mutual advancement or mutual retraction of the slider members by the respective actuation means. In essence, therefore, this form of dual slider mechanism acts in a scissoring manner, to advance or retract the pivot member (attached to or carried on or with the carriage carrying the cutting means) by its sliding engagement with the dual slots or channels of the dual slider members in the manner of a "scissor lift" type mechanism.

In an alternative, reversed, configuration of either of the above slider mechanisms, the slider member(s) may instead be attached to or carried on or with the carriage, and the pivot member may instead be connected to, and advanceable or retractable in a longitudinal direction by the one or more actuation means.

Such sliding of the pivot member in the said slots or channels in the slider members to move the carriage in the said transverse direction relative to the pipeline longitudinal axis may thus effect transposition of the carriage into an advanced positon or a retracted positon of the cutting means (carried on the carriage) relative to the pipeline wall.

The orientation angle of the or each slot or channel of the respective slider members which engage the pivot member may for example be an angle of from about 20 or 30° to about 60 or 70°, e.g. from about 40° to about 50° (e.g.in the region of around 45°), either side (as appropriate) of 90° relative to the longitudinal axis of the pipeline. This order of angular orientation of the slot(s) or channel(s) may promote or facilitate optimum sliding of the pivot therein and therealong, especially in the case of dual slider members of the more preferred arrangement defined above, as the slider members are actuated by the respective pressurised fluid or other actuation means.

Smooth sliding of the pivot member in and along the slot(s) or channel(s) may be assisted by virtue of the slot(s) or channel(s) each having one or more, preferably opposite, sides which are substantially smooth. Optionally a lubricant could be used to further assist such smooth sliding of the pivot member in the slot(s) or channel(s).

In an especially useful example form, two such slider mechanisms may be provided, one on one longitudinal side of the carriage carrying the cutting means and the other on an opposite longitudinal side of the carriage. In this case it may be preferred that each slider mechanism comprises its own dedicated pressurised fluid or other actuation means, with each such pressurised fluid or other actuation means preferably acting in an opposite orientation relative to the other, so that each respective actuation means acts to advance or retract its respective slider member simultaneously with the other, but from opposite, parallel directions. In this manner a more symmetrical displacement arrangement may be provided, thereby leading to a more efficient and responsive displacement mechanism for advancing and retracting the carriage, and thus the cutting means, into and out of its cutting relationship with pipeline wall as and when required. In an example of one practical form of this alternative arrangement, the slider members of the slider mechanisms on each longitudinal side of the carriage may be individual, longitudinally spaced apart portions of a or a respective common slider member, such that a given single slider member comprises respective longitudinally spaced apart portions constituting the slider members of both mechanisms on both longitudinal sides of the carriage. This arrangement may lead to an even more efficient and responsive displacement mechanism for advancing and retracting the carriage, and thus the cutting means, into and out of its cutting relationship with pipeline wall as and when required.

It is to be understood that during any given cutting operation, since it may well be required that the cutting means is to be driven into the pipeline wall a certain distance during the cutting operation, especial for instance in the drilling of a hole or aperture in the pipeline wall, the displacement means may be operated to continue to advance or retract, as the case may be, the cutting means even while the cutting operation is in progress.

In some embodiments of the invention the apparatus may further comprise positioning or locator means for positioning or locating or orienting the cutting means at a required or desired location or position in the pipeline at or in which it is to perform its cutting operation. 15 Such positioning or locator means may for example comprise sensing or tracking means for detecting or monitoring a position or location or orientation of the apparatus within the pipeline, such that it can determine when or if the apparatus is at, or positioned in, or oriented in, any desired location and/or position at or in which performance of its cutting operation is needed or which it is ready to perform.

In some practical embodiments such sensing or tracking means may comprise one or more cameras, e.g. optical or even IR cameras, for observing the pipeline interior and/or the apparatus's environment.

If desired or if it is applicable in a given practical scenario, for instance in the making of a new consumer service connection to a replacement pipeline in which the apparatus of the invention is to be placed for use, such one or more cameras may be used in conjunction with one or more sources of visible light external to the apparatus, which light source(s) may be placed or inserted into a service connection or other side-or tributary-pipeline whose connection into the replacement pipeline is to be made and so as to lie externally adjacent a sidewall of the replacement pipeline. In this manner light from the light source(s) on the "other side" of the pipeline side wall from the apparatus can be detected by the camera(s) provided thereon, and thus provide appropriate location, positon or orientation data for the purpose of accurately positioning, aligning or orienting the apparatus most appropriately for performing its cutting task. Such arrangements may be applicable in particular to pipeline materials which are at least partially transparent or translucent to visible light, e.g. yellow or other non-black coloured polyethylene (PE) pipes which are commonly used in the industry.

In some embodiments a plurality of, e.g. two or more spaced apart, cameras or other sensing or tracking means may be provided, in order to provide three-dimensional information or data about the pipeline interior and/or the apparatus's environment and so to more accurately detect and monitor if or when the apparatus is in an optimum or required location, position or orientation to carry out its intended cutting task. In practice example set-ups, a suitable monitoring interface may be incorporated in any overall control system, e.g. at ground level, for controlling the apparatus taking into account such three-dimensional location, positional or orientational information or data.

In other possible embodiments it may be possible to utilise other forms of sensing or tracking means, either instead of or in combination with one or more cameras, e.g. one or more sonic, ultrasonic, magnetic, electromagnetic (e.g. microwave or RF) or other devices, preferably coupled with a corresponding detector (in place of the one or more light sources mentioned above in the context of camera(s)) to provide corresponding location, positional or orientational data with respect to a service connection to be made to the pipeline. Such arrangements may be applicable in particular to pipeline materials which are opaque or substantially opaque to visible light, e.g. black coloured polyethylene (PE) pipes, which may sometimes be used in the industry.

Within the scope of this application it is envisaged that the various aspects, embodiments, examples and alternatives, and in particular the individual features thereof, set out in the preceding paragraphs, in the claims and/or in the following description and drawings, may be taken independently or in any combination. For example features described in connection with one embodiment are applicable to all embodiments, unless expressly stated otherwise or such features are incompatible.

For the avoidance of doubt, it is to be understood that features described with respect to one aspect of the invention may be included within any other aspect of the invention, alone or in appropriate combination with one or more other features.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention in its various aspects will now be described, by way of example only, with reference to the accompanying drawings, in which: FIGURE 1 is a plan view schematic illustration of a pipeline robot according to an embodiment of the present invention; FIGURE 2 is a cross-sectional view of a typical operating environment of a pipeline robot according to an embodiment of the present invention; FIGURE 3 is a more detailed plan view, corresponding to FIG. 1, of a major portion of a prototype modular pipeline robot according to an embodiment of the invention; FIGURE 4 is a close-up plan view of part of a simplified prototype modular robot according to another embodiment, which part comprises a drill module in accordance with that 15 embodiment; FIGURE 5(a) is a cut-away top plan view of the drill module alone of a more advanced prototype drill module according to yet another embodiment of the invention; FIGURE 5(b) is an enlarged cut-away internal side view of part of the gearing mechanism which drives the cutting tool, e.g. drill bit, of the drill module of FIG. 5(a); FIGURE 6 is a cut-away top perspective view of the drill module of FIGS. 5(a) & 5(b), showing the displacement mechanism which advances and retracts the cutting tool into or from its cutting position against the pipeline inner wall; FIGURE 7(a) is a cut-away side view of the displacement mechanism shown in FIG. 6, showing the cutting tool in a retracted (i.e. lowered, non-cutting) position; FIGURE 7(b) is a cut-away side view, corresponding to that of FIG. 7(a), of the displacement mechanism shown in FIG. 6, but showing the cutting tool in an advanced (i.e. raised, cutting) position; FIGURE 8 is a top plan view of the central portion of the drill module of FIGS. 5 to 7, showing an arrangement of cameras for use in correctly locating, positioning, aligning or orienting the cutting tool ready for cutting.

DETAILED DESCRIPTION OF EMBODIMENTS

FIG. 1 is a plan view schematic illustration of a pipeline robot 100 located within a newly installed utilities main pipeline 101. A reduced scale view of a typical operational environment of the robot 100 is shown in FIG. 2. It can be seen from FIG. 2 that, in the scenario illustrated, the robot 100 has been introduced into a newly installed main pipeline 101 via an underground inspection well 101A. It is to be understood that the free end 101 F of the main pipeline 101 that is exposed to the well 101A may be coupled to the free end 101F2 of a second length of newly installed main pipeline 101 that also terminates in the well 101A once service connection pipelines have been connected to the main pipeline 101.

The newly installed utilities main pipeline 101 is itself located within a pre-existing main pipeline 101E of larger diameter.

By way of one working example, the robot 100 is configured to install a pipeline fitting in a newly installed main pipeline in order to allow a service connection pipeline to be connected to the main pipeline. The robot 100 achieves this by drilling an aperture in a sidewall of the pipeline and coupling the pipeline fitting to the pipeline in order to allow a fluid-tight connection to be made between the service connection pipeline and main pipeline. The robot 100 is also able to test the integrity of a joint between a service connection pipeline and the main pipeline. This allows an operator to determine whether or not a successful connection of the service connection pipeline to the main pipeline has been made.

The robot 100 has six modules coupled to one another in series. In the embodiment shown in FIG. 1 the modules are a tractor module 110, a pneumatic supply module 120, a drill module 130, an insertion module 140, a leak test module 150 and a trailer module 160. In some embodiments a second tractor module 110 may be coupled to the leak test module 150 instead of the trailer module 160. One or more additional modules may be included in some embodiments. In some embodiments the trailer module 160 may be eliminated. It is to be further understood that the modules may be coupled to one another in a different order in some embodiments. For example, in some embodiments the pneumatic supply module 120 may be provided adjacent the leak test module 150. In addition or instead, the pneumatic supply module 120 may be provided adjacent the insertion module 140, for example if the insertion module 140 is powered by pneumatic means such as a pneumatic piston or pneumatic motor.

Each module 110 -160 has at least three support arms 110R, 120R, 130R, 140R, 150R, 160R that are configured to project outwardly therefrom at an acute angle with respect to a longitudinal axis of each module. The support arms 11OR -160R pivot about an axis at a proximal end within a body portion 110B-160B of each module 110-160. Each arm 11OR -160R is spring-loaded and carries a roller in the form of a wheel at its free end. The arms 11 OR -160R are configured to urge the respective rollers away from the body portion 110B-160B and against an inner wall of the pipeline 101 in order to support the modules 110-160 substantially coaxially of the pipeline 101. The spring loading of the arms 110R-160R assists the robot 100 to maintain a coaxial location whilst accommodating variations in diameter or cross-sectional shape of the pipeline 101, for example in regions that are not circular such as elliptical or other non-circular cross-sectional shape, and to negotiate bends in the pipeline 101. It is to be understood that maintaining a coaxial location is not necessarily critical in all applications.

The tractor, pneumatic supply and trailer modules 110, 120, 160 each have four support arms 110R, 120R, 160R, respectively arranged in quadrature about the longitudinal axis of the modules. In the orientation shown in FIG. 1 one arm projects substantially vertically upwardly, one arm projects substantially vertically downwardly and two arms project substantially laterally in opposite directions.

The drill, insertion and leak test modules 130, 140, 150 each have three support arms 130R, 140R, 150R, one arm projecting substantially vertically downwardly and two arms projecting substantially laterally in opposite directions in the orientation depicted in FIG. 1.

In some alternative embodiments, one or more of the modules may have rollers that are attached to a body of the module rather than to spring-loaded arms. The rollers may be non-spring-loaded in some embodiments, being configured to rotate about an axis at a substantially fixed distance from a longitudinal axis of the respective module of which they form part. For example, one or more rollers may be provided such as wheels, caterpillar tracks or other suitable roller arrangements. The rollers may be arranged such that the robot 100 may crawl along the pipeline 101 with the rollers contacting only a lower internal surface area of the pipeline 101.

In the embodiment of FIG. 1 the rollers of the tractor module 110 are configured to be driven by electric motors that are powered by means of an electrical powerline carried by an umbilical cable 100C. The umbilical cable 100C runs along a length of the robot 100 along a conduit provided through each module.

The tractor module 110 also carries an onboard robot control portion 115. The onboard control portion 115 includes a computing device that is in data communication via a data line carried by the umbilical cable 110C with a main or primary interface module 110PM external to the pipeline 101 as shown schematically in FIG. 2. The primary interface module 110PM is connected to a secondary interface module 110SM which in the present embodiment is provided by a portable computing device having a keyboard and display screen. The secondary interface module 110SM allows a user to control the primary interface module 110PM to send electrical control and power signals, and supply compressed air at a required pressure, to the robot control portion 115. By means of the secondary interface module 110SM an operator may control the tractor module 110 to cause the robot 100 to move in a forward and reverse direction within the pipeline 101 and to operate each of the drill module 130, insertion module 140 and leak test module 150 to install a pipe fitting allowing connection of a consumer service pipeline to a main pipeline. The robot 100 may also be controlled to leak-test the newly connected consumer service pipeline. It is to be understood that, in the event the robot becomes immobilised for any reason within the pipeline 101, the robot may typically be retrieved by pulling on the umbilical cable 110C.

A supply of compressed air, or other pressurised fluid (if appropriate to the needs of the various operational modules of the robot 100), is provided by the pneumatic supply module 120. The supply is conveniently in the form of a reservoir of compressed air, possibly at elevated storage pressure relative to a working pressure of the relevant operational devices of the one or more operational modules 100, 130, 140, 150, 160 of the robot 100, and may be rechargeable from a ground station either whilst the robot is within the pipeline or (sometimes more preferably) once it has been removed therefrom. The reservoir or tank, which may be in the form of a cylindrical or part-cylindrical tank or coiled tube, is thus carried onboard the robot 100 as the main component of one of its modules 120. In this manner the pneumatic supply module 120 provides an onboard supply of compressed air that is carried with the robot 100 as it moves along the pipeline 101.

For brevity, the insertion module 140 and the leak-test module 150 will not, and need not, be described in further detail here, but it is to be understood that they may each have any appropriate or desired construction, configuration and operation as required of the apparatus or its intended use, either in terms of known or novel principles and/or features.

However, for the purpose of the present invention reference is now made to FIGS. 3 to 8, which show various embodiments of drill module 130 and portions thereof in accordance with the invention.

FIG. 3 shows in clearer detail an example of a major portion of a prototype modular pipeline robot 100 according to an embodiment of the invention, which for the most part corresponds to the embodiment shown in FIGS. 1 and 2, although it is to be understood that certain of its modules may be transposed with respect to other(s) so that various modules may be connected together within the robot 100 in any desired or appropriate order or sequence. As shown in FIG. 3, the robot 100 as shown comprises a drill module 130, a pneumatic supply module 120 for providing the drill module 130 (plus any other module(s) which require it) with an onboard supply of compressed air, and a trailer or clear-up module 160, e.g. for clearing, sweeping or vacuum-cleaning up waste left from a cutting operation performed by the drill module 130. The pneumatic and drill modules 120, 130 are shown here as being connected together by a linking section 125 which contains within it appropriate pipework, conduits, electrical cabling and suchlike for connecting these two modules together and to the other modules of the overall robot 100. The portion of the robot 100 shown in this FIG. 3 is also shown as being bounded at each end by a manifold 195a, 195b for onward connection to neighbouring modules, optionally via other respective linking sections.

FIG. 4 is a close-up plan view of part of a simplified prototype modular robot according to another embodiment, which part comprises a drill module in accordance with that embodiment. As shown here, a central portion of the drill module houses a carriage 430 on which is mounted a drill bit or other cutting tool 440. In this embodiment the drill bit 440 is driven by a single DC electric motor 410, via gearbox G, which lies to one longitudinal side of the carriage 430. To the opposite side thereof are located a pair of pneumatic cylinders 120a, 120b which provide an onboard supply of compressed air for, among possibly other purposes, actuating the carriage displacement mechanism 460 which raises or lowers the carriage between a raised (i.e. advanced) position in which it is in its cutting positon against the pipeline inner wall, and a lowered (i.e. retracted) position in which it is withdrawn from its cutting positon and spaced from the pipeline inner wall.

FIG. 5(a) shows the drill module alone of a more advanced prototype drill module according to yet another embodiment of the invention. The drill bit 440, which is mounted within a chuck of carriage 430, is driven by a pair of DC electric motors 410a, 410b. Each motor 410a, 410b is connected to the drill bit 440 via a respective gearbox arrangement G1, G2, which includes, as illustrated (including more clearly in FIG. 5(b)) respective mitre/bevel gear wheel pairs 443a, 443b, and tall spur gears 448a, 448b. Thus, the horizontal rotation of each motor 410a, 410b is transferred to vertical rotation via the gearbox using, inter alia, the straight mitre gears of the mitre/bevel pairs 443a, 443b, wherein each mitre gear of the pair rotates a shaft 444a, 444b (as shown in FIG. 5(b)) which also contains a small spur gear 445a, 445b, which translates the now vertical rotation to the rest of the gearbox.

In this illustrated example the gear ratio of each gearbox 01, G2 may be expressed as: 14 13 14 13x19 = 19 = 0.7368: 1 although it is to be understood that any other suitable gear ratio may be employed.

Continuous contact between the gearing within the carriage 430 of the drill module and the drive motor gearing is achieved through the use of the respective tall spur gears 448a, 448b.

FIG. 6 shows the displacement mechanism which, in the drill module of FIGS. 5(a) and 5(b), advances and retracts the cutting tool 440 into or from its cutting position against the pipeline inner wall, as or when required. As shown, the displacement mechanism is based on a pair of oppositely oriented compressed air cylinder devices 420a, 420b, which act on a transposition device, as described further below, which advances or retracts the carriage 430 carrying the drill bit 440 transversely with respect to the pipeline (and usually also with respect to the longitudinal axis of the main body of the drill module itself). The carriage 443 itself is slidably mounted on an array of guide pins 449, thereby permitting movement of the carriage substantially only in a transverse direction relative to pipeline/drill module body.

The transposition device which actuates and controls the sliding of the carriage either up or down (which corresponds to the orientation shown in the drawing, although in practice it could be in any spatial orientation, even in a horizontal or sideways fashion) along its transverse bearing guide pins 449 is based on a dual transposition mechanism, with the two parts working in tandem. The mechanism comprises a pair of slide plates 460a, 460b; 462, 462b adjacent one another in a face-to-face configuration, which are connected to, and advanceable or retractable in a longitudinal direction by, the respective compressed air cylinders 420a, 420b. As shown in the drawing, each slide plate is divided into a pair of respective slide plate portions 460a, 460b; 462a, 462b, one on each longitudinal side of the carriage 430, so as to effectively form a pair of (namely the "dual") transposition devices one on each longitudinal side of the carriage 430. In this manner a symmetrical transposition or lifting arrangement is provided, which may lead to smoother operation and improved efficiency and responsiveness of the overall mechanism.

The slide plates 460a, 460b; 462, 462b contain respective smooth-walled slots or channels 470a, 470b; 472a, 472b therein, which each have a length dimension oriented so as to be angled by e.g. about 45° to one or other side of 90° (as the case may be, as shown in the drawing) relative to the longitudinal axis of the pipeline. Attached to the carriage 430 are a pair of pivot pins 468a, 468b which are engaged in and with both slots or channels 470a, 470b; 472a, 472b of the respective slide plate pairs at the slots/channels' cross-over points, so that the pivot pins 468a, 468b are slidable therein upon advancement or retraction of the slide plates 460a, 460b; 462, 462b by the respective compressed air cylinders 420a, 420b.

Thus, upon advancement or retraction of the slide plates by the respective respective compressed air cylinders 420a, 420b, the respective pivot pins 468a, 468b, slide in their respective combined slots or channels 470a, 470b; 472a, 472b at the cross-over points therein in the manner of a "scissor-lift" mechanism. As a result, the carriage 430 is moved in its transverse direction between, or into either of its, upper (i.e. advanced, cutting) position and/or its lower (i.e. retracted, non-cutting) position, depending on the direction of action of the respective compressed air cylinders 420a, 420b.

FIG. 7(a) shows the displacement mechanism of FIG. 6 having been actuated so that the drill bit 440 is in its retracted, i.e. lowered and non-cutting, position, and will be readily understood from the foregoing.

FIG. 7(b) shows the same displacement mechanism, but having been actuated so that the drill bit 440 is now in its advanced, i.e. raised and cutting position against the pipeline inner wall, and will be readily understood from the foregoing.

FIG. 8 shows the central portion of the drill module of FIGS. 5 to 7, with an arrangement of cameras 500 for use in correctly locating, positioning, aligning or orienting the cutting tool ready for cutting.

For this purpose of aligning, or otherwise correctly locating, positioning or orienting, the drill module 130 into its correct position ready for drilling, there are integrated into the drill module two optical cameras 500. These cameras 500 are in a fixed position, spaced apart, on opposite sides of the drill bit carriage 430 and use a machine vision system, optionally with appropriate associated electronics and/or software (e.g. contained in the robot's overall control system) to align the drill module 130 of the robot and the drill bit 440 in the correct position. For example, the images received from the cameras may be correlated against known coordinates to allow drilling in the required location. This technique may be carried out manually through the user interface of the robot's overall control system or it may at least to some extent be automated using additional control software with consequential reduction in necessary hardware.

By way of example, such an alignment technique may utilise an external visible light source (not shown) to effectively place a drill position mark on an external side of the wall of the pipeline to be drilled, which mark is visible to the cameras on the drill module on the internal side of the wall. By placing the pair of cameras 500 spaced apart and in an angled position pointing toward just above the drill bit 440, the true central location of the drilling site may be accurately assured.

This method of alignment may however in practice only be suitable for operations within yellow PE pipe (which is currently widely used in the industry), which is partially translucent to visible light. In the case of e.g. black PE pipe, which is substantially opaque to visible light, an alternative type of marker may be used to identify the correct drilling site, again using the same principles as a visible light marker. Such alternative markers may include for example electromagnetic (e.g. microwave or RF), thermal, sonar or ultrasonic markers.

In such cases, of course, the optical cameras 5000 would be replaced with appropriate detectors.

Once the cutting operation by the drill bit 440 has been completed, the swarf from the drill is particularly suited to removal through the use of brushes and blowers, e.g. contained within a trailer or clean-up module 160 of the robot. If desired or necessary, and as an example of a further development of this embodiment, the swarf produced may for instance be better able to be cleared away if it is broken up into smaller fragments during its production by appropriately altering the tip profile of the drill bit 440 and "pecking" the hole out.

Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of the words, for example "comprising" and "comprises", means "including but not limited to", and is not intended to (and does not) exclude other moieties, additives, components, integers or steps.

Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.

Claims (27)

1. CLAIMS1. Apparatus for performing a cutting operation on an inner wall of a pipeline from within the pipeline, the apparatus being propellable longitudinally along and within the pipeline, wherein the apparatus comprises: cutting means for performing the cutting operation on the pipeline from therewithin, drive means for driving the cutting means so as to perform the cutting operation when in a cutting relationship with the pipeline inner wall to be cut, and displacement means for advancing or retracting the cuffing means into or from the said cutting relationship with the pipeline inner wall.
2. 2. Apparatus according to claim 1, wherein the displacement means is constructed and arranged to advance or retract the cutting means in a direction generally transverse to the longitudinal axis of the pipeline.
3. 3. Apparatus according to claim 1 or claim 2, wherein the cutting operation is a cuffing operation on one or more walls of a replacement pipeline to be inserted within, or having already been inserted within, or in the process of being inserted in, a pre-existing pipeline.
4. 4. Apparatus according to any one of claims 1 to 3, wherein the cutting operation is selected from one or more of any of the following: - drilling of a hole or aperture, of any shape, through the pipeline wall; - partial drilling-or culling-through of an inner surface or wall of the pipeline; - thermal or high-pressure punching of a hole or aperture through the pipeline wall; -bevelling, chamfering, de-burring or other shaping or finishing of one or more edges of a hole or aperture formed in the pipeline wall.
5. 5. Apparatus according to any preceding claim, wherein the cutting means comprises a drill, dill bit, or other cutting tool for performing the cutting operation, and is optionally constructed and/or configured for effecting either a single cutting operation or a plurality of different cutting operations simultaneously or sequentially.
6. 6. Apparatus according to any preceding claim, wherein the cutting means is mounted or carried on a carriage, such that the cutting means is movable by displacement by the displacement means into or out of its cutting relationship with respect to the pipeline wall.
7. 7. Apparatus according to any preceding claim, wherein the cutting means is drivable to effect its cutting operation on or in the pipeline wall by drive means comprising one or more electric motors, optionally via at least one gearbox.
8. 8. Apparatus according to claim 7, wherein the cutting means is drivable by a pair of electric motors arranged to drive the cutting means in a parallel, reversed-orientation arrangement, optionally via a pair of respective gearboxes.
9. 9. Apparatus according to any preceding claim, wherein the displacement means comprises: transposition means for allowing the cutting means to move transversely towards or away from the pipeline wall; and -actuation means for effecting said movement of the cutting means towards or away from the pipeline wall.
10. 10. Apparatus according to claim 9, wherein said movement is provided by virtue of the carriage being slidably mounted on at least one rod, pin, bearing or other sliding device permitting said transverse movement of the carriage relative to the remainder of the apparatus and the pipeline wall under actuation of the actuation means.
11. 11. Apparatus according to claim 9 or claim 10, wherein the actuation means which effects movement of the carriage towards or away from the pipeline wall comprises one or more pressurised fluid devices.
12. 12. Apparatus according to claim 11, wherein the actuation means further comprise one or more supplies of pressurised fluid for the one or more pressurised fluid devices, the said one or more supplies of pressurised fluid comprising one or more reservoirs or tanks provided on or in the apparatus and carried therewith as it travels along the pipeline to any site at which it is to conduct its cutting operation.
13. 13. Apparatus according to any one of claims 9 to 12, wherein the transposition means is constructed and arranged to permit movement of the cutting means in a transverse direction, optionally substantially only in a transverse direction, relative to the pipeline longitudinal axis.
14. 14. Apparatus according to claim 13, wherein the transposition means comprises at least one slider mechanism comprising: a slider member connected to, and advanceable or retractable in a longitudinal direction by, one or more actuation means, the slider member containing a slot or channel therein, the slot or channel having a length dimension oriented so as to be non-perpendicular and non-parallel relative to the longitudinal axis of the pipeline; and a pivot member attached to or carried on or with a carriage carrying the cutting means, the pivot member being engaged with the slot or channel so as to be slidable therein upon advancement or retraction of the slider member by the actuation means, whereby upon said advancement or retraction of the slider member by the actuation means, the pivot member slides in the said slot or channel in the slider member to move the carriage in the said transverse direction relative to the pipeline longitudinal axis.
15. 15. Apparatus according to claim 14, wherein the slider mechanism comprises a pair of slider members, each connected to, and advanceable or retractable in opposite longitudinal directions by respective ones of a pair of oppositely oriented actuation means, wherein each said slider member contains a respective slot or channel therein, the respective slots or channels in the slider members each having a respective length dimension oriented at a substantially equal but opposite angle (each relative to the other) either side of 90° relative to the longitudinal axis of the pipeline, and wherein the slider members are positioned adjacent one another such that the pivot member is engaged with both slots or channels of both slider members so as to be slidable in both slots or channels simultaneously upon mutual advancement or mutual retraction of the slider members by the respective actuation means.
16. 16. Apparatus according to claim 14 or claim 15, wherein the or each slider member is instead attached to or carried on or with the carriage, and the pivot member is instead connected to, and advanceable or retractable in a longitudinal direction by the one or more actuation means.
17. 17. Apparatus according to any one of claims 14 to 16, wherein the orientation angle of the or each slot or channel is an angle of from about 20 or 30° to about 60 or 70° either side of 90° relative to the longitudinal axis of the pipeline.
18. 18. Apparatus according to any one of claims 14 to 17, wherein two said slider mechanisms are provided, one on one longitudinal side of the carriage carrying the cutting means and the other on an opposite longitudinal side of the carriage.
19. 19. Apparatus according to claim 18, wherein the slider members of each of the slider mechanisms on each longitudinal side of the carriage are individual, longitudinally spaced apart portions of a or a respective common slider member, such that a given single slider member comprises respective longitudinally spaced apart portions constituting the slider members of both mechanisms on both longitudinal sides of the carriage.
20. 20. Apparatus according to any preceding claim, further comprising positioning or locator means for positioning or locating or orienting the cutting means at a required or desired location or position in the pipeline at or in which it is to perform its cutting operation.
21. 21. Apparatus according to claim 20, wherein the positioning or locator means comprises sensing or tracking means for detecting or monitoring a position or location or orientation of the apparatus within the pipeline, such that it can determine when or if the apparatus is at, or positioned in, or oriented in, any desired location and/or position at or in which performance of its cutting operation is needed or which it is ready to perform.
22. 22. Apparatus according to claim 21, wherein the sensing or tracking means comprises one or more cameras for observing the pipeline interior and/or the apparatus's 20 environment.
23. 23. Apparatus according to claim 21 or claim 22, wherein a plurality of sensing or tracking means are provided so as to provide three-dimensional information or data about the pipeline interior and/or the apparatus's environment.
24. 24. A system for performing a cutting operation on an inner wall of a pipeline from within the pipeline, wherein the system comprises: a robot which is propellable longitudinally along and within the pipeline, the robot comprising: cutting means for performing the cutting operation on the pipeline from therewithin, drive means for driving the cutting means so as to perform the cutting operation when in a cutting relationship with the pipeline inner wall to be cut, and displacement means for advancing or retracting the cutting means into or from the said cutting relationship with the pipeline inner wall; and the system further comprises control means for controlling actuation and operation of the robot.
25. 25. A method of performing a cutting operation on an inner wall of a pipeline from within the pipeline, the method comprising: providing an apparatus according to any one of claims 1 to 23; inserting the apparatus into the pipeline and propelling it therealong to a desired site of operation; operating the displacement means to advance the cutting means into cutting relationship with the pipeline inner wall, and operating the drive means to drive the cutting means to perform the cutting operation in or on the pipeline inner wall.
26. 26. A method according to claim 25, further comprising: operating the displacement means to retract the cutting means from the said cutting relationship with the pipeline inner wall.
27. 27. Apparatus or a system or a method, substantially as described herein with reference to the accompanying drawings.